Page 1 Operating Instructions Diesel Engine 12V4000G34F 12V4000G94F 16V4000G34F 16V4000G94F MS15060/01E...
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
3.1 Engine side and cylinder designations 8 Troubleshooting 4 Technical Data 8.1 Troubleshooting 4.1 Product data 12V4000G34F, 12V4000G94F 8.2 Fault messages of the ADEC (ECU 9) engine 4.2 Product data 16V4000G34F / 16V4000G94F governor for Series 4000 genset engines 4.3 Firing order 4.4 Engine –...
Page 4 10.3 Tightening specifications for screws, nuts 9.14 Coolant Circuit, General, High-Temperature and bolts Circuit 10.4 MTU Contact/Service Partners 9.14.1 Engine coolant – Level check 9.14.2 Engine coolant – Change 11 Appendix B 9.14.3 Engine coolant – Draining 9.14.4 Engine coolant – Filling 11.1 Special Tools...
Page 5: 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 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 7: 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 8 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 9: 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 10: 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 11: 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 12 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 13: 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 14 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 15 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 16 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 17: 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 18 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 19: 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 20: 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 | MS15060/01E 2018-12...
Page 21: Lifting Specifications
2.2 Lifting specifications 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 2 Center of gravity 3 Engine lifting eye pull 10°...
Page 22: 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 23 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 24 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 25: 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 26: 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 27: Technical Data
4 Technical Data 4.1 Product data 12V4000G34F, 12V4000G94F DL Reference value: Continuous power. Continuously attainable power at 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.
Page 28 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) Power-related data Rated engine speed 1500 1500 1500 1500 1500 1500 Continuous power ISO 1755 1755 1755...
Page 29 Consumption Specific fuel consumption g/kWh (be) - 100% DL (+5%; EN 590; 42.8MJ/kg) Specific fuel consumption g/kWh (be) - 100% BL (+5%; EN 590; 42.8MJ/kg) Fuel consumption at zero kg/h load Model-related data (basic design) Engine with exhaust tur- bocharging (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Operating method: four-...
Page 30 Exhaust gas volumetric m³/s flow (at exhaust gas tem- perature) - BL Exhaust gas temperature °C after engine, max. (ex- haust turbocharger) Coolant system (high-temperature circuit) Coolant temperature (at °C engine connection: outlet to cooling equipment) Coolant temperature after °C engine, limit 1 Coolant temperature after °C...
Page 31 Capacities Engine coolant capacity, Liters engine side (without cool- ing equipment) Charge-air coolant, en- Liters gine side Fuel, engine side Liters Engine oil, total, for initial Liters filling (standard oil sys- tem) (option: max. oper- ating inclinations) Oil change quantity, max. Liters (standard oil system) (op- tion: max.
Page 32 Exhaust noise, unsilenced dB(A) - BL (sound power level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) - DL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) - DL (sound power...
Page 33: Product Data 16V4000G34F / 16V4000G94F
4.2 Product data 16V4000G34F / 16V4000G94F DL Reference value: Continuous power. Continuously attainable power at 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.
Page 34 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 Continuous power ISO 2170 2170 2170 3046 (10% overload pos- sible) (power range DIN 6280, ISO 8528) Fuel stop power ISO 2837 2837...
Page 35 Model-related data (basic design) Engine with exhaust tur- bocharging (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Operating method: four- stroke cycle, diesel, sin- gle-action Combustion method: di- rect injection Cooling method: treated water Direction of rotation: c.c.w. (viewed on driving end) Number of cylinders Cylinder arrangement:...
Page 36 Coolant temperature after °C engine, limit 2 Coolant antifreeze con- tent, max. Coolant system (low-temperature circuit) Coolant temperature (at °C 64.5 64.5 64.5 68.0 68.0 68.0 engine connection: outlet to cooling equipment) Coolant temperature be- °C fore intercooler, limit 1 Coolant temperature be- °C fore intercooler, limit 2...
Page 37 Engine oil, total, for initial Liters filling (standard oil sys- tem) (option: max. oper- ating inclinations) Oil change quantity, max. Liters (standard oil system) (op- tion: max. operating incli- nations) Oil pan capacity at dip- Liters stick mark “min.” (stand- ard oil system) (option: max.
Page 38 Engine surface noise with dB(A) attenuated intake noise (filter) - DL (sound power level LW, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) – BL (free-field sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A)
Page 39: Firing Order
4.3 Firing order Firing order Number of cylinders Firing order A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 MS15060/01E 2018-12 | Technical Data | 39...
Page 40: Engine - Main Dimensions
4.4 Engine – Main dimensions Main engine dimensions Engine model Length (A) Width (B) Height (C) 12V4000Gx4F with 2-cylinder HP pump 2433.4 mm 1660.5 mm 2176.5 mm 12V4000Gx4F with 4-cylinder HP pump 2495.0 mm 1660.5 mm 2176.5 mm 16V4000Gx4F with 4-cylinder HP pump 2981.6 mm 1660.5 mm 2176.5 mm...
Page 41: Functional Description
5 Functional Description 5.1 Engine models 12/16V4000G34F and 12/16V4000G94F – Overview Engine overview – Driving end (KS) The illustration shows an overview of the 12V engine, however it also applies similarly to the 16V model. 1 Wastegate 5 Engine mounting 9 Engine governor 2 LT thermostat housing 6 Crankcase...
Page 42 Technical data Application group Engine Power Speed Displacement 3E, standby power, overload ca- 12V4000G34F 1755 kW 1500 rpm 57.2 l pability according to ICXN 146 kW/cyl. 4.77 l/cyl. 3D, standby power, fuel stop...
Page 43 Application group Engine Power Speed Displacement 3E, standby power, overload ca- 16V4000G34F 2170 kW 1500 rpm 76.3 l pability according to ICXN 136 kW/cyl. 4.77 l/cyl. 3D, standby power, fuel stop 16V4000G94F 2387 kW 1500 rpm 76.3 l power, IFN 149 kW/cyl.
Page 44: Crankcase With Oil Pan
5.2 Crankcase with oil pan 1 Crankcase 7 Coolant transfer 13 Crankshaft bearing 2 Main oil gallery 8 Oil dipstick 14 Oil spray nozzle for piston 3 Upper end cover 9 Oil filler neck cooling 4 Coolant chamber 10 Inspection port cover 15 Camshaft bearing 5 Cylinder liner 11 Oil pan...
Page 45 Benefits • High level of rigidity • Low noise and vibration level Function The crankcase (1) is the component where the power generated by the combustion process of the fuel/air mixture in the cylinders is transmitted to the crankshaft. The crankcase is cast as a single solid unit to with- stand the forces involved.
Page 46: Gear Train
5.3 Gear train 1 Gear train for coolant pump, 5 Drive gear for HP fuel pump 9 Drive gear for engine oil LT circuit and fuel delivery pump pump 2 Gear train for coolant pump, 6 Idler gear 10 Drive gear for oil replenish- HT circuit 7 Drive gear for battery-charg- ment pump...
Page 47: Running Gear
5.4 Running gear 1 Flywheel 4 Conrod 7 Crankshaft counterweight 2 Crankshaft 5 Vibration damper 8 Ring gear 3 Piston 6 Crankshaft gear KS = Driving end Running gear The running gear is installed in the crankcase. It is supported in sleeve bearings and locked in axial direction. Engine oil from the crankcase is used to lubricate the bearings, vibration damper, and pistons.
Page 48 Crankshaft • Forged • Bolt-on counterweights • Press-fitted crankshaft gear • Low-wear sleeve bearings, oil supply from lube-oil system • Axial fixing by thrust bearing • Radial-lip shaft seals for sealing against external influences (driving end and free end) Vibration damper (free end) •...
Page 49: Cylinder Head With Injector
5.5 Cylinder head with injector 1 Cylinder head 6 Valve guide a Charge-air 2 Hold-down clamp 7 Intake valves b Exhaust gas 3 Injector 8 Sealing ring c Coolant 4 HP fuel line 9 Exhaust valves d Engine oil 5 Fuel return line 10 Plunger Cylinder head with injector The cylinder heads containing the valve gear and fuel injection equipment are mounted on the crankcase.
Page 50 Function Charge air flows into the combustion chamber of the cylinder when the intake valves (7) are open. The injector (3) injects fuel into the combustion chamber creating an air/fuel mixture which ignites sponta- neously under compression. When the exhaust valves (9) open, exhaust gas created by the combustion process flows via the outlet duct to the exhaust manifold leading to the exhaust turbochargers.
Page 51: Valve Gear
5.6 Valve gear 1 Camshaft drive gear 6 Pushrod 11 Rocker arm (exhaust) 2 Swing follower shaft 7 Rocker shaft 12 Rocker arm bearing block 3 Swing follower (intake) 8 Rocker arm (intake) 13 Valve bridge 4 Swing follower (exhaust) 9 Locknut 5 Camshaft 10 Adjusting screw...
Page 52 Function The camshaft (5) controls opening and closing of the intake and exhaust valves. The motion applied from the cams of the camshaft to actuate the valves is transferred by swing followers (3, 4), pushrods (6) and rocker arms (8, 11) onto the valve bridges (13) of the intake and exhaust valves. The valves open against spring pressure and close with the pressure exerted by the valve springs.
Page 53: Fuel System With Common Rail Injection
5.7 Fuel system with Common Rail injection 1 Injector 7 Additional fuel filter 13 HP fuel pump 2 Connecting line, HP fuel line 8 Connection, fuel return to 14 HP fuel distributor (only 16/20V engines) tank 15 Pressure limiting valve 3 Connecting line, return line 9 Connection, supply line 16 HP fuel line to injector...
Page 54 High pressure The high-pressure fuel system (Common Rail injection system) comprises: • HP fuel pump • HP distributor with pressure limiting valve • HP fuel lines (Common Rails) • Injectors with built-in injector accumulator and flow restrictor valve Return • From the injectors and the HP distributor (in emergency mode) to the tank line Open-loop control •...
Page 55: Charge-Air And Exhaust System
5.8 Charge-air and exhaust system 1 Crankcase breather 6 Connection housing for in- 11 Cylinder head 2 Exhaust manifold tercooler KGS Free end 3 Exhaust turbocharger 7 Intercooler a Intake air 4 Air filter 8 Blow-off valve (bypass flap) b Exhaust gas 5 Exhaust outlet 9 Charge-air elbow c Charge air...
Page 56 Benefits • Low exhaust emissions • Low fuel consumption • High degree of engine efficiency • Optimum load application characteristics • Optimized inflow to compressor • Straightforward connection to external exhaust gas system • Increased thermal and mechanical load capacity of pipework before the intercooler Operation Exhaust system When the exhaust valves open, the exhaust gases flow out of the combustion chamber of the cylinders...
Page 57: Lube Oil System
5.9 Lube oil system 1 Exhaust turbocharger 10 Oil suction basket 19 Cylinder head 2 Shutoff valve 11 Lube oil pump 20 Conrod bearings 3 Centrifugal oil filter (option) 12 Pressure limiting valve be- 21 Crankshaft axial bearings 4 Oil heat exchanger fore engine 22 Crankshaft support bearing, 5 Oil filter...
Page 58 The main oil flow is directed through the five engine oil filters (5) directly to the lubrication points in the en- gine and to the main oil gallery. The following components / assemblies are supplied directly: • HP fuel pump (14) •...
Page 59: Cooling System
5.10 Cooling system 1 Connection, LT circuit vent 10 Charge-air coolant inlet 19 Crankcase line from charge-air coolant 20 Engine coolant preheater in- 2 Connection, HT circuit vent cooler line 11 Charge-air coolant pump 21 Coolant manifold 3 Space heater supply con- 12 Charge-air coolant drain 22 Intercooler nection...
Page 60 Benefits • Engine, oil and charge-air reach optimum operating temperature very quickly • Prevention of white smoke by preheating the charge-air during idling and low-load operation • Charge-air cooling during load-operation Operation 1 Coolant manifold 5 Charge-air coolant pump 9 Cylinder head 2 Coolant ventilation 6 Engine coolant pump 10 Intercooler...
Page 61 Charge-air coolant circuit (LT) The charge-air coolant pump (5) installed on the engine pumps the charge-air coolant to the intercooler (10). The charge-air coolant reaches the thermostat (4) via the intercooler (10). The charge-air coolant flows to the external charge-air coolant cooler via the thermostat when the engine is at operating temperature. Cooled charge-air coolant coming from the charge-air coolant cooler flows to the charge-air coolant pump (5).
Page 62: Fuel Cooler
5.11 Fuel cooler Extremely high injection pressure increases the temperature of the uncombusted, depressurized fuel when it is returned to the tank. This may lead to high fuel return temperature and, in consequence, to an engine shutdown. Moreover, excessive temperatures could exceed the material-dependent temperature limits of the day tank and the injection system.
Page 63 Technical data Cooler for 12V engines Frequency 50 Hz 60 Hz Maximum spec. heat dissipation 0.33 kW/K 0.37 kW/K Air flow 2900 m 3480 m Sound level 85 dB(A) 89 dB(A) Maximum operating temperature 130°C (266°F) 130°C (266°F) Cooler for 16/20V engines Frequency 50 Hz 60 Hz...
Page 64: Engine Management And Monitoring
5.12 Engine management and monitoring 1 Customer's control system 4 Data and signals 7 Connection of engines sen- 2 Power supply 24 V DC 5 EIL sory equipment 3 SmartConnect 6 ECU 9 P System E Electronic engine manage- ment system Engine management and monitoring The engine monitoring system continuously analyzes the operating data of the engine.
Page 65 • Flat housing with three self-locking plug connectors • 24 V DC power supply • Communication with other units and higher-level systems via CAN bus (with MTU devices via PCS-5 redun- dant, with external devices via J1939) • Integrated engine monitoring •...
Page 66 • Software version identification (application, firmware, CCS, ...) • Data logger for remote maintenance Benefits • Simple handling • No MTU Service personnel required EIL (Engine Ident Label) • Identification of engine hardware • Data storage, e.g. aging data 66 | Functional Description | MS15060/01E 2018-12...
Page 67: Sensors And Actuators - Overview
5.13 Sensors and actuators – Overview The illustrations show an overview of the 12V engine, however these also apply similarly to the 16V engine. Designation Monitors EIL (Engine Ident Label) B5.1 Pressure sensor, lube oil after filter Charge-air temperature sensor B34.1 Pressure sensor, fuel after filter Fuel inlet temperature sensor...
Page 68 Designation Monitors Charge-air pressure sensor B48.2 HP fuel pressure sensor (rail) XB533 HT coolant level sensor (remote expansion tank) XB557 LT coolant level sensor (remote expansion tank) K39B1-K39B6 Injectors, right engine side 68 | Functional Description | MS15060/01E 2018-12...
Page 69 Designation Monitors Crankshaft speed sensor MS15060/01E 2018-12 | Functional Description | 69...
Page 70 Designation Monitors Camshaft speed sensor B5.1 Pressure sensor, lube oil after filter B5.3 Pressure sensor, lube oil before filter Coolant temperature sensor Lube oil temperature sensor Charge-air coolant temperature sensor Crankcase pressure sensor XB54 Connector for optional oil refill pump Designation Monitors Exhaust turbocharger speed sensor...
Page 71: Operation
6.1 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 72: Putting Into Operation After Scheduled Out-Of-Service-Period
6.2 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 177); Coolant circuit Check engine coolant level (→ Page 184). Check charge-air coolant level (→ Page 207). Coolant circuit Heat engine coolant with coolant preheater.
Page 73: Starting The Engine In Manual Mode (Test Run)
6.3 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 74: Re-Starting The Engine Following An Automatic Safety Shutdown
6.4 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 75: Safety System - Override
6.5 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 76: Operational Monitoring
6.6 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 77: Emergency Engine Start (Override Mode)
6.7 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 78: Stopping The Engine In Manual Mode (Test Run)
6.8 Stopping the engine 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 79: Emergency Engine Stop
6.9 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 80: After Stopping The Engine - Engine Remains Ready For Operation
6.10 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 80 | Operation | MS15060/01E 2018-12...
Page 81: After Stopping The Engine - Putting The Engine Out Of Operation
6.11 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 186); Drain charge-air coolant (→ Page 210) if: •...
Page 82: Plant - Cleaning
6.12 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 83: Maintenance
7 Maintenance 7.1 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 84 Task Item Maintenance tasks WM00216 FUEL SUPPLY SYSTEM Check reading on vacuum gauge (→ Page 160) WM00215 FUEL SUPPLY SYSTEM Drain water and contaminants from fuel prefilter (→ Page 158) (→ Page 155) WM00214 FUEL SUPPLY SYSTEM Replace filter element (→...
Page 85: Troubleshooting
8 Troubleshooting 8.1 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 86 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 87 Blue exhaust gas Cause Corrective action u Drain engine oil (→ Page 174). Too much engine oil in the engine u Replace filter (→ Page 120). Oil separator of crankcase breather contaminated Exhaust turbocharger, cylinder u Contact Service. head, piston rings or cylinder liner defective White exhaust gas Cause...
Page 88: Fault Messages Of The Adec (Ecu 9) Engine Governor For Series 4000 Genset Engines
8.2 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 89: 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 90 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 91 44 – LO Coolant Level Intercooler Cause Corrective action Coolant level in LT circuit at 1. Check charge-air coolant level (→ Page 207). switch B557 is too low. 2. Check relief bore of charge-air coolant pump (→ Page 215). 3. Check coolant circuit visually for leaks. 4.
Page 92 65 – LO P-Fuel Cause Corrective action The fuel pressure at sensor B34.1 1. Replace fuel prefilter (→ Page 161). has violated limit value 1. Fuel 2. Replace additional fuel filter (→ Page 153). pressure is too low. 3. Replace fuel filter (→ Page 152). 4.
Page 93 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 153). time after starter disengagement 3.
Page 94 118 – 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 226). 3.
Page 95 325 – AL Wiring Cylinder A5 Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 219). wiring for cylinder A5 or injector 2. Replace injector (→ Page 134). faulty. 3. Contact Service. 326 –...
Page 96 332 – AL Wiring Cylinder B2 Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 219). wiring for cylinder B2 or injector 2. Replace injector (→ Page 134). faulty. 3. Contact Service. 333 –...
Page 97 339 – AL Wiring Cylinder B9 Cause Corrective action Short circuit fault in injector 1. Check wiring of affected injector (→ Page 219). wiring cylinder B9 or injector 2. Replace injector (→ Page 134). faulty. 3. Contact Service. 340 – AL Wiring Cylinder B10 Cause Corrective action Short circuit fault in the injector...
Page 98 347 – AL Open Load Cylinder A7 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 219). for cylinder A7. 2. Contact Service. 348 – AL Open Load Cylinder A8 Cause Corrective action Disruption fault in injector wiring 1.
Page 99 355 – AL Open Load Cylinder B5 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 219). to cylinder B5. 2. Contact Service. 356 – AL Open Load Cylinder B6 Cause Corrective action Disruption fault in injector wiring 1.
Page 100 449 – 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 101 745 – 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 102 844 – 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 103 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 104 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 105 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 106 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 107 1056 – AL Inj. Drift Limit 2 Cyl. A5 Cause Corrective action u Replace injector (→ Page 134). 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 108 1062 – AL Inj. Drift Limit 2 Cyl. B1 Cause Corrective action u Replace injector (→ Page 134). 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 109 1068 – AL Inj. Drift Limit 2 Cyl. B7 Cause Corrective action u Replace injector (→ Page 134). 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 110 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 111 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 226). even when the engine is running.
Page 112: Task Description
9 Task Description 9.1 Engine 9.1.1 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 113 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 114: Engine - Cranking On Starting System
9.1.2 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 115: Engine - Test Run
9.1.3 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 116: Cylinder Liner
9.2 Cylinder Liner 9.2.1 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 130). Remove injector (→...
Page 117 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 118). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...
Page 118: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination
9.2.2 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 119 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 120: Crankcase Breather
9.3 Crankcase Breather 9.3.1 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 121: Valve Drive
9.4 Valve Drive 9.4.1 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 122 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 123 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 124 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 125: Valve Gear - Lubrication
9.4.2 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 130). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjusting screws with oil.
Page 126: Valve Clearance - Check And Adjustment
9.4.3 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 gauge Y20098771 Valve setting gauge Y4349603...
Page 127 Note: Danger of confusion: There might be an addi- tional OT/A1 mark (1) on the outer perimeter of the flywheel. The additional OT/A1 mark (1) (if applicable) on the outer perimeter of the flywheel must not be used for reference. Diagram for 8V engines –...
Page 128 Diagram for 16V engines – Two crankshaft positions Diagram for 20V engines – Two crankshaft positions Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. •...
Page 129 Adjusting valve clearance Release locknut (1). Insert valve setting gauge (3) between valve bridge and rocker arm. Note: Replace or rectify adjusting screws and/or locknuts which do not move freely. Using angular screw driver, set adjusting screw (2) so that the specified valve clear- ance is provided.
Page 130: Cylinder Head Cover - Removal And Installation
9.4.4 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 131 9.5 Injection Pump / HP Pump 9.5.1 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 pipe F30378207 Engine oil WARNING...
Page 132 Preparatory steps (two-cylinder HP pump) Undo nut (2) and remove oil line (1) from HP pump. Preparatory steps (four-cylinder HP pump) Undo nut (2) and remove oil line (1) from HP pump. Filling HP pump (two-cylinder HP pump) Remove union (1). Note: Excess engine oil runs into gear box.
Page 133 Screw in union (1) and use a torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Union M16x1.5 Tightening torque 40 Nm Filling HP pump (four-cylinder HP pump) Remove union (1). Note: Excess engine oil runs into gear box. Use fuel suction pipe to fill HP pump with 2 liters of clean engine oil.
Page 134 9.6 Injector 9.6.1 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 135). 134 | Injector | MS15060/01E 2018-12...
Page 135 9.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6789889 Milling cutter F30452739 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340...
Page 136 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 137 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 138 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 139 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 140 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 141 9.6.3 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 142 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 143 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 144 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 145 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 146 Fit cable connector on injector. Note: Do not reset drift correction (CDC) after re-in- stalling a used injector. After fitting new injectors (→ Page 135). Final steps Install cylinder head cover (→ Page 130). Open fuel supply to engine. 146 | Injector | MS15060/01E 2018-12...
Page 147 9.7 Fuel System 9.7.1 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 148 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 149 9.7.2 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 150 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 151: Fuel Cooler – External Contamination And Leak
9.7.3 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 152 9.8 Fuel Filter 9.8.1 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 153 9.8.2 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 154 9.8.3 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 155 9.8.4 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 156 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 157 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 158 9.8.5 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 159 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 160: Fuel Prefilter (Switchable) – Low Pressure
9.8.6 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 161 9.8.7 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 165). Fuel prefilter (switchable) Fuel prefilter, replace filter element (→ Page 162). MS15060/01E 2018-12 | Fuel Filter | 161...
Page 162: Fuel Prefilter (Switchable) – Filter Element
9.8.8 Fuel prefilter (switchable) – Filter element replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 Ratchet 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 163 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 164 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 165: Fuel Prefilter (Non-Switchable) – Filter Element
9.8.9 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 166 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 167 9.8.10 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 168 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 169: Intercooler – Checking Condensate Drain For
9.9 Charge-Air Cooling 9.9.1 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 170: Air Filter
9.10 Air Filter 9.10.1 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 172). Reset signal ring of service indicator (→ Page 173). 170 | Air Filter | MS15060/01E 2018-12...
Page 171 9.10.2 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 170). MS15060/01E 2018-12 | Air Filter | 171...
Page 172 9.10.3 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 173: Air Intake
9.11 Air Intake 9.11.1 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 170). After installation of new filter, press reset button (1).
Page 174: Lube Oil System, Lube Oil Circuit
9.12 Lube Oil System, Lube Oil Circuit 9.12.1 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 175 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 176 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 177). 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 177 9.12.2 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 178 9.12.3 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 179 Use equipment and chemicals in MTU test kit to analyze engine oil for: • Dispersancy (spot test) • Water content • Dilution by fuel MS15060/01E 2018-12 | Lube Oil System, Lube Oil Circuit | 179...
Page 180 9.12.4 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 181: Oil Filtration / Cooling
9.13 Oil Filtration / Cooling 9.13.1 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 182: Centrifugal Oil Filter – Cleaning And Filter
9.13.2 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 183 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 184: Coolant Circuit, General, High-Temperature
9.14 Coolant Circuit, General, High-Temperature Circuit 9.14.1 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 185 9.14.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 186). Fill with engine coolant (→ Page 188). MS15060/01E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 185...
Page 186 9.14.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing rings (→ Spare Parts Catalog) DANGER Falling from great heights. Risk of serious injury – danger to life! •...
Page 187 Draining point driving end, left and right side. Final steps Using a torque wrench, tighten all drain valves to specified tightening torque. Name Size Type Lubricant Value/Standard Spindle A/F11 Tightening torque 12 Nm Close all remaining open drain points. Position valve cover on filler neck and close. MS15060/01E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 187...
Page 188 9.14.4 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 189 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). MS15060/01E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 189...
Page 190 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 191 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 192 9.14.5 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 193: Engine Coolant – Sample Extraction And
9.14.6 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 194 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/..)). 194 | Coolant Circuit, General, High-Temperature Circuit | MS15060/01E 2018-12...
Page 195: Preheater – Overview
9.14.7 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 196: Preheater – Function And Leak Check
9.14.8 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 197: Preheater – Overhaul
9.14.9 Preheater – Overhaul Preconditions ☑ Engine is stopped and starting disabled. ☑ All preheater power sources are disconnected. Replacing solenoid switch Replace solenoid switch (→ Page 201). Cleaning heating element and replacing gasket Clean heating element and housing and check (→ Page 198). Replacing thermostat Replace thermostat (→...
Page 198: Preheater – Heating Element And Housing
9.14.10 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 199 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 200 Final steps Connect preheater power sources. Switch on preheater. 200 | Coolant Circuit, General, High-Temperature Circuit | MS15060/01E 2018-12...
Page 201: Preheater – Solenoid Switch Replacement
9.14.11 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 202 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 203: Preheater Thermostats – Replacement
9.14.12 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 204 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 205 Final steps Connect preheater to power supply. Switch on preheater. MS15060/01E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 205...
Page 206: Coolant Expansion Tank Valve Cover
9.14.13 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 207: Low-Temperature Circuit
9.15 Low-Temperature Circuit 9.15.1 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 208 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 212). 208 | Low-Temperature Circuit | MS15060/01E 2018-12...
Page 209: Charge-Air Coolant – Change
9.15.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 210). Fill with charge-air coolant (→ Page 212). MS15060/01E 2018-12 | Low-Temperature Circuit | 209...
Page 210: Charge-Air Coolant – Draining
9.15.3 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 211 Drain remaining coolant at intercooler (ar- rowed). Use a torque wrench to tighten drain valve on charge-air coolant pump to specified tightening torque. Name Size Type Lubricant Value/Standard Spindle A/F11 Tightening torque 12 Nm Screw in drain screws on thermostat housing and intercooler with new sealing rings. Position valve cover on filler neck at coolant expansion tank and close.
Page 212: Charge-Air Coolant – Filling
9.15.4 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. Coolant WARNING Coolant is hot and under pressure.
Page 213 Filling coolant with pump Open plug screw (1) and connect appropriate pump with a hose. Undo the vent line union at the distributor piece (arrowed). Pump coolant at pressure of at least 0.5 bar into engine. Tighten union (arrowed) if coolant leaks out at loose union.
Page 214 Alternatively: Filling coolant through filler neck Undo the vent line union at the distributor piece (arrowed). Top up coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. Tighten union (arrowed) if coolant leaks out at loose union.
Page 215: Charge-Air Coolant Pump – Relief Bore Check
9.15.5 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 216: Belt Drive
9.16 Belt Drive 9.16.1 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 217: Battery-Charging Generator
9.17 Battery-Charging Generator 9.17.1 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 bit F30027341 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340...
Page 218: Battery-Charging Generator Drive – Drive Belt
9.17.2 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 bit F30027341 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Drive belt...
Page 219: Wiring (General) For Engine/Gearbox/Unit
9.18 Wiring (General) for Engine/Gearbox/Unit 9.18.1 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 220: Engine Mounting / Support
9.19 Engine Mounting / Support 9.19.1 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 221 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 222: Engine Mounting – Checking Resilient Element
9.19.2 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 223: Generator Mounting – Check
9.19.3 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 224: Generator Mounting – Securing Screw Firm
9.19.4 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. 224 | Engine Mounting / Support | MS15060/01E 2018-12...
Page 225: Accessories For (Electronic) Engine
9.20 Accessories for (Electronic) Engine Governor / Control System 9.20.1 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 226: Governor / Control System
9.20.2 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 227: Engine Control Unit Ecu 9 – Removal And
9.20.3 Engine Control Unit 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 228: Parameters For Drift Correction (Cdc
9.20.4 Parameters for drift correction (CDC) – Resetting with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Parameters for drift correction (CDC) – Resetting with DiaSys® Note: The engine will lose its emissions certification of the drift correction parameters (CDC) if not reset. Use DiaSys®...
Page 229: 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 230 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 231 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 232: Conversion Tables
10.2 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 233 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 234 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 235 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 236: Tightening Specifications For Screws, Nuts
10.3 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 237 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 238 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 239 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 240 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 241 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 242 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 243 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 244 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 245 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 246 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 247 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 248 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 249 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 250: Appendix B
11 Appendix B 11.1 Special Tools Angular screw driver Part No.: F30002815 Qty.: Used in: 9.4.3 Valve clearance – Check and adjustment (→ Page 126) Barring tool Part No.: F6555766 Qty.: Used in: 9.1.1 Engine – Barring manually (→ Page 112) Qty.: Used in: 9.2.1 Cylinder liner –...
Page 251 Crossbeam Part No.: T80092360 Qty.: Used in: 2.1 Transport (→ Page 20) Depth gauge, 200 mm Part No.: Y20000918 Qty.: Used in: 9.4.1 Valve protrusion – Measurement (→ Page 121) Endoscope Part No.: Y20097353 Qty.: Used in: 9.2.1 Cylinder liner – Endoscopic examination (→...
Page 252 Filter wrench Part No.: F30379104 Qty.: Used in: 9.8.1 Fuel filter – Replacement (→ Page 152) Qty.: Used in: 9.8.2 Additional fuel filter – Replacement (→ Page 153) Qty.: Used in: 9.13.1 Engine oil filter – Replacement (→ Page 181) Fuel suction pipe Part No.: F30378207...
Page 253 Qty.: Used in: 9.6.2 Injector – Removal and installation (→ Page 135) Qty.: Used in: 9.6.3 Injector rings – Replacement (→ Page 141) MTU test kit Part No.: F6798833 Qty.: Used in: 9.12.3 Engine oil – Sample extraction and analysis (→...
Page 254 Oil filter wrench Part No.: F30455924 Qty.: Used in: 9.13.2 Centrifugal oil filter – Cleaning and filter sleeve re- placement (→ Page 182) Ratchet bit Part No.: F30027341 Qty.: Used in: 9.4.4 Cylinder head cover – Removal and installation (→ Page 130) Qty.: Used in: 9.6.2 Injector –...
Page 255 Ratchet bit Part No.: F30027340 Qty.: Used in: 9.6.2 Injector – Removal and installation (→ Page 135) Qty.: Used in: 9.6.3 Injector rings – Replacement (→ Page 141) Qty.: Used in: 9.8.8 Fuel prefilter (switchable) – Filter element replace- ment (→ Page 162) Qty.: Used in: 9.8.9 Fuel prefilter (non-switchable) –...
Page 256 Torque screwdriver, 1–5 Nm Part No.: F30452774 Qty.: Used in: 9.6.2 Injector – Removal and installation (→ Page 135) Qty.: Used in: 9.6.3 Injector rings – Replacement (→ Page 141) Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 2.3 Crankshaft transport locking device (→...
Page 257 Torque wrench, 300–800 Nm Part No.: F30047798 Qty.: Used in: 9.19.1 Engine mounting – Checking securing screws for firm seating (→ Page 220) Torque wrench, 4–20 Nm Part No.: F30044239 Qty.: Used in: 9.7.1 Fuel system – Venting (→ Page 147) Qty.: Used in: 9.13.2 Centrifugal oil filter –...
Page 258 Torque wrench, 6–50 Nm Part No.: F30027336 Qty.: Used in: 9.8.8 Fuel prefilter (switchable) – Filter element replace- ment (→ Page 162) Qty.: Used in: 9.8.9 Fuel prefilter (non-switchable) – Filter element re- placement (→ Page 165) Valve setting gauge Part No.: Y4349603 Qty.:...
Page 259: Index
11.2 Index Crankcase breather – Oil mist separator Abbreviations 229 – Replacement 120 Actuators Crankshaft – Overview 67 – Transport locking device Additional fuel filter – Installation/removal 22 – Replacement 153 Cylinder ADEC 64 – Designation 26 After stopping the engine Cylinder head cover ...
Page 260 – Leak-tightness 151 Main dimensions 40 – Cleaning 149 Maintenance schedule Fuel filter – Maintenance task reference table [QL1] 83 – Replacement 152 MTU contact persons 249 pan 44 Oil priming pump – Visual inspection 180 Operational monitoring 76 260 | Index | MS15060/01E 2018-12...
Page 261 19 – Solenoid switch 201 Safety system – Thermostat 203 – Override 75 Product data 12V4000G34F Sensors – 3E standby power, overload capability acc. to ICXN – Overview 67 – EPA Nonroad T2 Compliant 27 Service indicator – Fuel optimized 27...
Page 262 Valve protrusion – Measurement 121 Warning notices, standards 19 262 | Index | MS15060/01E 2018-12...

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12v4000g94f 16v4000g34f 16v4000g94f

MTU 12V4000G34F Operating Instructions Manual

1 Safety

2 Transport

3 General Information

4 Technical Data

5 Functional Description

6 Operation

7 Maintenance

8 Troubleshooting

9 Task Description

10 Appendix A

11 Appendix B

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