MTU 20V4000G44F Operating Instructions Manual
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MTU 20V4000G44F Operating Instructions Manual

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Operating Instructions
Diesel Engine
20V4000G44F
20V4000G44LF
20V4000G94F
20V4000G94LF
MS15058/04E

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Summary of Contents for MTU 20V4000G44F

  • Page 1 Operating Instructions Diesel Engine 20V4000G44F 20V4000G44LF 20V4000G94F 20V4000G94LF MS15058/04E...
  • 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 WARNING WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system.

  • Page 5: Table Of Contents

    8.2.2 Cylinder liner – Instructions and comments on endoscopic and visual examination 4 Technical Data 8.3 Crankcase Breather 8.3.1 Crankcase breather – Oil mist separator 4.1 Product data 20V4000G44F, replacement 20V4000G44LF 8.3.2 Crankcase breather – Filter element 4.2 Product data 20V4000G94F,...
  • Page 6 9.3 Tightening specifications for screws, nuts 8.14.7 Preheater – Overview and bolts 8.14.8 Preheater – Overhaul 9.4 MTU Contact/Service Partners 8.14.9 Preheater – Function and leak check 8.14.10 Preheater – Heating element and housing 10 Appendix B check 8.14.11 Preheater – Solenoid switch replacement 10.1 Special Tools...

  • Page 7: Safety

    Nameplates, model designation or serial number can be found on the product. All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv- ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system is not visible without the removal of components, the system integrator must install the second nameplate in a clearly visible area on the vehicle/system.
  • Page 8 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 9: Important Requirements For Power Generation Application Products

    1.2 Important requirements for Power Generation application products Project-specific operational environment During integration and use of the diesel engine, all currently valid and relevant standards and guidelines on safety and specified operation must be implemented and observed. This applies to persons responsible for: •...
  • Page 10 Chemical resistance Only use hoses, pipes, fittings, etc. that can tolerate the fluids and lubricants in accordance with the Fluids and Lubricants Specifications. Only use options that are resistant to the fluids and lubricants in accordance with the Fluids and Lubricants Specifications. Electrical devices The IP protection class of the electrical devices required by the manufacturer must be observed.

  • Page 11: Gendrive Engines - Intended Use

    • 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 12: Personnel And Organizational Requirements

    1.4 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 13: Safety Regulations For Initial Start-Up And Operation

    1.5 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 14 Do not inhale the exhaust gases of the product. The following requirements must be fulfilled before the product is started: • Wear ear protectors. • Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent. Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live.

  • Page 15: Safety Regulations For Assembly, Maintenance, And Repair Work

    1.6 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 from oil vapors, fluids and lubricants, risk of burning).
  • Page 16 Assume a safe standing position when performing assembly work. 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 17 Welding work Welding operations on the product or mounted units are not permitted. Cover the product when welding in its vicinity. Before starting welding work: • Switch off the power supply master switch. • Disconnect the battery cables or actuate the battery isolating switch. •...
  • Page 18 Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur- ing operation by: • Contact with sharp edges • Chafing on components • Contact with hot surfaces. Do not secure cables on lines carrying fluids. Do not use cable ties to secure lines.

  • Page 19: Fire And Environmental Protection, Fluids And Lubricants

    Process materials can also be or contain hazardous or toxic substances. When using process materials and other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi- cations must be used.
  • Page 20 Particularly hazardous substances used with our products are named in a list: • For drive systems: www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products • For power generation: www.mtuonsiteenergy.com/technische-infos → Tools and Downloads → SVHC ACC. REACH IN MTU PRODUCTS Compressed air •...

  • Page 21: Standards For Warning Notices In The Text And Highlighted Information

    1.8 Standards for warning notices in the text and highlighted information 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 22: Transport

    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. 20 | Transport | MS15058/04E 2018-12...

  • Page 23: Lifting Requirements

    2.2 Lifting requirements DANGER Suspended load. Danger to life! • Use suitable equipment and lifting devices. • Never stand beneath a suspended load and keep a safe distance. • Wear personal protective equipment (e.g. protective helmet, safety shoes). 1 Max. admissible diagonal B 1434.2 mm E 932 mm pull 10°...

  • Page 24: 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 25 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 26 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 27: 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 28: 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 29: Engine Layout

    3.2 Engine layout 1 Intercooler 5 Engine mounting 9 Engine Control Unit ECU 2 Exhaust turbocharger 6 Charge-air pipework 10 Starter 3 Crankcase breather 7 Cylinder head 11 Flywheel 4 Coolant pipework 8 Cylinder head cover MS15058/04E 2018-12 | General Information | 27...
  • Page 30 1 Oil cooler 7 Wastegate 13 Gearcase 2 Exhaust pipework 8 Oil filler neck 14 HP fuel pump 3 Exhaust pipe bellows 9 Additional fuel filter 15 Vibration damper 4 Intake housing 10 Fuel filter 16 Coolant distribution housing 5 Air filter 11 Fuel hand pump 17 LT thermostat housing 6 Starter...

  • Page 31: Sensors And Actuators - Overview

    3.3 Sensors and actuators – Overview 1 A19 (EIL – Engine Ident La- 4 B34.3 (fuel pressure before 7 B9 (charge-air temperature bel) intermediate filter) sensor) 2 B48.1 (diverter / bleeder 5 B48.1 (HP pressure sensor, flap) A side) 3 K39A1 - K39A10 (injector, 6 B34.1 (fuel pressure after cylinder A1 - A10) filter)
  • Page 32 1 B50 (crankcase pressure 4 B5.1 (lube oil pressure sen- 7 B54 (pressure sensor, lube sensor) sor after filter) oil replenishment pump) 2 B5.3 (lube oil pressure sen- 5 B1 (camshaft speed sensor) 8 B26 (charge-air coolant sor before filter) 6 M8 (HP fuel pump restric- temperature sensor) 3 B7 (lube oil temperature...
  • Page 33 1 XF557 (LT coolant level sen- 3 K39B1 - K39B10 (injector, 5 B10 (charge-air pressure sor (remote expansion cylinder B1 - B10) sensor) tank)) 4 B48.2 (HP pressure sensor, 2 XF533 (HT coolant level B side) sensor (remote expansion tank)) MS15058/04E 2018-12 | General Information | 31...
  • Page 34 1 B13 (crankshaft speed sen- sor) 1 M46 (diverter / bleeder 2 B44 (exhaust turbocharger flap) speed sensor) 32 | General Information | MS15058/04E 2018-12...

  • Page 35: Technical Data

    4 Technical Data 4.1 Product data 20V4000G44F, 20V4000G44LF Legend DL Reference value, continuous power, continuously attainable 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 Approximate value, typical average value for information, not ideally suitable for purposes of design L Limit value, value which must not be violated (lower limit value, min.
  • Page 36 Reference condition Intake air temperature °C Charge air coolant tem- °C perature Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut-in / cut-out control) Rating Rated engine speed 1500...
  • Page 37 Consumption Specific fuel consumption g/kWh 198 * 196 * 198 * (be) - 100% DL (+5%; EN 590; 42.8 MJ/kg) Fuel consumption at zero kg/h load Model-related data (basic design) Engine with exhaust tur- bocharging (ETC) and charge-air cooling (inter- cooler) Uncooled exhaust lines Operating method: four-...
  • Page 38 Coolant system (HT circuit) Coolant temperature (at °C 100.0 100.0 100.0 100.0 100.0 100.0 engine connection: outlet to cooling equipment) Coolant temperature after °C 102.0 102.0 102.0 102.0 102.0 102.0 engine, limit 1 Coolant temperature after °C 104.0 104.0 104.0 104.0 104.0 104.0...
  • Page 39 Capacities Engine coolant, engine- Liters side (w/o cooling equip- ment) Charge-air coolant, en- Liters gine side Fuel, engine side Liters Total engine oil capacity, Liters initial filling (standard oil system) (option: max. op- erating inclinations) Oil change quantity, max. Liters (standard oil system) (op- tion: max.
  • Page 40 Engine surface noise with dB(A) attenuated intake noise (filter) - DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) - DL (sound power level LW, ISO 6798, +2 db(A) tolerance) 38 | Technical Data | MS15058/04E 2018-12...

  • Page 41: Product Data 20V4000G94F, 20V4000G94Lf

    4.2 Product data 20V4000G94F, 20V4000G94LF DL Reference value: Continuous power, continuously attainable power under standard conditions BL Reference value: Fuel stop power, maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations) A Design value, value required to design an external system (plant) R Guideline value, typical average value for information, not ideally suitable for purposes of design L Limit value, value which must not be violated (lower limit value, min.
  • Page 42 Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut-in / cut-out control) Power-related data Rated engine speed 1500 1500 1500 1500 1500 1500 Fuel stop power ISO 3088 3088 3088 3308 3308 3308 3046 Site conditions (for max. power) Intake depression (new mbar filter)
  • Page 43 Model-related data (basic design) Engine with exhaust tur- bocharging (ETC) and charge-air cooling (inter- cooler) Uncooled exhaust lines Operating method: four- stroke cycle, diesel, sin- gle-acting Combustion method: di- rect injection Cooling method: treated water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V Degrees...
  • Page 44 Coolant system (LT circuit) Coolant temperature (at °C 70.0 80.0 70.0 70.0 80.0 70.0 engine connection: outlet to cooling equipment) Coolant temperature be- °C 75.0 75.0 75.0 75.0 75.0 75.0 fore intercooler, limit 1 Coolant temperature be- °C 78.0 78.0 78.0 78.0 78.0...
  • Page 45 Oil pan capacity at dip- Liters stick mark “min.” (stand- ard oil system) (option: max. operating inclina- tions) Oil pan capacity at dip- Liters stick mark “max.” (stand- ard oil system) (option: max. operating inclina- tions) Mass / main dimensions Engine mass, dry (stand- 9650 9650...

  • Page 46: Firing Order

    4.3 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 44 | Technical Data | MS15058/04E 2018-12...

  • Page 47: Engine- Main Dimensions

    4.4 Engine– Main dimensions Engine model Length (A) Width (B) Height (C) 20V4000Gx4F/LF 3478.3 mm 1699.2 mm 2251.9 mm MS15058/04E 2018-12 | Technical Data | 45...

  • Page 48: 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 49: 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 153); Coolant circuit Check engine coolant level (→ Page 160). Check charge-air coolant level (→ Page 183). Coolant circuit Heat engine coolant with coolant preheater.

  • Page 50: Starting The Engine In Manual Mode (Test Run)

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

  • Page 51: Re-Starting The Engine Following An Automatic Safety Shutdown

    5.4 Re-starting the engine following an automatic safety shutdown NOTICE Re-starting the engine following an automatic safety shutdown. Risk of severe engine damage! • Before starting the engine, make sure the root cause of the safety shutdown was eliminated. • If the root cause cannot be identified or eliminated, contact Service. Note: •...

  • Page 52: Safety System - Override

    5.5 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 53: Operational Monitoring

    5.6 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 Exhaust gases are harmful to health and may cause cancer.

  • Page 54: Emergency Engine Start (Override Mode)

    5.7 Emergency engine start (Override mode) 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 55: Engine - Stopping In Manual Mode (Test Run)

    5.8 Engine – Stopping in Manual mode (test run) Preconditions ☑ Generator (if applicable) is not connected to network ☑ Engine is in Manual mode DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 56 After engine shutdown Item Action Coolant circulating pump Allow to run on for sufficient time after stopping. 54 | Operation | MS15058/04E 2018-12...

  • Page 57: Emergency Engine Stop

    5.9 Emergency engine stop 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 A high level of noise is produced when the engine is running.

  • Page 58: After Stopping The Engine - Engine Remains Ready For Operation

    5.10 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 56 | Operation | MS15058/04E 2018-12...

  • Page 59: After Stopping The Engine - Putting The Engine Out Of Operation

    5.11 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 162); Drain charge-air coolant (→ Page 186) if: •...

  • Page 60: Plant - Cleaning

    5.12 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 61: Maintenance

    6 Maintenance 6.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte- nance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
  • Page 62 Task Item Maintenance tasks WM00215 FUEL SUPPLY SYSTEM Drain water and contaminants from fuel prefilter (→ Page 129) (→ Page 131) WM00214 FUEL SUPPLY SYSTEM Replace filter element (→ Page 136) (→ Page 138) WM00228 FUEL PIPEWORK FROM PUMP Check cooler elements for external contamination and leak-tightness (→...

  • Page 63: 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 64 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 65 Blue exhaust gas Cause Corrective action u Drain engine oil (→ Page 150). Too much engine oil in the engine u Replace filter (→ Page 96). Oil separator of crankcase breather contaminated Exhaust turbocharger, cylinder u Contact Service. head, piston rings or cylinder liner defective White exhaust gas Cause...

  • Page 66: Fault Messages Of The Adec (Ecu 9) Engine Governor For Series 4000 Genset Engines

    7.2 Fault messages of the ADEC (ECU 9) engine governor for Series 4000 genset engines Possible engine reactions to yellow alarm: Warning, power limitation / reduction, speed limitation, engine stop Possible engine reactions to red alarm: Engine stop, power limitation / reduction, speed limitation, warning Procedure following an automatic safety shutdown (→...

  • Page 67: Engine

    10 – SS T-Coolant Intercooler Cause Corrective action The intercooler coolant 1. Reduce power. temperature measured at sensor 2. Check whether alarm 23 is pending. B26 has violated limit value 2. 3. Check cooler (plant side) for contamination. Coolant temperature in 4.
  • Page 68 27 – HI Level Leakage Fuel Cause Corrective action u Contact Service. Switch F46 in the collection tank has tripped. A leak has occurred in the HP fuel system. 30 – SS Engine Overspeed Cause Corrective action Engine speed has violated the 1.
  • Page 69 44 – LO Coolant Level Intercooler Cause Corrective action Coolant level in LT circuit at 1. Check charge-air coolant level (→ Page 183). switch B557 is too low. 2. Check relief bore of charge-air coolant pump (→ Page 192). 3. Check coolant circuit visually for leaks. 4.
  • Page 70 65 – LO P-Fuel Cause Corrective action The fuel pressure at sensor B34.1 1. Replace fuel prefilter (→ Page 135). has violated limit value 1. Fuel 2. Replace additional fuel filter (→ Page 126). pressure is too low. 3. Replace fuel filter (→ Page 125). 4.
  • Page 71 90 – SS Idle Speed Not Reached Cause Corrective action Engine speed has not reached 1. Check pressure supply (plant) of starter. idling speed within the specified 2. Check additional fuel filter, replace as necessary (→ Page 126). time after starter disengagement 3.
  • Page 72 118 – LO ECU Power Supply Voltage Cause Corrective action The supply voltage of the ECU has 1. Check state of charge of batteries (plant side). undershot specified limit value 1. 2. Check plug connections to Engine Control Unit (→ Page 207). 3.
  • Page 73 325 – AL Wiring Cylinder A5 Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 196). wiring for cylinder A5 or injector 2. Replace injector (→ Page 110). faulty. 3. Contact Service. 326 –...
  • Page 74 332 – AL Wiring Cylinder B2 Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 196). wiring for cylinder B2 or injector 2. Replace injector (→ Page 110). faulty. 3. Contact Service. 333 –...
  • Page 75 339 – AL Wiring Cylinder B9 Cause Corrective action Short circuit fault in injector 1. Check wiring of affected injector (→ Page 196). wiring cylinder B9 or injector 2. Replace injector (→ Page 110). faulty. 3. Contact Service. 340 – AL Wiring Cylinder B10 Cause Corrective action Short circuit fault in the injector...
  • Page 76 347 – AL Open Load Cylinder A7 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 196). for cylinder A7. 2. Contact Service. 348 – AL Open Load Cylinder A8 Cause Corrective action Disruption fault in injector wiring 1.
  • Page 77 355 – AL Open Load Cylinder B5 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 196). to cylinder B5. 2. Contact Service. 356 – AL Open Load Cylinder B6 Cause Corrective action Disruption fault in injector wiring 1.
  • Page 78 449 – SS P-Charge Air Cause Corrective action The charge-air pressure at sensor 1. Power reduction. B10 has violated limit value 2. The 2. Check sensor B10 and replace as necessary. charge-air pressure is too high. 3. Contact Service. 454 – SS Power Reduction Active Cause Corrective action Power reduction activated.
  • Page 79 745 – AL Emission Fault 1 Cause Corrective action Emission fault summary alarm 1. Check for additional messages. 2. Contact Service. 759 – AL L1 T-Fuel b.Engine Cause Corrective action The charge-air pressure at sensor 1. Check sensor B33, replace if required. B33 has violated upper limit value 2.
  • Page 80 844 – AL HI T-Charge Air before EGR Cause Corrective action The charge-air temperature at 1. Check sensor B9.1, replace as necessary. sensor B9.1 has violated upper 2. Contact Service. limit value 1. Charge-air temperature is too high. 845 – AL HIHI T-Charge Air before EGR Cause Corrective action The charge-air temperature at...
  • Page 81 1032 – AL Inj. Drift Limit 1 Cyl. A1 Cause Corrective action u Schedule an injector replacement. The drift correction for energization (start and duration) of injector A1 has violated limit 1. The injector has soon reached its maximum drift limit. 1033 –...
  • Page 82 1038 – AL Inj. Drift Limit 1 Cyl. A7 Cause Corrective action u Schedule an injector replacement. The drift correction for energization (start and duration) of injector A7 has violated limit 1. The injector has soon reached its maximum drift limit. 1039 –...
  • Page 83 1044 – AL Inj. Drift Limit 1 Cyl. B3 Cause Corrective action u Schedule an injector replacement. The drift correction for energization (start and duration) of injector B3 has violated limit 1. The injector has soon reached its maximum drift limit. 1045 –...
  • Page 84 1050 – AL Inj. Drift Limit 1 Cyl. B9 Cause Corrective action u Schedule an injector replacement. The drift correction for energization (start and duration) of injector B9 has violated limit 1. The injector has soon reached its maximum drift limit. 1051 –...
  • Page 85 1056 – AL Inj. Drift Limit 2 Cyl. A5 Cause Corrective action u Replace injector (→ Page 110). The drift correction for energization (start and duration) of injector A5 has violated limit 2. The injector has reached its maximum drift limit. 1057 –...
  • Page 86 1062 – AL Inj. Drift Limit 2 Cyl. B1 Cause Corrective action u Replace injector (→ Page 110). The drift correction for energization (start and duration) of injector B1 has violated limit 2. The injector has reached its maximum drift limit. 1063 –...
  • Page 87 1068 – AL Inj. Drift Limit 2 Cyl. B7 Cause Corrective action u Replace injector (→ Page 110). The drift correction for energization (start and duration) of injector B7 has violated limit 2. The injector has reached its maximum drift limit. 1069 –...
  • Page 88 1167 – AL Implausible NOx High Limit1 Cause Corrective action u Contact Service. NOx emissions too high. The NOx emissions from the engine have violated limit value 1 cumulatively. 1168 – AL Implausible NOx Low Limit1 Cause Corrective action NOx emissions too low. u Contact Service.
  • Page 89 1376 – AL Refdrive Impossibl Ubat Low Cause Corrective action The ECU supply voltage is too low 1. Check state of charge of batteries (plant side). for successful homing of all flaps 2. Check plug connections to Engine Control Unit (→ Page 207). even when the engine is running.

  • Page 90: 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 tool 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 91 Engage barring tool (2) in ring gear of fly- wheel and mount on flywheel housing. Fit ratchet (1) on barring tool. 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 92: Engine - Cranking On Starting System

    8.1.2 Engine – Cranking 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 93: Engine - Test Run

    8.1.3 Engine – Test run 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 Exhaust gases are harmful to health and may cause cancer.

  • Page 94: 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 107). Remove injector (→...
  • Page 95 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 94). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 96: 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 97 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 98: Crankcase Breather

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

  • Page 99: 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 element (→ Spare Parts Catalog) Sealing ring (→...
  • Page 100 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 use torque wrench to tighten nut (2) to specified tightening torque.

  • Page 101: 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 gauge, 200 mm Y20000918 Measuring jig 2, optional Y4350010 Preparatory steps Remove cylinder head covers (→...
  • Page 102 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 103 Loosen 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 gauge. • The specified value for a new cylinder head: 93.8 mm.
  • Page 104 Note: Do not remove rocker arm (2). Loosen 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 105: 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 107). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 106: 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 107 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 108 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 109: 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. Torque wrench, 10–60 Nm F30510423 Ratchet bit F30027341 Assembly compound (Kluthe Hakuform 30-15) X00067260 Engine oil O-ring...

  • Page 110: 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 111 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 112: 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 117). 110 | Injector | MS15058/04E 2018-12...

  • Page 113: Injector Rings - Replacement

    8.6.2 Injector rings – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6789889 Milling cutter F30452739 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Torque wrench, 60–320 Nm...
  • Page 114 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 115 Note: Always be aware of system pressure. 10 mi- nutes after an engine stop, the residual pres- sure in the HP fuel system is approx. 25 bar. Slowly loosen nuts (4, 6) and remove HP fuel line (5). Note: The fuel stored in the injector drains out when the adapter (3) is unscrewed.
  • Page 116 Installing injector, replacing rings Note: • Replace sealing ring (1) between injector and water sleeve whenever the injector is disassembled. • Make sure that the sealing ring (consisting of CE-ring and support ring) is correctly seated: The closed CE-ring side must be abut on the injector, and the protruding (open) CE-ring side must face towards the combustion chamber.
  • Page 117 Coat screw head mating face and thread of hold-down clamp (2) with engine oil. Position hold-down clamp (1) properly and use a torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 100 Nm+10 Nm Undo hold-down clamp screw again.
  • Page 118 Fit cable connector on injector. Note: Do not reset drift correction (CDC) after re-in- stalling a used injector. After fitting new injectors (→ Page 117). Final steps Install cylinder head cover (→ Page 107). Open fuel supply to engine. 116 | Injector | MS15058/04E 2018-12...

  • Page 119: Injector - Removal And Installation

    8.6.3 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6789889 Milling cutter F30452739 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340...
  • Page 120 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 121 Note: Always be aware of system pressure. 10 mi- nutes after an engine stop, the residual pres- sure in the HP fuel system is approx. 25 bar. Slowly undo unions on HP line (4, 6). Remove HP fuel line (5). Note: When the adapter is unscrewed, the stored volume of the injector is emptied.
  • Page 122 Installing new injector Note: • The new sealing ring is included in the scope of supply of the injector. • A multi-purpose grease without solids con- tent must be used. Install new sealing ring (1) abutted to (Multi- purpose grease) and ensure that the installa- tion position is correct.
  • Page 123 Coat screw head mating face and thread of hold-down clamp (2) with engine oil. Position hold-down clamp (1) properly and use a torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 100 Nm+10 Nm Undo hold-down clamp screw again.
  • Page 124 Fit cable connector on injector. Reset CDC parameters after installing new injectors Note: If the drift correction (CDC) is not reset, the emission certification becomes invalid. Reset drift compensation (CDC) using DiaSys® and enter injector code (IIG) (→ Dialog system DiaSys® E531920/..).

  • Page 125: 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. Torque wrench, 4–20 Nm F30044239 Diesel fuel WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
  • Page 126 Note: See figure (a). Unlock hand pump: Hold sleeve (2) firmly. Turn handle (1) counterclockwise until the sleeve can be pushed backwards (arrowed). 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 127: 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 128 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 129 8.8.3 Fuel prefilter – Pressure ratios WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Liquid or gaseous media, e.g.
  • Page 130 8.8.4 Fuel prefilter – Draining Note: The descriptions also apply to heavy-duty fuel prefilters Fuel prefilter (non-switchable) Drain water and contaminants from fuel prefilter (→ Page 129). Fuel prefilter (switchable) Drain water and contaminants from fuel prefilter (→ Page 131). 128 | Fuel Filter | MS15058/04E 2018-12...
  • Page 131 8.8.5 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 132 Open threaded vent plug (1) of filter to be serviced. Open drain plug (1). Allow water to drain until fuel emerges. Close drain plug (2) again. Drain second filter on module, from (→ Step 4). Close threaded vent plug again. Open fuel supply.
  • Page 133 8.8.6 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 134 During engine operation, turn the switchover level as far as the stop (arrowed) 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 135 Draining fuel prefilter in case of 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 plug (1) be- cause fuel or water can spurt out.

  • Page 136: Fuel Prefilter (Switchable) – Low Pressure

    8.8.7 Fuel prefilter (switchable) – Low pressure indicator check Low pressure indicator on switchable fuel prefilter Check low pressure indicator reading at low pressure gauge (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 137 8.8.8 Fuel prefilter – Filter element replacement Note: The descriptions also apply to heavy-duty fuel prefilters Fuel prefilter (non-switchable) Fuel prefilter, replace filter element (→ Page 136). Fuel prefilter (switchable) Fuel prefilter, replace filter element (→ Page 138). MS15058/04E 2018-12 | Fuel Filter | 135...

  • Page 138: Fuel Prefilter (Non-Switchable) – Filter Element

    8.8.9 Fuel prefilter (non-switchable) – Filter element replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 Ratchet bit F30027340 Diesel fuel Filter parts kit (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
  • Page 139 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 140: Fuel Prefilter (Switchable) – Filter Element

    8.8.10 Fuel prefilter (switchable) – Filter element replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 Ratchet bit 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 141 Replacing fuel prefilter with low pressure, version A Note: • During engine operation, the filter elements must only be replaced on the cut-out filter module! • At engine standstill, the filter elements on both filter modules can be replaced! Provide a suitable container in which to collect the fuel. During engine operation, turn the switchover level as far as the stop (arrowed) to cut out the filter module to be serviced.
  • Page 142 Replacing fuel prefilter with high pressure, version B Note: The filter modules must only be replaced with the engine at a standstill! Provide a suitable container in which to collect the fuel. Stop engine and disable engine start. Close fuel inlet. Open threaded vent plug and ensure that fuel does not emerge continuously.
  • Page 143 8.8.11 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 144 Undo threaded vent plugs (2, 3) unscrewing at least one rotation. Note: • Only operate the fuel priming pump man- ually! • Move the pump plunger only vertically to avoid damaging the pump! Unlock fuel priming pump, screw out han- dle (1).

  • Page 145: Intercooler – Checking Condensate Drain For

    8.9 Charge-Air Cooling 8.9.1 Intercooler – Checking condensate drain for coolant leak 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 A high level of noise is produced when the engine is running.

  • Page 146: 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 146). Reset signal ring of service indicator (→ Page 149). 144 | Air Filter | MS15058/04E 2018-12...
  • Page 147 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 144). MS15058/04E 2018-12 | Air Filter | 145...
  • Page 148 8.10.3 Air filter – Removal and installation 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 149: Heavy Duty Air Filter – Filter Insert And Filter

    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 150 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 151: 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 144). After installation of new filter, press reset button (1).

  • Page 152: Lube Oil System, Lube Oil Circuit

    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 153 Unscrew one of the drain plugs (1 to 8) and drain engine oil. Screw in drain plug (1 to 8) with new sealing ring. Engine oil treatment Check layer thickness of oil residues in the centrifugal oil filter, clean centrifugal oil filter and replace filter sleeve (→...
  • Page 154 Filling with new engine oil Open cover (1) on filler neck. Pour oil in at filler neck up to 'max.' mark at oil dipstick. Close cover (1) on filler neck. Check engine oil level (→ Page 153). Note: Observe the following instructions to avoid engine damage: Adequate oil pressure for an engine start is only provided when the quick- start function is deactivated.
  • Page 155 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 156 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 157 Screw Tightening torque (Engine oil) 20 Nm +2 Nm Use equipment and chemicals in MTU test kit to analyze engine oil for: • Dispersancy (spot test) • Water content • Dilution by fuel MS15058/04E 2018-12 | Lube Oil System, Lube Oil Circuit | 155...
  • Page 158 8.12.4 Oil priming pump – Visual inspection Preconditions ☑ Engine is stopped and starting disabled. Visually inspecting oil priming pump Inspect oil priming pump and connections for firm seating and leaks. Retighten loose threaded connections as necessary. Check leak telltale bore (2) for oil discharge. Result: If oil emerges, the gear pump (1) usually has to be replaced (→...

  • Page 159: Oil Filtration / Cooling

    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 160: Centrifugal Oil Filter – Cleaning And Filter

    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 Torque wrench, 60–320 Nm F30452768 Ratchet bit F30027340...
  • Page 161 Cleaning centrifugal oil filter Wash rotor cover (3), rotor tube (7), conical disk (8) and rotor base (13) with cold cleaner. Blow out rotor cover (3), rotor tube (7), conical disk (8) and rotor base (13) with compressed air. Assembling centrifugal oil filter Coat new sealing rings (9) and (10) with as- sembly compound and insert in grooves on bearing shaft (11).

  • Page 162: Coolant Circuit, General, High-Temperature

    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 163 8.14.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 162). Fill with engine coolant (→ Page 164). MS15058/04E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 161...
  • Page 164 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 165 Close all other open drain points. Position valve cover on filler neck and close. MS15058/04E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 163...
  • Page 166 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. Coolant DANGER Falling from great heights. Risk of serious injury – danger to life! •...
  • Page 167 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. Variant 1: Filling with coolant from below using a pump Open venting point on distributor (arrow). MS15058/04E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 165...
  • Page 168 Note: An empty engine must always filled with cool- ant from below, i.e. using the drain valve con- nection of the engine coolant pump. 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.
  • Page 169 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 170 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 Hot components/surfaces.

  • Page 171: Engine Coolant – Sample Extraction And

    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 F6798833 DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 172 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/..)). 170 | Coolant Circuit, General, High-Temperature Circuit | MS15058/04E 2018-12...
  • Page 173 8.14.7 Preheater – Overview 1 Outlet 5 Control thermostat 9 Pump 2 24 VDC input 6 Intake Arrow Flow direction 3 Main power supply input 7 Safety thermostat 4 Control box 8 Housing cover Variant Heating output Rated voltage Frequency Phases 9 kW 400 V...
  • Page 174 8.14.8 Preheater – Overhaul Preconditions ☑ Engine is stopped and starting disabled. ☑ All preheater power sources are disconnected. Replacing solenoid switch Replace solenoid switch (→ Page 177). Cleaning heating element and replacing gasket Clean heating element and housing and check (→ Page 174). Replacing thermostat Replace thermostat (→...
  • Page 175 8.14.9 Preheater – Function and leak 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. Function check Note: The preheater operates properly if the measured value of the coolant temperature is within the control range...

  • Page 176: Preheater – Heating Element And Housing

    8.14.10 Preheater – Heating element and housing check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Screw locking compound (Loctite 586) 40033 O-ring (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
  • Page 177 Open drain plug at coolant inlet (arrow) and drain coolant. Undo clamps on both lines on preheater side. Checking heating element and housing for contamination Undo screws (1) between electrical part (2) and housing. Pull electrical part (2) with heating element out of housing.
  • Page 178 Final steps Connect preheater power sources. Switch on preheater. 176 | Coolant Circuit, General, High-Temperature Circuit | MS15058/04E 2018-12...
  • Page 179 8.14.11 Preheater – Solenoid switch replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solenoid switch (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
  • Page 180 Mark all cables (4) prior to disconnection. Disconnect all cables (4) from solenoid switch (1). Note: The solenoid switch is secured to the rail (2) by a spring clip (3). Pull out the spring clip with a screwdriver and slide the solenoid switch off the rail. Fit a new solenoid switch on the rail and fully engage the spring clip.
  • Page 181 8.14.12 Preheater thermostats – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Thermostat (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
  • Page 182 Mark cables prior to disconnection. Disconnect terminals from blade terminals of measuring unit (2). Undo thermostat clip (1) and remove safety thermostat. Insert new safety thermostat in recess. Secure thermostat clip. Connect cable. Fit cover and tighten screws. Replacing control thermostat Undo screws (1) on housing cover (2) of con- trol thermostat and remove cover.
  • Page 183 Final steps Connect preheater to power supply. Switch on preheater. MS15058/04E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 181...

  • Page 184: Coolant Expansion Tank Valve Cover

    8.14.13 Coolant expansion tank 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 185: Low-Temperature Circuit

    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. 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 186 Checking charge-air coolant level by means of level sensor Note: The charge-air coolant level is monitored automatically by the engine control system. Switch on engine control system and check readings on the display. Top up with charge-air coolant as necessary (→ Page 188). 184 | Low-Temperature Circuit | MS15058/04E 2018-12...

  • Page 187: Charge-Air Coolant – Change

    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 186). Fill with charge-air coolant (→ Page 188). MS15058/04E 2018-12 | Low-Temperature Circuit | 185...

  • Page 188: Charge-Air Coolant – Draining

    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) DANGER Falling from great heights. Risk of serious injury – danger to life! •...
  • Page 189 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 190: Charge-Air Coolant – Filling

    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 DANGER Falling from great heights.
  • Page 191 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. Variant 1: Filling coolant with pump Connect suitable pump with hose to drain valve (1).
  • Page 192 To accelerate the venting procedure, open the venting point at the intercooler (1) after the first cycle until no more air emerges. Close drain valve. Check proper condition of valve cover and clean sealing faces if required. Fit valve cover on filler neck and close. Start engine (→...
  • Page 193 To accelerate the venting procedure, open the venting point at the intercooler (1) after the first cycle until no more air emerges. Fit valve cover and close. Start engine (→ Page 48). After 10 seconds of running the engine with- out load, shut down the engine (→...

  • Page 194: Charge-Air Coolant Pump – Relief Bore Check

    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 Hot components/surfaces.

  • Page 195: Battery-Charging Generator

    8.16 Battery-Charging Generator 8.16.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. WARNING Exposed rotating parts can eject drawn-in components or draw in body parts. Risk of crushing, limbs or extremities may be pinched, trapped or entangled! Risk of injury due to flying parts! •...

  • Page 196: Battery-Charging Generator – Drive Belt

    8.16.2 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 bit F30027341 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 WARNING...

  • Page 197: Battery-Charging Generator Drive – Drive Belt

    8.16.3 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 bit F30027341 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Drive belt...

  • Page 198: Wiring (General) For Engine/Gearbox/Unit

    8.17 Wiring (General) for Engine/Gearbox/Unit 8.17.1 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 199: Engine Mounting / Support

    8.18 Engine Mounting / Support 8.18.1 Engine mounting – Checking securing screws for firm seating Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm F30452768 Torque wrench, 300–800 Nm F30047798 Ratchet bit F30027341...
  • Page 200 Version B – rigid engine mount- ing with standalone generator Check that securing screws (1, 2, 3) and base frame screw connections (arrowed) are tight. Use a torque wrench to tighten loose screw connections (1, 2) to specified tightening torque. Name Size Type...

  • Page 201: Engine Mounting – Checking Resilient Element

    8.18.2 Engine mounting – Checking resilient element NOTICE Contamination of engine mounts made of natural rubber with fuel or oil. Engine mounts swell. Risk of shorter service life or destruction of the mounts! • Cover engine mounts when working with fuel or oil. •...

  • Page 202: Generator Mounting

    8.19 Generator Mounting 8.19.1 Generator mounting – Securing screw firm seating check Preconditions ☑ Engine is stopped and starting disabled. Generator mounting, securing screw firm seating check Check securing screws for firm seating. Tighten loose screws. 200 | Generator Mounting | MS15058/04E 2018-12...

  • Page 203: Generator Mounting – Check

    8.19.2 Generator mounting – Check Special tools, Material, Spare parts Designation / Use Part No. Qty. Resilient element (→ Spare Parts Catalog) NOTICE Contamination of engine mounts made of natural rubber with fuel or oil. Engine mounts swell. Risk of shorter service life or destruction of the mounts! •...

  • Page 204: Radiator

    8.20 Radiator 8.20.1 Fuel cooler – External contamination and leak-tightness check Preconditions ☑ Engine is stopped and starting disabled. ☑ All fuel cooler power sources are disconnected. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 205: Fuel Cooler – Cleaning

    8.20.2 Fuel cooler – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ All fuel cooler power sources are disconnected. WARNING Hot components/surfaces. Risk of burns! • Allow the engine to cool down to below 50 °C before beginning work. •...
  • Page 206 Cleaning with compressed-air pistol Blow out cooler elements with a jet of compressed air working against the direction of the cooling air parallel to the cooling fins. Remove and dispose of dirt before putting engine into operation. Use industrial high-pressure cleaner to clean fuel cooler in case of stubborn contamination. Cleaning with industrial high-pressure cleaner Note: •...

  • Page 207: Accessories For (Electronic) Engine

    8.21 Accessories for (Electronic) Engine Governor / Control System 8.21.1 Resetting CDC parameter and entering IIG with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Note: The engine will lose its emissions certification of the drift correction parameters (CDC) if not reset. Parameters for drift correction (CDC) –...

  • Page 208: Governor / Control System

    8.21.2 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. test prod. The contacts in the plug connection can be bent! •...

  • Page 209: Engine Governor Plug Connections – Check

    8.21.3 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 210: Engine Governor Ecu 9 – Removal And

    8.21.4 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 211: Appendix A

    American National Standards Institute Association of American standardization organiza- tions Air Temperature Sensor Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica- tion No. A001061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Drift correction setting with DiaSys in engine gover-...
  • Page 212 Abbre- Meaning Explanation viation Electrically Erasable Programmable Read 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 Einzelspeicherdruck Injector accumulator pressure Exhaust turbocharger/exhaust turbocharg-...
  • Page 213 Abbre- Meaning Explanation viation Maximum Continuous Rating Torque limitation curve Not Applicable Normal Null Reference surface for heights above sea level 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 (TDC)

  • Page 214: Conversion Tables

    9.2 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 = ft 0.6215...
  • Page 215 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 multiplied by factor = Unit A l/min 0.264 = gal/min (U.S.) 7.48 = gal/min (U.S.) /min (cfm)
  • Page 216 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 multiplied by factor = Unit B lbf ft 1.3558 = Nm Unit B multiplied by factor = Unit A 0.7376...
  • Page 217 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 = kW 0.7457 = kW BTU/s 1.054 = kW kcal/h 1.163 = lbf ft/s...

  • Page 218: Tightening Specifications For Screws, Nuts

    9.3 Tightening specifications for screws, nuts and bolts Tightening torques for setscrew and connections as per MTN 5008 standard This standard applies to setscrews not subject to dynamic loads and the associated nuts according to: • MMN 384 • ISO 4762 (DIN 912) •...
  • Page 219 Hand-tightening Machine-tightening Thread 8.8 M (Nm) 10.9 M (Nm) 8.8 M (Nm) 10.9 M (Nm) M20 x 1.5 M22 x 1.5 M24 x 1.5 M24 x 2 1250 1175 M27 x 2 1350 1275 1200 1700 1100 1600 M30 x 2 1350 1900 1250...
  • Page 220 Tightening torque for self-locking hex nuts (Nm) Thread Lubricants 7.5 +1 – 17 +2 – 35 +4 – 59 +6 – 100 +10 – 140 +14 – 290 +29 – = tightening torques Tightening torque for stress bolt connections as per MTN 5007 standard This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of strength class 10.9 as well as to the associated nuts.
  • Page 221 Not torsion-protected M (Nm) Torsion-protected M (Nm) Thread 1250 1575 *Protect screw shaft from torsion when tightening. = tightening torques. Tightening torques for plug screws as per MTN 5183-1 standard This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852 Form A (sealed with sealing ring to DIN 7603-Cu).
  • Page 222 Tightening torques M are given for screw plugs made of steel (St) with surface protected by a phosphate coating and oiled or galvanized. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
  • Page 223 screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M64 x 2 = tightening torques Tightening torque for plug screws DIN 7604C (with long screwed end) screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M8 x 1 M22 x 1.5...
  • Page 224 The stated tightening torques M apply to steel (St) banjo screws with a phosphatized surface and oiled or galvanized and for copper-aluminum alloy. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
  • Page 225 Tightening torques for male connectors as per MTN 5183-3 standard This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by sealing ring to DIN 7603-Cu). Tightening torques M are given for male unions made of steel (St) with phosphatized surface coating and oiled, or galvanized.
  • Page 226 Tightening torques for union nuts as per DIN 3859-2 1 Union nut 2 Screw fixture 3 O-ring 4 Linear ball bearing Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase in force), it should be tightened another 1/4 turn (90°) past this point. Tightening torques for spigot unions with O-ring to ISO 6149-2 Thread Torque (Nm) +10%...
  • Page 227 Thread Torque (Nm) +10% M27 x 2 M33 x 2 M42 x 2 M48 x 2 M60 x 2 Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789) Tightening torques for screwed plugs with O-ring as per ISO 6149-3 Thread Torque (Nm) +10% M8 x 1...
  • Page 228 Tightening torques for plug screw joints as per MTN 5183-6 screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M10 x 1 10 +2 M12 x 1.5 14 +2 M14 x 1.5 15 +3 M16 x 1.5 18 +3 M18 x 1.5 23 +3...
  • Page 229 Sealing head/sealing cone with metric union nut Metric thread Pipe outer dia. Torque (Nm) M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5 M26 x 1.5 M30 x 2 M36 x 2 M42 x 2 M45 x 2 M52 x 2 Sealing head with BSP union nut...
  • Page 230 ORFS – flat sealing with union nut UNF thread Size Torque (Nm) 9/16–18 –4 14 +2 11/16–16 –6 24 +3 13/16–16 –8 43 +4 1–14 –10 60 +8 1.3/16–12 –12 90 +5 1.3/16–12 –14 90 +5 1.7/16–12 –16 125 +10 1.11/16–12 –20 170 +20...
  • Page 231 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 232: Appendix B

    10 Appendix B 10.1 Special Tools Barring tool Part No.: F6555766 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 88) Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 92) Crossbeam Part No.: T80091826 Qty.: Used in: 2.1 Transport (→...
  • Page 233 Depth gauge, 200 mm Part No.: Y20000918 Qty.: Used in: 8.4.1 Valve protrusion – Measurement (→ Page 99) Endoscope Part No.: Y20097353 Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 92) Feeler gage Part No.: Y20098771 Qty.: Used in: 8.4.3 Valve clearance –...
  • Page 234 Fuel suction device Part No.: F30378207 Qty.: Used in: 8.5.1 HP fuel pump – Filling with engine oil (→ Page 108) High-pressure cleaner Part No.: Qty.: Used in: 5.12 Plant – Cleaning (→ Page 58) Installation/removal jig Part No.: F6789889 Qty.: Used in: 8.6.2 Injector rings –...
  • Page 235 Qty.: Used in: 8.6.2 Injector rings – Replacement (→ Page 111) Qty.: Used in: 8.6.3 Injector – Removal and installation (→ Page 117) MTU test kit Part No.: F6798833 Qty.: Used in: 8.12.3 Engine oil – Sample extraction and analysis (→...
  • Page 236 Ratchet bit Part No.: F30027341 Qty.: Used in: 8.4.3 Valve clearance – Check and adjustment (→ Page 104) Qty.: Used in: 8.4.4 Cylinder head cover – Removal and installation (→ Page 107) Qty.: Used in: 8.6.2 Injector rings – Replacement (→ Page 111) Qty.: Used in: 8.6.3 Injector –...
  • Page 237 Ratchet with extension Part No.: F30006212 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 88) Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 92) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 8.4.3 Valve clearance – Check and adjustment (→...
  • Page 238 Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 2.3 Crankshaft transport locking device (→ Page 22) Qty.: Used in: 8.3.2 Crankcase breather – Filter element replacement (→ Page 97) Qty.: Used in: 8.5.1 HP fuel pump – Filling with engine oil (→ Page 108) Qty.: Used in: 8.6.2 Injector rings –...
  • Page 239 Torque wrench, 4–20 Nm Part No.: F30044239 Qty.: Used in: 8.7.1 Fuel system – Venting (→ Page 123) Qty.: Used in: 8.13.2 Centrifugal oil filter – Cleaning and filter sleeve re- placement (→ Page 158) Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in:...

  • Page 240: Index

    10.2 Index Crankshaft  – Transport locking device   Abbreviations 209 – Installation/removal  22 Actuators  Cylinder  – Overview  29 – Designation  26 Additional fuel filter  Cylinder head cover  – Replacement  126 – Installation  107 After stopping the engine  – Removal  107 – Engine remains ready for operation  56 Cylinder liner ...
  • Page 241  202 – Cleaning  203 Fuel filter  Maintenance schedule  – Replacement  125 – Maintenance task reference table [QL1]  59 Fuel prefilter  MTU contact persons 229 – Draining  128 – Non-switchable  129 – Switchable  131 Oil priming pump  – Filter element replacement  135 –...
  • Page 242 – Solenoid switch  177 – Nuts  216 – Thermostat  179 – Screws and bolts  216 Product data  – Screws, nuts and bolts  216 – 20V4000G44F  33 Transport  – 20V4000G44LF  33 – Description  20 – 20V4000G94F  39 Transport locking device  – 20V4000G94LF  39...

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