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MTU 20V4000G44F Operating Instructions Manual

20v4000gx4f series
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Operating Instructions

Diesel engine
20V4000Gx4F
MS15058/01E

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Summary of Contents for MTU 20V4000G44F

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 20V4000Gx4F MS15058/01E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    8.3.2 Crankcase breather – Filter element 4 Technical Data replacement 8.4 Valve Drive 4.1 Product data 20V4000G44F, 20V4000G94F 8.4.1 Valve protrusion – Measurement 4.2 Firing order 8.4.2 Valve gear – Lubrication 4.3 Engine – Main dimensions 8.4.3 Valve clearance – Check and adjustment 8.4.4 Cylinder head cover –...
  • Page 4 8.14.2 Engine coolant – Change 9.1 Conversion tables 8.14.3 Engine coolant – Draining 9.2 Abbreviations 8.14.4 Engine coolant – Filling 9.3 MTU Contact/Service Partners 8.14.5 Engine coolant pump – Relief bore check 8.14.6 Engine coolant – Sample extraction and 10 Appendix B analysis 8.14.7 Preheater –...

  • Page 5: Safety

    (→ Page 6). Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life. Exception: Engines used exclusively in land-based, military applications other than by US government agen- cies.

  • Page 6: Correct Use Of All Products

    • With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al- so applies to engine control/parameters) •...

  • Page 7: Personnel And Organizational Requirements

    1.3 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.

  • Page 8: Safety Regulations For Initial Start-Up And Operation

    1.4 Safety regulations for initial start-up and operation Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 9 Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live. Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times. MS15058/01E 2017-05 | Safety | 9...

  • Page 10: Safety Regulations For Assembly, Maintenance, And Repair Work

    1.5 Safety regulations for assembly, maintenance, and repair work Safety regulations for work prior to assembly, maintenance, and repair Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 11 Never use the product as a climbing aid. When working high on the equipment, always use suitable ladders and work platforms. Special instructions for outdoor areas: There must be no risk of slipping e.g. due to icing. Removing, installing and cleanliness Pay particular attention to cleanliness at all times.
  • Page 12 Before starting welding work: • Switch off the power supply master switch. • Disconnect the battery cables or actuate the battery isolating switch. • Separate the electrical ground of electronic equipment from the ground of the unit. No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld- ing is in progress.
  • Page 13 Do not secure cables on lines carrying fluids. Do not use cable ties to secure lines. Always use connector pliers to tighten union nuts on connectors. Subject the device as well as the product to functional testing on completion of all repair work. The emergen- cy stop function must be tested in particular.

  • Page 14: Fire Prevention And Environmental Protection, Fluids And Lubricants, Indirect Materials

    The safety data sheet may be obtained from the relevant manufacturer or from MTU. Only use fluids and lubricants which have been approved by the manufacture and are specified in the Fluids and Lubricants Specifications.

  • Page 15: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • Avoid direct contact with lead or pastes containing lead. • Do not inhale lead vapors. • Wash affected areas after contact with lead or substances containing lead. Compressed air •...

  • Page 16: Standards For Safety Notices In The Text

    1.7 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...

  • Page 17: Transport

    Set the system down on a firm, flat surface only. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set the engine down on its oil pan unless expressly authorized to do so by MTU. MS15058/01E 2017-05 | Transport | 17...

  • Page 18: Lifting Requirements

    2.2 Lifting requirements DANGER Suspended load. Danger to life! • Use appropriate lifting devices and appliances. • Never stand beneath a suspended load. 1 Max. admissible diagonal B 1434.2 mm E 932 mm pull 10° C 12.4 mm 2 Center of gravity D 1318 mm A 1880 mm Take note of the engine center of gravity...

  • Page 19: Crankshaft Transport Locking Device

    2.3 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Engine oil Transport locking devices Note: The transport locking device on both sides protects the crankshaft bearings from shocks and vibration dam- age during engine transport.
  • Page 20 Installing the transport locking device on driving end (KS) Note: Install plate (6) on the upper part of the openings only. Secure the plates (6) with screws (4) and washers (5) at the lateral openings on both sides of the flywheel housing and tighten to the specified tightening torque.
  • Page 21 Installing guard plates and en- gine mounting brackets (if appli- cable) on driving end (KS) Note: Always use the screws supplied with the equipment or removed from the guard plates and engine supports to secure them on the engine. Install engine supports (2) on both sides with guard plates (1) washers (3) and screws (4) and tighten to specified tightening torque tightening.

  • Page 22: Engine Mount Shipping Lock

    2.4 Engine mount shipping lock Preconditions ☑ Engine coolant and engine oil must be filled. Shipping lock Note: The shipping lock protects the engine mount from damage resulting from shock and vibration during engine transportation. For installation and removal of the transport locking device, follow the in- structions below: Remove the transport locking device from all resilient mounts before putting the engine into operation.

  • Page 23: General Information

    3 General Information 3.1 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite)

  • Page 24: Engine Layout

    3.2 Engine layout 1 Oil cooler 7 PTO system, driving end 13 Fuel filter 2 Exhaust manifold 8 Starting equipment 14 Gear train 3 Exhaust turbocharger 9 Engine mounting 15 HP fuel pump 4 Air pipework 10 Cylinder head cover 16 Vibration damper 5 Intake housing 11 Cylinder head...

  • Page 25: Sensors And Actuators - Overview

    3.3 Sensors and actuators – Overview 1 Y39.A10 - Y39.A1 (injector) 4 B33 (temperature in HP fuel 7 F46 (leak fuel level, option) 2 A19 (EIL – Engine Ident La- system) 8 B9 (charge-air temperature) bel) 5 B34.1 (fuel pressure after 3 B34.3 (fuel pressure before filter) intermediate filter)
  • Page 26 1 B50 (crankcase pressure) 4 B48 (fuel pressure in HP 7 B54 (oil refill pump pres- 2 B7 (lube oil temperature) system (rail)) sure, option) 3 B5.1 (lube oil pressure after 5 B1 (camshaft speed) 8 B26 (charge-air coolant filter) 6 XB54 (connector for option- temperature) al oil refill pump)
  • Page 27 1 XF57 (LT coolant level (re- 3 XF33 (HT coolant level (re- 5 B10 (charge-air pressure) mote expansion tank)) mote expansion tank)) 2 XM50 (connector for power 4 Y39.B1 - Y39.B10 (injector) supply of bypass drain valve) 1 B13 (crankshaft speed) MS15058/01E 2017-05 | General Information | 27...
  • Page 28 1 M50.3 (bypass valve for 2 B44 (turbocharger speed) wastegate) 28 | General Information | MS15058/01E 2017-05...

  • Page 29: Technical Data

    4 Technical Data 4.1 Product data 20V4000G44F, 20V4000G94F Legend DL Reference value: Continuous power; Continuous drivable power under standard conditions BL Reference value: Fuel stop power; Maximum engine power; Can not be driven continuously in some applications (adjustment reserve) A Design value: Value required to design an external system (plant) R Guideline value: Typical average value for information;...
  • Page 30 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 2807 2807 load possible) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 3088 3088 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
  • Page 31 Cylinder displacement Liters 4.77 4.77 4.77 4.77 Total displacement Liters 95.4 95.4 95.4 95.4 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow - DL m³/s Combustion air volumetric flow - BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s perature) - DL Exhaust gas volume (at exhaust gas tem-...
  • Page 32 Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to Minimum continuous load (runtime > kW/cyl. 10 h) 18. Capacities Engine coolant capacity, engine side Liters (without cooling equipment) Charge-air coolant, engine side Liters Fuel, engine side Liters Engine oil capacity, initial filling (standard Liters...
  • Page 33 Engine surface noise with attenuated in- dB(A) take noise (filter) - DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) - DL (sound power level LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)

  • Page 34: Firing Order

    4.2 Firing order Number of Firing order cylinders A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 34 | Technical Data | MS15058/01E 2017-05...

  • Page 35: Engine - Main Dimensions

    4.3 Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 20V4000Gx4F 3478.3 mm 1699.2 mm 2251.9 mm MS15058/01E 2017-05 | Technical Data | 35...

  • Page 36: Operation

    5.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications (A001070/..) available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item Action Engine Depreserve (→...

  • Page 37: Putting Into Operation After Scheduled Out-Of-Service-Period

    5.2 Putting into operation after scheduled out-of-service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 157); Coolant circuit Check engine coolant level (→ Page 164). Check charge-air coolant level (→ Page 181). Coolant circuit Heat engine coolant with coolant preheater.

  • Page 38: Engine - Starting In Manual Mode (Test Run)

    5.3 Engine – Starting in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network. ☑ External start interlock is not active. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 39: Safety System - Override

    5.4 Safety system – Override NOTICE Safety functions and engine shutdown alarms will be disregarded. Severe material damage! • Initiate emergency start only in emergency situations. NOTICE Inadmissible operating status. Severe damage to property! • Use override function only in hazardous situations to ensure full capability in the event of engine faults.

  • Page 40: Operational Monitoring

    5.5 Operational monitoring DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 41: Starting The Engine In Emergency Situations (Override Mode)

    5.6 Starting the engine in emergency situations (override mode) NOTICE Safety functions and engine shutdown alarms will be disregarded. Severe material damage! • Initiate emergency start only in emergency situations. Preparation Item Measure Operating mode switch Change to override mode (manual mode, if applicable). Starting the engine in emergency situations Item Measure...

  • Page 42: Engine - Stopping In Manual Mode (Test Run)

    5.7 Engine – Stopping in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network ☑ Engine in manual mode NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress- Overheating of and, therefore, damage to components is possible! •...

  • Page 43: Emergency Engine Stop

    5.8 Emergency engine stop CAUTION Shutting down from full-load operation may cause hot water to escape from the expansion tank. Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety goggles / safety mask. NOTICE An emergency stop subjects the engine system to an extremely high load.

  • Page 44: After Stopping The Engine - Engine Remains Ready For Operation

    5.9 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. control 44 | Operation | MS15058/01E 2017-05...

  • Page 45: After Stopping The Engine - Putting The Engine Out Of Operation

    5.10 After stopping the engine – Putting the engine out of operation Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. After stopping the engine Item Action Coolant circuit Drain engine coolant (→ Page 166); Drain charge-air coolant (→ Page 183) if: •...

  • Page 46: Plant - Cleaning

    5.11 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaner (→ Tools Catalog) Cleaner (Hakupur 50/136) X00056700 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 47: Maintenance

    6 Maintenance 6.1 Maintenance task reference table [QL1] The required maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
  • Page 48 Task Maintenance tasks W1828 Preheater: Check function and inspect for leaks. (→ Page 179) W4172 Check general condition of rubber mount (visual inspection). (→ Page 193) Table 2: Maintenance task reference table [QL1] 48 | Maintenance | MS15058/01E 2017-05...

  • Page 49: Troubleshooting

    7 Troubleshooting 7.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery low or faulty u Charge or replace (→ manufacturer's documentation). Cable connections faulty u Check cable connections for secure seating (→ manufacturer's documentation). u Check whether cable connections are properly secured. Starter (electric): Engine cabling or starter faulty Contact Service.
  • Page 50 Engine governor defective u Contact Service. Charge-air temperature too high Cause Corrective action Engine coolant treatment u Check (→ MTU test kit). incorrect u Contact Service. Intercooler dirty u Check fans and intake/exhaust lines. Engine room: Air-intake temperature too high...
  • Page 51 Blue exhaust gas Cause Corrective action u Drain engine oil (→ Page 155). Too much engine oil in the engine u Replace filter (→ Page 110). Oil separator of crankcase breather contaminated Exhaust turbocharger, cylinder u Contact Service. head, piston rings or cylinder liner defective White exhaust gas Cause...

  • Page 52: Fault Messages Of The Engine Governor (Ecu 9) For Series 4000 Genset Engines (Preliminary)

    7.2 Fault messages of the engine governor (ECU 9) for Series 4000 genset engines (preliminary) 003 – HI T-Fuel ZKP-Number: 2.0122.931 Limit value 1 Cause Corrective action u Contact Service. Fuel temperature too high. 004 – SS T-Fuel ZKP-Number: 2.0122.932 Limit value 2 Cause Corrective action...
  • Page 53 010 – SS T-Coolant Intercooler ZKP-Number: 2.0124.932 Limit value 2 Cause Corrective action Coolant temperature in u Reduce power. intercooler too high. Engine shutdown. 015 – LO P-Lube Oil ZKP-Number: 2.0100.921 Limit value 1 Cause Corrective action u Check oil level, top up as necessary (→ Page 157). Lube oil pressure too low.
  • Page 54 022 – SS T-Exhaust B ZKP-Number: 2.0127.932 Limit value 2 Cause Corrective action Exhaust gas temperature (B-side) 1. Check cabling (→ Page 192). too high. Engine shutdown. 2. Contact Service. 023 – LO Coolant Level ZKP-Number: 2.0152.921 Limit value 1 Cause Corrective action Coolant level too low.
  • Page 55 030 – SS Engine Overspeed ZKP-Number: 2.2510.932 Limit value 2 Cause Corrective action Reduced fuel injection. 1. Acknowledge alarm. 2. Attempt to restart engine. 031 – HI ETC1 Overspeed ZKP-Number: 2.3011.931 Limit value 1 Cause Corrective action Speed of primary turbocharger u Contact Service.
  • Page 56 037 – SS ETC2 Overspeed ZKP-Number: 2.3013.912 Limit value 2 Cause Corrective action Speed of first secondary 1. Reduce power. turbocharger too high. 2. Contact Service. 038 – AL ETC Speed Deviation ZKP-Number: 1.8004.205 Cause Corrective action Synchro fault between primary 1.
  • Page 57 057 – LO P-Coolant ZKP-Number: 2.0101.921 Limit value 1 Cause Corrective action Coolant pressure too low. u Check coolant circuit. 058 – SS P-Coolant ZKP-Number: 2.0101.922 Limit value 2 Cause Corrective action Coolant pressure too low. Engine 1. Automatic engine shutdown. shutdown or reduced fuel 2.
  • Page 58 064 – SS P-Crank Case ZKP-Number: 2.0106.932 Limit value 2 Cause Corrective action Crankcase pressure too high. 1. Replace oil separator element (→ Page 110). Engine shutdown. 2. Contact Service. 065 – LO P-Fuel ZKP-Number: 2.0102.921 Limit value 1 Cause Corrective action Fuel supply pressure too low.
  • Page 59 068 – SS T-Coolant ZKP-Number: 2.0120.932 Limit value 2 Cause Corrective action Coolant temperature too high. 1. Allow engine to cool down. Engine shutdown. 2. Check engine coolant cooler, clean if dirty. 3. Restart engine (→ Page 38). 4. Contact Service. 081 –...
  • Page 60 086 – HIHI T-Umblasen ZKP-Number: 2.0128.932 Limit value 2 Cause Corrective action Recirculation temperature too u Reduce power. high. 089 – SS Engine Speed too Low ZKP-Number: 2.2500.030 Cause Corrective action Engine speed too low. u Check for additional messages. 090 –...
  • Page 61 094 – LO T-Preheat ZKP-Number: 2.1090.921 Limit value 1 Cause Corrective action Preheating temperature too low. u Check preheater. coolant temperature too low for engine start. 095 – AL Prelubrication Fault ZKP-Number: 2.1090.920 Cause Corrective action u Check oil priming system. Oil priming fault.
  • Page 62 120 – HI ECU Power Supply Voltage ZKP-Number: 2.0140.931 Limit value 1 Cause Corrective action Supply voltage too high. 1. Check supply voltage of engine governor. 2. Contact Service. 121 – HIHI ECU Power Supply Voltage ZKP-Number: 2.0140.932 Limit value 2 Cause Corrective action Supply voltage too high.
  • Page 63 176 – AL LifeData not available ZKP-Number: 2.4000.004 Cause Corrective action No (appropriate) LifeData backup u Contact Service. system available, ECU reset after expiration of time-out period. 177 – AL LifeData restore incomplete ZKP-Number: 2.4000.006 Cause Corrective action u Contact Service. This fault message is generated if a CRC is faulty during a data upload to ADEC (indicated for...
  • Page 64 184 – AL CAN PU-Data Flash Error ZKP-Number: 2.0500.684 Cause Corrective action A program fault occurred while u Contact Service. trying to copy a received application environment data module. 186 – AL CAN1 Bus Off ZKP-Number: 2.0500.686 Cause Corrective action CAN controller 1 is in “Bus-Off”...
  • Page 65 201 – SD T-Coolant ZKP-Number: 1.8004.570 Cause Corrective action Coolant temperature sensor u Check sensor and cabling (B6), replace as necessary. faulty. Short circuit or wire break. Error cleared after restarting the engine. 202 – SD T-Fuel ZKP-Number: 1.8004.572 Cause Corrective action Fuel temperature sensor faulty.
  • Page 66 207 – SD T-Exhaust B ZKP-Number: 18.004.577 Cause Corrective action Exhaust temperature sensor on B- u Check sensor and cabling (B4.22), replace as necessary. side faulty. Short circuit or wire break. 208 – SD P-Charge Air ZKP-Number: 1.8004.566 Cause Corrective action u Check sensor and cabling (B10), replace as necessary.
  • Page 67 215 – SD P-HD ZKP-Number: 1.8004.567 Cause Corrective action Rail pressure sensor faulty. High- u Check sensor and cabling (B48), replace as necessary. pressure regulator in emergency Error cleared after restarting the engine. mode ==> Short circuit or wire break. 216 –...
  • Page 68 223 – SD Level Coolant Intercooler ZKP-Number: 1.8004.583 Cause Corrective action Sensor for intercooler coolant u Check sensor and cabling (F57), replace as necessary. level faulty. Short circuit or wire Error cleared after restarting the engine. break. 227 – SD P-Lube Oil before Filter ZKP-Number: 1.8004.620 Cause Corrective action...
  • Page 69 232 – SD Charger 1 Speed ZKP-Number: 1.3011.128 Cause Corrective action Speed sensor of primary u Check sensor and cabling (B44.1), replace as necessary. turbocharger faulty. Short circuit Error cleared after restarting the engine. or wire break. 233 – SD Charger 2 Speed ZKP-Number: 1.3011.129 Cause Corrective action...
  • Page 70 244 – SD P-Lube Oil (R) ZKP-Number: 1.8004.621 Cause Corrective action Redundant lube oil pressure u Check sensor and cabling, replace as necessary. sensor faulty. Short circuit or wire Error cleared after restarting the engine. break. 245 – SD ECU Power Supply Voltage ZKP-Number: 2.8006.589 Cause Corrective action...
  • Page 71 301 – AL Timing Cylinder A1 ZKP-Number: 1.8004.500 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears frequently injector: Flight time value (→ Page 123). extremely low or extremely high. 302 – AL Timing Cylinder A2 ZKP-Number: 1.8004.501 Cause Corrective action...
  • Page 72 307 – AL Timing Cylinder A7 ZKP-Number: 1.8004.506 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears frequently injector: Flight time value (→ Page 123). extremely low or extremely high. 308 – AL Timing Cylinder A8 ZKP-Number: 1.8004.507 Cause Corrective action...
  • Page 73 313 – AL Timing Cylinder B3 ZKP-Number: 1.8004.512 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears frequently injector: Flight time value (→ Page 123). extremely low or extremely high. 314 – AL Timing Cylinder B4 ZKP-Number: 1.8004.513 Cause Corrective action...
  • Page 74 319 – AL Timing Cylinder B9 ZKP-Number: 1.8004.518 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears frequently injector: Flight time value (→ Page 123). extremely low or extremely high. 320 – AL Timing Cylinder B10 ZKP-Number: 1.8004.519 Cause Corrective action...
  • Page 75 325 – AL Wiring Cylinder A5 ZKP-Number: 1.8004.524 Cause Corrective action Cabling fault in injector cabling to 1. Check solenoid valve. cylinder. Result: Misfiring 2. Contact Service. 326 – AL Wiring Cylinder A6 ZKP-Number: 1.8004.525 Cause Corrective action Cabling fault in injector cabling to 1.
  • Page 76 332 – AL Wiring Cylinder B2 ZKP-Number: 1.8004.531 Cause Corrective action Cabling fault in injector cabling to 1. Check solenoid valve. cylinder. Result: Misfiring 2. Contact Service. 333 – AL Wiring Cylinder B3 ZKP-Number: 1.8004.532 Cause Corrective action Cabling fault in injector cabling to 1.
  • Page 77 339 – AL Wiring Cylinder B9 ZKP-Number: 1.8004.538 Cause Corrective action Cabling fault in injector cabling to 1. Check solenoid valve. cylinder. Result: Misfiring 2. Contact Service. 340 – AL Wiring Cylinder B10 ZKP-Number: 1.8004.539 Cause Corrective action Cabling fault in injector cabling to 1.
  • Page 78 346 – AL Open Load Cylinder A6 ZKP-Number: 1.8004.545 Cause Corrective action Disruption fault in injector cabling 1. Check solenoid valve. to cylinder. Result: Misfiring 2. Contact Service. 347 – AL Open Load Cylinder A7 ZKP-Number: 1.8004.546 Cause Corrective action Disruption fault in injector cabling 1.
  • Page 79 353 – AL Open Load Cylinder B3 ZKP-Number: 1.8004.552 Cause Corrective action Disruption fault in injector cabling 1. Check solenoid valve. to cylinder. Result: Misfiring 2. Contact Service. 354 – AL Open Load Cylinder B4 ZKP-Number: 1.8004.553 Cause Corrective action Disruption fault in injector cabling 1.
  • Page 80 360 – AL Open Load Cylinder B10 ZKP-Number: 1.8004.559 Cause Corrective action Disruption fault in injector cabling 1. Check solenoid valve. to cylinder. Result: Misfiring 2. Contact Service. 361 – AL Power Stage Low ZKP-Number: 1.8004.496 Cause Corrective action Internal electronic fault 1.
  • Page 81 371 – AL Wiring TO 1 ZKP-Number: 1.8004.634 Cause Corrective action Short circuit or wire break on 1. Check charger valve/cabling, repair as necessary. transistor output 1 (TO 1). 2. Replace engine governor. 372 – AL Wiring TO 2 ZKP-Number: 1.8004.635 Cause Corrective action Short circuit or wire break on...
  • Page 82 383 – AL Wiring TOP 3 ZKP-Number: 2.8006.640 Cause Corrective action Short circuit or wire break on u Check cabling to plant. transistor output, plant-side 3 (TOP 3). 384 – AL Wiring TOP 4 ZKP-Number: 2.8006.641 Cause Corrective action u Check cabling to plant. Short circuit or wire break on transistor output, plant-side 4 (TOP 4).
  • Page 83 395 – SS P-Lube Oil Red ZKP-Number: 2.0112.922 Limit value 2 Cause Corrective action Redundant lube oil pressure 1. Check wiring and sensor. reading too low. 2. Contact Service. 396 – TD T-Coolant Sensor Deviation ZKP-Number: 1.0480.193 Cause Corrective action Maximum coolant temperature 1.
  • Page 84 403 – AL Open Load Digital Input 4 ZKP-Number: 2.8006.628 Cause Corrective action Line disruption on digital input 4. 1. Check cabling. Cabling faulty or no resistance 2. Check target device input. over switch. 3. Contact Service. 404 – AL Open Load Digital Input 5 ZKP-Number: 2.8006.629 Cause Corrective action...
  • Page 85 410 – LO U-PDU ZKP-Number: 2.0141.921 Limit value 1 Cause Corrective action Injector voltage too low. 1. Check cabling. 2. Check supply. 3. Contact Service. 411 – LOLO U-PDU ZKP-Number: 2.0141.922 Limit value 2 Cause Corrective action Injector voltage too low. 1.
  • Page 86 415 – LO P-Coolant InterCooler ZKP-Number: 2.0107.921 Limit value 1 Cause Corrective action Coolant pressure in intercooler u Top up coolant (→ Page 185). too low. 416 – SS P-Coolant InterCooler ZKP-Number: 2.0107.922 Limit value 2 Cause Corrective action Coolant pressure in intercooler u Top up coolant (→...
  • Page 87 428 – AL L1 T-Aux 1 ZKP-Number: 2.0130.921 Limit value 1 Cause Corrective action Temperature signal of Aux 1 has u Determine cause of limit value violation and rectify fault. exceeded / not attained limit value 1, depending on configuration. 430 –...
  • Page 88 442 – AL L2 P-Aux 1 ZKP-Number: 2.0110.931 Limit value 2 Cause Corrective action Pressure signal of Aux 1 has u Determine cause of limit value violation and rectify fault. exceeded / not attained limit value 2, depending on configuration. 444 –...
  • Page 89 454 – SS Power Reduction Active ZKP-Number: 2.7000.011 Cause Corrective action Power reduction is active 1. Check for additional fault messages. 2. Determine cause of power reduction and rectify fault. 455 – AL L1 Aux1 Plant ZKP-Number: 2.8006.650 Limit value 1 Cause Corrective action Input signal of Aux 1 (plant side)
  • Page 90 462 – HI T-Coolant EMU ZKP-Number: 2.8006.654 Limit value 1 Cause Corrective action EMU coolant temperature value u Check configuration with DiaSys. too high / low. 464 – SD P-AUX 1 ZKP-Number: 1.8004.589 Cause Corrective action Analog input signal for Aux 1 u Check pressure transmitter and cabling, replace as necessary.
  • Page 91 471 – SD Coil Current ZKP-Number: 1.8004.592 Cause Corrective action Control of HP fuel control block u Check sensor and cabling, replace as necessary. faulty. Short circuit or wire break. Error cleared after restarting the engine. 472 – AL Stop SD ZKP-Number: 2.8006.593 Cause Corrective action...
  • Page 92 478 – AL Comb. Alarm Yel (Plant) ZKP-Number: 2.8006.001 Cause Corrective action Combined alarm YELLOW from u Check additional messages. plant. 479 – AL Comb. Alarm Red (Plant) ZKP-Number: 2.8006.002 Cause Corrective action Combined alarm RED from plant. u Check additional messages. 480 –...
  • Page 93 485 – SS T-Exhaust C ZKP-Number: 20.133.932 Limit value 2 Cause Corrective action Exhaust gas temperature (C-side) 1. Reduce power. too high. 2. Contact Service. 486 – HI T-Exhaust D ZKP-Number: 20.134.931 Limit value 1 Cause Corrective action Exhaust gas temperature (D-side) 1.
  • Page 94 491 – SS ETC4 Overspeed ZKP-Number: 23.015.932 Limit value 2 Cause Corrective action Speed of the third secondary u Reduce power. turbocharger too high. 492 – AL ETC4 Cutin Failure ZKP-Number: 18.004.202 Cause Corrective action ETC4 failed to cut in. u Check control valve at turbocharger 4.
  • Page 95 503 – AL Battery Not Charging ZKP-Number: 14.500.903 Cause Corrective action Battery is not charged by battery- u Check battery-charging generator and cabling. charging generator 504 – AL CAN POM Node Lost ZKP-Number: 14.500.904 Cause Corrective action POM missing on CAN bus. u Check connection and POM.
  • Page 96 515 – AL Starter Not Engaged ZKP-Number: 21.090.926 Cause Corrective action Starter on CPM / POM could not 1. Repeat starting attempt be engaged. If the number of 2. Check CPM, starter and cabling automatic start attempts from PR 2.1090.134 Number of Start Attempts is used up then start is canceled.
  • Page 97 525 – SD P-Lube Oil (R2) ZKP-Number: 18.004.638 Cause Corrective action Redundant lube-oil pressure u Check sensor and cabling, replace as necessary. sensor faulty. Short circuit or wire break. 526 – SD T-Coolant (R2) ZKP-Number: 18.004.639 Cause Corrective action u Check sensor and cabling, replace as necessary. Redundant coolant pressure sensor faulty.
  • Page 98 543 – AL Multiple FDH Slaves ZKP-Number: 20.555.005 Cause Corrective action There is more than one device u Contact Service. activated as backup medium for 544 – AL Configuration Changed ZKP-Number: 20.555.003 Cause Corrective action u Fault remains active until changes are revoked or data have been This fault becomes active in cases in which the system configuration transferred by active maintenance.
  • Page 99 555 – AL Call MTU Field Service ZKP-Number: 20.555.001 Cause Corrective action This fault becomes active if a u Request enabling code via internet. maintenance case has been processed by the ECU Field Data Handling (FDH) feature that results in a change of engine parameters.
  • Page 100 580 – AL MD CAN Speed Limitation ZKP-Number: 21.063.513 Cause Corrective action MD speed limitation demand => node failure (node 3,4 or 5) 581 – AL MD CAN Stop ZKP-Number: 21.063.515 Cause Corrective action MD CAN stop demand => node failure (node 3,4 or 5) 100 | Troubleshooting | MS15058/01E 2017-05...

  • Page 101: Task Description

    8 Task Description 8.1 Engine 8.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring gear F6555766 Ratchet with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 102 Engage barring gear (2) in ring gear of fly- wheel and mount on flywheel housing. Fit ratchet (1) on barring gear. Note: No resistance other than compression resist- ance must be encountered. Rotate crankshaft in engine direction of rota- tion. Result: If the resistance exceeds the normal com- pression resistance, contact Service.

  • Page 103: Engine - Turning On Starting System

    8.1.2 Engine – Turning on starting system DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before barring the engine, make sure that there are no persons in the engine's danger zone. •...

  • Page 104: Engine - Test Run

    8.1.3 Engine – Test run DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.

  • Page 105: Cylinder Liner

    8.2 Cylinder Liner 8.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 120). Remove injector (→...
  • Page 106 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 107). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 107: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    8.2.2 Cylinder liner – Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina- tion report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 108 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and burn marks are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 109: Crankcase Breather

    8.3 Crankcase Breather 8.3.1 Crankcase breather – Oil mist fine separator replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil mist fine separator (→ Spare Parts Catalog) O-ring (→...

  • Page 110: Crankcase Breather - Filter Element Replacement

    8.3.2 Crankcase breather – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Engine oil Filter insert (→ Spare Parts Catalog) Sealing ring (→...
  • Page 111 Unscrew nut (2) remove together with wash- ers. Remove cover (1) and sealing ring. Replace filter element (3). Replace sealing ring as necessary. Install sealing ring and cover (1). Screw on new nut (2) with new washers and tighten nut (2) to specified torque using a torque wrench. Name Size Type...

  • Page 112: Valve Drive

    8.4 Valve Drive 8.4.1 Valve protrusion – Measurement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Measuring jig 1 Y4350009 Depth gage, 200 mm Y20000918 Measuring jig 2, optional Y4350010 Preparatory steps Remove cylinder head covers (→...
  • Page 113 Turn measuring unit screws (1) into the threads and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque 20 Nm Set all dial gages to 0. Unscrew measuring unit (2) from calibration plate (3). Step 1: Measure valve protrusion at the valve head with measuring jig 1 Check TDC position of piston in cylinder A1: •...
  • Page 114 Release adjusting screw (1) and remove valve bridge. Do not remove rocker arm (2). Measure distance (A) between valve stem end and cylinder head top at the injector bore with depth gage. • The specified value for a new cylinder head: 93.8 mm.
  • Page 115 Note: Do not remove rocker arm (2). Release adjusting screw (1) and remove valve bridge. Place measuring unit 2 (2) on the cylinder head (3). Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specified torque using a torque wrench.

  • Page 116: Valve Gear - Lubrication

    8.4.2 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication Remove cylinder head covers (→ Page 120). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 117: Valve Clearance - Check And Adjustment

    8.4.3 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y20098771 Torque wrench, 60–320 Nm F30452768...
  • Page 118 Note: Risk of confusion: Additional OT/A1 mark (1) on flywheel, if fitted. The additional OT/A1 mark (1) on the perim- eter of the flywheel must not be used for ref- erence. Diagram for 20V engines (two crankshaft positions) Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: •...

  • Page 119: Adjusting Valve Clearance

    Adjusting valve clearance Release locknut (1). Insert feeler gauge (3) between valve bridge and rocker arm. Note: Replace or rectify adjusting screws and/or locknuts which do not move freely. Using Allen key, set adjusting screw (2) so that the specified valve clearance is provided. Note: Feeler gauge must just pass through the gap.

  • Page 120: Cylinder Head Cover - Removal And Installation

    8.4.4 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Assembly compound (Kluthe Hakuform 30-15) X00067260 O-ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal.

  • Page 121: Injection Pump / Hp Pump

    8.5 Injection Pump / HP Pump 8.5.1 HP fuel pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Fuel suction device F30378207 Engine oil WARNING...
  • Page 122 Preparatory steps Loosen nut (2) and remove oil line (1) from HP pump. HP pump – Filling Remove union (1). Note: Excess engine oil runs into gear box. Use fuel suction device to fill HP pump with 2 liters of clean engine oil. Screw in union (1) and use torque wrench to tighten to specified tightening torque.

  • Page 123: Injector

    8.6 Injector 8.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 124). MS15058/01E 2017-05 | Injector | 123...

  • Page 124: Injector - Removal And Installation

    8.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal device F6789889 Milling cutter F30452739 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340...
  • Page 125 Nameplate The nameplate contains the following infor- mation: 1. DMC - Data Matrix Code 2. L'Orange part number 3. MTU part number 4. IIG code (Initial Injector Equalization) 5. EMI-ID code 6. Serial number 7. Date of manufacture Preparatory steps Allow HP system to cool down.
  • Page 126 Note: Be aware of system pressure. Slowly loosen union on HP line (4). Remove HP fuel line (4). Note: When the adapter is unscrewed, the stored volume of the injector is drained. Remove adapter (3). Remove screw (2) and take off hold-down clamp (1).
  • Page 127 Installing new injector Note: • The new sealing ring is included in the scope of supply of the injector. • A multi-purpose grease without solids must be used. Install new sealing ring (1) abutted to (Multi- purpose grease) and ensure that the installa- tion position is correct.
  • Page 128 Coat screw mating face (2) and thread with engine oil. Fit hold-down clamp (1) in correct position, fit screw (2) and tighten by hand. Note: Make sure parts are perfectly clean. Apply engine oil to thread, sealing taper and thrust ring of adapter (3). Apply (Assembly compound (Kluthe Haku- form 30-15)) to O-rings on adapter (3).
  • Page 129 Installing HP lines (double-walled HP system) Note: Make sure parts are perfectly clean. Coat thread, sealing cone and thrust ring of HP line (5) with engine oil. Coat O-rings with (Assembly compound (Kluthe Hakuform 30-15)). Thread in HP line (5), ensuring that the sealing areas are not damage. Use torque wrench to tighten HP line (5) according following to tightening sequence to specified tightening torque.

  • Page 130: Fuel System

    8.7 Fuel System 8.7.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
  • Page 131 Note: See figure (a). Unlock hand pump: Hold sleeve (2) firmly. Turn handle (1) counterclockwise until the sleeve can be pushed backwards (arrow). Note: • See figure (b). • After pulling the handle, wait briefly until the chamber is optimally filled. Operate the pump with the handle (1) until bubble-free fuel escapes from the vent plug.

  • Page 132: Fuel Filter

    8.8 Fuel Filter 8.8.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 133: Additional Fuel Filter - Replacement

    8.8.2 Additional fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 134: Fuel Prefilter - Pressure Ratios

    8.8.3 Fuel prefilter – Pressure ratios Pressure ratios Note: • If the fuel prefilter is above the full level of the fuel tank, during engine operation the fuel pressure in the filter is lower than ambient pressure (vacuum). • If the fuel prefilter is below the empty level of the fuel tank, during engine operation the fuel pressure in the filter is higher than ambient pressure (overpressure).

  • Page 135: Fuel Prefilter (Non-Switchable) - Draining

    8.8.4 Fuel prefilter (non-switchable) – Draining DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Fuels are combustible and explosive.
  • Page 136 Open threaded vent plug (1) of filter to be serviced. Open drain screw (1). Allow water to drain. Close drain screw (2) again. Drain second filter on module, from (→ Step 4). Open fuel supply. Vent fuel prefilter (→ Page 146). Draining fuel prefilter with high pressure, version B Note:...

  • Page 137: Fuel Prefilter (Switchable) - Draining

    8.8.5 Fuel prefilter (switchable) – Draining DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Fuels are combustible and explosive.
  • Page 138 During engine operation, turn the switchover level as far as the stop (arrow) to cut out the filter module to be serviced. Result: • Filter module (1) is cut in • Filter module (2) is cut out Open threaded vent plug (1) of filter to be serviced.
  • Page 139 Draining fuel prefilter with high pressure, version B Note: The filter modules can be drained without switchover during engine operation and at engine stand- still! Provide a suitable container to collect the water. Take care when opening drain screw (1) be- cause fuel or water can spurt out.

  • Page 140: Fuel Prefilter (Switchable) - Contamination Indicator Check

    8.8.6 Fuel prefilter (switchable) – Contamination indicator check Contamination indicator on switchable fuel prefilter Check contamination indicator at low pres- sure gage (3): • Red zone (1): -1.0 bar to -0.4 bar (low pressure) • Green zone (2): -0.4 bar to +0.5 bar (nor- mal operation) Switch over the fuel prefilter or replace a fil- ter element (→...
  • Page 141 8.8.7 Fuel prefilter (non-switchable) – Filter element replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 Ratchet adapter F30027340 Diesel fuel Filter parts kit (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
  • Page 142 Open threaded vent plug and ensure that fuel does not emerge continuously. Result: The filter can now be changed! If fuel emerges continuously, check shutoff valve in fuel supply, notify Service. Note: • As soon as the filter housing is opened, absolute cleanness is imperative! •...

  • Page 143: Replacement

    8.8.8 Fuel prefilter (switchable) – Filter element replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 Ratchet adapter F30027340 Diesel fuel Filter parts kit (→ Spare Parts Catalog) DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 144 During engine operation, turn the switchover level as far as the stop (arrow) to cut out the filter module to be serviced. Result: • Filter module (1) is cut in • Filter module (2) is cut out Check fuel level in filter. Result: If the fuel level is stable, the filter can be changed!
  • Page 145 Open threaded vent plug and ensure that fuel does not emerge continuously. Result: The filter can now be changed! If fuel emerges continuously, check shutoff valve in fuel supply, notify Service. Note: • As soon as the filter housing is opened, absolute cleanness is imperative! •...
  • Page 146 8.8.9 Fuel prefilter – Venting DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Fuels are combustible and explosive.
  • Page 147 Release threaded vent plugs (2, 3) and un- screw at least one rotation. Note: • Only operate the fuel priming pump man- ually! • Only hold the pump plunger vertically to avoid damaging the pump! Unlock fuel priming pump, screw out han- dle (1).
  • Page 148 8.9 Charge-Air Cooling 8.9.1 Charge-air cooler – Check water drain for coolant leakage and obstruction DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 149: Air Filter

    8.10 Air Filter 8.10.1 Air filter ‒ Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Air filter ‒ Replacement Remove air filter and install new one (→ Page 151). Reset signal ring of service indicator (→ Page 154). MS15058/01E 2017-05 | Air Filter | 149...

  • Page 150: Air Filter – Check

    8.10.2 Air filter – Check Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Checking air filter Check entire circumference of air filter for damage. Fit new air filter if damaged (→ Page 151). 150 | Air Filter | MS15058/01E 2017-05...
  • Page 151 8.10.3 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque screwdriver, 1–5 Nm F30452774 Removing and installing air fil- Release clamp (2). Remove air filter (1) and clamp (2) from con- necting flange of intake housing (3).

  • Page 152: Element Removal And Installation

    8.10.4 Heavy duty air filter – Filter insert and filter element removal and installation Preconditions ☑ Engine-generator set is stopped and starting disabled. ☑ Stepladder, platform, or similar equipment is provided. Special tools, Material, Spare parts Designation / Use Part No. Qty.
  • Page 153 Heavy duty air filter – Version B Release closures (1). Remove cover (2). Remove filter insert (3) and filter element (4). Wipe out filter housing (5) and cover (2) with a damp cloth. Insert new filter element (4) and filter in- sert (3).

  • Page 154: Air Intake

    8.11 Air Intake 8.11.1 Service indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position When the yellow piston (2) has reached the red-shaded Service lettering (3), replace air filter (→ Page 149). After installation of new filter, press reset button (1).

  • Page 155: Engine Oil – Change

    8.12 Lube Oil System, Lube Oil Circuit 8.12.1 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty.
  • Page 156 Draining residual oil from equip- ment carrier (only with un- scheduled engine oil change) Provide a suitable container in which to col- lect the engine oil. Remove drain plug (1) and drain engine oil from engine oil heat exchanger and from en- gine oil filter.
  • Page 157 8.12.2 Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Oil is hot. Oil can contain residue/substances which are harmful to health. Risk of injury and poisoning! • Allow the product to cool to below 50 °C before beginning work. •...
  • Page 158 8.12.3 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit F6798833 Engine oil DANGER Components are moving or rotating.
  • Page 159 Screw Tightening torque (Engine oil) 20 Nm +2 Nm Use equipment and chemicals in MTU test kit to analyze engine oil for: • Dispersing capacity (spot test) • Proportion of water • Dilution by fuel MS15058/01E 2017-05 | Lube Oil System, Lube Oil Circuit | 159...
  • Page 160 8.12.4 Oil priming pump – Visual check Oil priming pump, visual check Inspect oil priming pump and connections for secure condition and leaks. Retighten thread- ed connections if necessary. Check whether oil emerges at the leak tell- tale bore (2). If oil emerges, the gear pump (1) usually has to be changed.
  • Page 161 8.13 Oil Filtration / Cooling 8.13.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Oil is hot.
  • Page 162 8.13.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 10–60 Nm F30452769 Cold cleaner (Hakutex 60) X00056750 Filter sleeve (→...
  • Page 163 Wash rotor cover (3), rotor tube (7), conical disk (8) and rotor base (13) with cold cleaner. Blow out with compressed air. Check sealing rings (9, 10, 12), fit new ones if necessary. Apply assembly compound to sealing rings (9, 10) and insert them in grooves of bearing axle (11). Assemble rotor tube (7), conical disk (8) and rotor base (13) with sealing ring (12).

  • Page 164: Circuit

    8.14 Coolant Circuit, General, High-Temperature Circuit 8.14.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 165 8.14.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 166). Fill with engine coolant (→ Page 168). MS15058/01E 2017-05 | Coolant Circuit, General, High-Temperature Circuit | 165...

  • Page 166: Draining Engine Coolant

    8.14.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. DANGER Falling from great heights. Risk of serious injury – danger to life! • When working high on the equipment, always use suitable ladders or work platforms. •...
  • Page 167 Close all other open drain points. Position valve cover on filler neck and close. MS15058/01E 2017-05 | Coolant Circuit, General, High-Temperature Circuit | 167...

  • Page 168: Engine Coolant – Filling

    8.14.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant DANGER Falling from great heights.
  • Page 169 Preparatory steps Turn valve cover on coolant expansion tank (1) counterclockwise until the first stop and release pressure. Continue to turn valve cover (1) counter- clockwise and remove. Filling with coolant from below using a pump Open venting point on distributor (arrow). MS15058/01E 2017-05 | Coolant Circuit, General, High-Temperature Circuit | 169...
  • Page 170 Note: Important: Fill engine only from below! Connect appropriate pump with hose to drain valve of engine coolant pump (1). Open shutoff cock on elbow of engine cool- ant pump (2) and pump coolant with at least 0.5 bar into engine. When coolant emerges from the venting point, close the venting point.
  • Page 171 Top up coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. When coolant emerges from the venting point, close the venting point. Check proper condition of valve cover (1) on coolant expansion tank and clean sealing faces if required.
  • Page 172 8.14.5 Engine coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
  • Page 173 8.14.6 Engine coolant – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 174 Using the equipment and chemicals from the MTU test kit, examine coolant for: • antifreeze concentration • Amount of corrosion protection oil • pH value For engine coolant change intervals, refer to (→ MTU Fluids and Lubricants Specifications (A001061/..)). 174 | Coolant Circuit, General, High-Temperature Circuit | MS15058/01E 2017-05...
  • Page 175 8.14.7 Preheater – Overview 1 Flange 4 Thermostat 7 Crankcase 2 Pump 5 Screw-in heating element 3 Non-return flap 6 Drain plug Variant Heating output Rated voltage Frequency Phases 6.75 kW 400 V 50 Hz 9 kW 440 V 60 Hz 9 kW 400 V 50 Hz...
  • Page 176 8.14.8 Preheater – Overhaul Preconditions ☑ Engine is stopped and starting disabled. DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! • Make certain that the power supply to the product is switched off before starting work. Secure against unintentional switching on! WARNING Hot components/surfaces.
  • Page 177 Overhauling preheater (once a year, minimum) Clean and flush housing (2). Check hoses for cracks and other damage. Replace as necessary. Check wiring for damage and overheating. Tighten screws, nuts and all electrical con- nections. Release screws (3) on protective caps of the heating elements (4) and remove protective caps.

  • Page 178: Check

    8.14.9 Electrical operation of heating elements – Check DANGER Electrical voltage at exposed terminals and components. Risk of serious injury - danger to life! • Work must be carried out by trained, qualified and approved according to the regional regulations personnel only! •...
  • Page 179 8.14.10 Preheater – Function and leak-tightness check Preconditions ☑ Preheater is switched on. WARNING Coolant is hot and highly pressurized. Risk of injury! Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking operation Note: The coolant temperature must correlate to the control range of the thermostat when the preheater is ready...
  • Page 180 8.14.11 Valve cover – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Valve cover (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 181 8.15 Low-Temperature Circuit 8.15.1 Charge-air coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
  • Page 182 8.15.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 183). Fill with charge-air coolant (→ Page 185). 182 | Low-Temperature Circuit | MS15058/01E 2017-05...
  • Page 183 8.15.3 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 184 Drain remaining coolant at intercooler (ar- row). Tighten drain valve to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Spindle 11 A/F Tightening torque 12 Nm Close the remaining drain valves and screw in drain plugs with new sealing rings. Fit valve cover on filler neck and close it.
  • Page 185 8.15.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING Coolant is hot and under pressure.
  • Page 186 Filling coolant with pump Connect appropriate pump with hose to drain valve (1). Release the vent line union at the distributor piece (1). Open drain valve and pump coolant into en- gine at 0.5 bar minimum. Tighten union (arrow) if coolant leaks out at loose union.
  • Page 187 Alternatively: Filling coolant through filler neck Release the vent line union at the distributor piece (1). Top up coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. Tighten union (arrow) if coolant leaks out at loose union.
  • Page 188 8.15.5 Charge-air coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 189: Belt Drive

    8.16 Belt Drive 8.16.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Protective cover is removed. Drive belt – Condition check Item Findings Measure Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace (→...
  • Page 190 8.17 Battery-Charging Generator 8.17.1 Battery-charging generator – Drive belt tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm F30452768 Ratchet adapter F30027341 Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340...
  • Page 191 8.17.2 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm F30452768 Ratchet adapter F30027341 Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340 Drive belt...
  • Page 192 8.18 Wiring (General) for Engine/Gearbox/Unit 8.18.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.
  • Page 193 8.19 Engine Mounting / Support 8.19.1 Engine mounting – Check Engine mounting – Check Item Findings Action Visually inspect resilient mounts. • Damage Replace (contact Service). • Brittleness • Deformation • Crack formation • Swelling MS15058/01E 2017-05 | Engine Mounting / Support | 193...
  • Page 194 8.20 Accessories for (Electronic) Engine Governor / Control System 8.20.1 Engine governor and connector – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g.
  • Page 195 8.20.2 Engine governor plug connections – Check Preconditions ☑ Engine stopped and starting disabled. ☑ Electronic engine management system is de-energized. NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! • Carry out check of plug connection only with test connectors. Checking plug connections at engine governor Check all plug connections for secure seating.

  • Page 196: Installation

    8.20.3 Engine governor ECU 9 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Protective cover over connectors on Heavy-Duty version removed. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.
  • Page 197 9 Appendix A 9.1 Conversion tables Length Unit A multiplied by factor = Unit B 25.4 = mm 0.3048 0.9144 stat. mile 1.609 = km 1.852 = km = ft = in Unit B multiplied by factor = Unit A 0.03937 = in 3.281...
  • Page 198 Unit B multiplied by factor = Unit A 0.2642 = gallon (U.S.) 0.22 = gallon (UK) Volumetric flow Unit A multiplied by factor = Unit B gal/min (GPM, U.S.) 3.79 = l/min gal/min (GPM, U.S.) 0.134 = ft /min (cfm) 1.70 /min (cfm) Unit B...
  • Page 199 Unit B multiplied by factor = Unit A 2.205 = lbf 0.10197 = kp 0.2248 = lbf Density Unit A multiplied by factor = Unit B 515.4 slug/ft = kg/m Unit B multiplied by factor = Unit A 0.00194 kg/m = slug/ft Torque Unit A...

  • Page 200: Fuel Consumption

    Energy Unit A multiplied by factor = Unit B lbf ft 1.356 kcal 4186.8 1055 1899 Unit B multiplied by factor = Unit A 0.7376 = lbf ft 0.0002388 = kcal 0.0009478 = BTU 0.00052656 = CHU Power Unit A multiplied by factor = Unit B 0.7355...
  • Page 201 Unit B multiplied by factor = Unit A km/l 2.3527 = mile/gal (US) l/km 0.4251 = gal/mile (US) MS15058/01E 2017-05 | Appendix A | 201...
  • Page 202 Abgasturbolader/Abgasturboaufladung Exhaust turbocharger/exhaust turbocharging Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica- tion No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Drift correction setting with DiaSys in engine gover- Check Engine Lamp...
  • Page 203 Abbre- Meaning Explanation viation Electrically Erasable Programmable Read Electrically Erasable Programmable Read Only Mem- PROM Only Memory EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal Exhaust Gas Recirculation Engine Ident Label EIM-ID Emission Identification Number Engine Monitoring Unit ESCM Extreme Site Condition Management Power reduction for operation in extreme conditions Single accumulator pressure Ersatzteilkatalog...
  • Page 204 Abbre- Meaning Explanation viation Normal Null Reference surface for heights above sea level Niedertemperatur Low temperature Original Equipment Manufacturer Optimized Idle Oil Level Sensor Monitors oil level Oil Pressure Sensor Monitors oil pressure Oil Temperature Sensor Monitors oil temperature Oberer Totpunkt Top Dead Center Panel Control panel...
  • Page 205 Local Support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h Hotline With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase, preventive maintenance and corrective operations in case of a malfunction, for information on changes in conditions of use and for supplying spare parts.

  • Page 206: Special Tools

    10 Appendix B 10.1 Special Tools Barring gear Part No.: F6555766 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 101) Barring tool Part No.: F6555766 Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 105) Crossbeam Part No.: T80091826 Qty.:...
  • Page 207 Crossbeam Part No.: T80092360 Qty.: Used in: 2.1 Transportation (→ Page 17) Depth gage, 200 mm Part No.: Y20000918 Qty.: Used in: 8.4.1 Valve protrusion – Measurement (→ Page 112) Endoscope Part No.: Y20097353 Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→...
  • Page 208 Filter wrench Part No.: F30379104 Qty.: Used in: 8.8.1 Fuel filter – Replacement (→ Page 132) Qty.: Used in: 8.8.2 Additional fuel filter – Replacement (→ Page 133) Qty.: Used in: 8.13.1 Engine oil filter – Replacement (→ Page 161) Fuel suction device Part No.: F30378207...
  • Page 209 8.4.1 Valve protrusion – Measurement (→ Page 112) Milling cutter Part No.: F30452739 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 124) MTU test kit Part No.: F6798833 Qty.: Used in: 8.12.3 Engine oil – Sample extraction and analysis (→ Page 158)
  • Page 210 MTU test kit Part No.: 5605892099/00 Qty.: Used in: 8.14.6 Engine coolant – Sample extraction and analysis (→ Page 173) Ratchet adapter Part No.: F30027341 Qty.: Used in: 8.4.3 Valve clearance – Check and adjustment (→ Page 117) Qty.: Used in: 8.6.2 Injector –...
  • Page 211 Ratchet with extension Part No.: F30006212 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 101) Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 105) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 8.4.3 Valve clearance – Check and adjustment (→...
  • Page 212 Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 2.3 Crankshaft transport locking device (→ Page 19) Qty.: Used in: 8.3.2 Crankcase breather – Filter element replacement (→ Page 110) Qty.: Used in: 8.5.1 HP fuel pump – Filling with engine oil (→ Page 121) Qty.: Used in: 8.6.2 Injector –...
  • Page 213 Torque wrench, 6–50 Nm Part No.: F30027336 Qty.: Used in: 8.8.7 Fuel prefilter (non-switchable) – Filter element re- placement (→ Page 141) Qty.: Used in: 8.8.8 Fuel prefilter (switchable) – Filter element replace- ment (→ Page 143) MS15058/01E 2017-05 | Special Tools | 213...
  • Page 214 10.2 Index Cylinder head cover  – Installation  120 Abbreviations 202 – Removal  120 Actuators  Cylinder liner  – Overview  25 – Endoscopic examination  105 Additional fuel filter  – Instructions and comments on endoscopic and visual – Replacement  133 examination  107 After stopping the engine  –...
  • Page 215 – Filter sleeve   – Replacement  162 Maintenance schedule  – Sample extraction and analysis  158 – Maintenance task reference table [QL1]  47 Engine oil filter  MTU contact persons 205 – Replacement  161 Engine oil level  – Check  157 Oil priming pump  Engine sides ...
  • Page 216 Safety system  – Override  39 Sensors  – Overview  25 Service indicator  – Check  154 Service partners 205 Shipping lock  – Engine mount   – Installation  22 – Removal  22 Spare parts service 205 Starting system  – Turning   – Engine  103 Transport locking device  –...

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