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MTU 20V4000G*3 series Operating Instructions Manual

6 exhaust turbochargers
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Operating Instructions
Diesel engine
20V4000Gx3x
6 exhaust turbochargers
MS150093/05E

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Summary of Contents for MTU 20V4000G*3 series

  • Page 1 Operating Instructions Diesel engine 20V4000Gx3x 6 exhaust turbochargers MS150093/05E...
  • 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

    Table of Contents 1 Revision Overview 5.7 Product data 20V4000Gx3x, standby operation 3D, EPA Stationary EMERG T2 1.1 Revision – Overview (40CFR60) and EPA Nonroad T2 Comp (40CFR89) 2 Safety 5.8 Product data 20V4000Gx3x, standby operation mode 3D, NEA Singapore for 2.1 Important provisions for all products ORDE and China Nonroad Mobile 2.2 Correct use of all products...
  • Page 6 6.2 Putting into operation after scheduled out- 9.6 Injector of-service-period 9.6.1 Injector – Replacement 6.3 Starting the engine in manual mode (test 9.6.2 Injector – Removal and installation run) 9.7 Fuel System 6.4 Re-starting the engine following an 9.7.1 Fuel system – Venting automatic safety shutdown 6.5 Safety system –...
  • Page 7 10 Appendix A 9.17 Belt Drive 9.17.1 Drive belt – Condition check 10.1 Abbreviations 9.18 Battery-Charging Generator 10.2 MTU Contact/Service Partners 9.18.1 Battery-charging generator – Drive belt tension adjustment 11 Appendix B 9.18.2 Battery-charging generator drive – Drive belt replacement 11.1 Special Tools...

  • Page 8: Revision Overview

    1 Revision Overview 1.1 Revision – Overview Revision overview – General Chapter MS150093/04 MS150093/05 Chapter “Safety”. Chapter updated to the latest status. Revision overview – Maintenance schedule Task No. Revision overview – Task description Chapter MS150093/04 MS150093/05 6 | Revision Overview | MS150093/05E 2018-12...

  • Page 9: 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 10 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 11: Correct Use Of All Products

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

  • Page 12: Personnel And Organizational Requirements

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

  • Page 13: Safety Regulations For Initial Start-Up And Operation

    2.4 Safety regulations for initial start-up and operation Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 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

    2.5 Safety regulations for assembly, maintenance, and repair work Safety regulations for work prior to assembly, maintenance, and repair Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion 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

    2.7 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 | MS150093/05E 2018-12...

  • Page 23: Lifting Instructions

    3.2 Lifting instructions Lifting instructions 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 Center of gravity A Max.

  • Page 24: Engine Mount Shipping Lock

    3.3 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 25: Crankshaft Transport Locking Device

    3.4 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 26 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 27 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 28: General Information

    4 General Information 4.1 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 •...
  • Page 29 Hand-tightening Machine-tightening Thread 8.8 M (Nm) 10.9 M (Nm) 8.8 M (Nm) 10.9 M (Nm) M18 x 1.5 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...
  • Page 30 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 31 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 32 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 33 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 34 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 35 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 36 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 37 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 38 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 39 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 40 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 41: Engine Side And Cylinder Designations

    4.2 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) Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

  • Page 42: Engine Layout

    4.3 Engine layout 1 Oil cooler 8 Intercooler 15 Gear train 2 Crankcase breather 9 Starter 16 Power supply 3 Exhaust turbocharger 10 Engine mounting 17 HP fuel pump 4 Intake air filter 11 Cylinder head cover 18 Vibration damper 5 Exhaust bellows 12 Cylinder head 19 Coolant distribution housing...

  • Page 43: Sensors And Actuators - Overview

    4.4 Sensors and actuators – Overview 1 B44 (turbocharger speed) 3 Sensor B34 (fuel pressure 5 B09 (charge-air tempera- 2 B10 (charge-air pressure) after filter) ture) 4 M8 (HP fuel pump) MS150093/05E 2018-12 | General Information | 41...
  • Page 44 1 B50 (crankcase pressure) 5 B48 (fuel pressure, rail) 9 B26 (charge-air coolant 2 B07 (lube-oil temperature) 6 B01 (camshaft speed) temperature) 3 B05.3 (lube oil pressure be- 7 XB54 (oil replenishment 10 B06 (coolant temperature) fore filter, optional) pump) 4 B05 (lube-oil pressure) 8 B33 (fuel temperature, rail) 1 X2 (Engine Control Unit)
  • Page 45 1 B13 (crankshaft speed) MS150093/05E 2018-12 | General Information | 43...

  • Page 46: Technical Data

    5 Technical Data 5.1 Product data 20V4000Gx3x, continuous operation 3A, optimized fuel consumption Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 47 Performance data Rated engine speed 1500 1500 1800 1800 Fuel stop power ISO 3046 2200 2420 2453 2739 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore...
  • Page 48 Coolant system (LT circuit) Coolant temperature before charge-air °C cooler (at engine inlet: from cooling equipment) Coolant antifreeze content, max. Pressure loss in off-engine cooling sys- tem, max. Lube oil system Lube-oil operating temperature before °C engine, from Lube oil operating temperature before °C engine, to Lube oil temperature before engine, limit...
  • Page 49 Engine oil capacity, initial filling (standard Liters 390 * 390 * 390 * 390 * oil system) (option: max. operating incli- nations) Oil change quantity, max. (standard oil Liters 340 * 340 * 340 * 340 * system) (option: max. operating inclina- tions) Oil pan capacity at dipstick mark “min.”...

  • Page 50: Product Data 20V4000Gx3X, Continuous Operation 3B, Optimized Fuel Consumption

    5.2 Product data 20V4000Gx3x, continuous operation 3B, optimized fuel consumption Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 51 Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level Performance data Rated engine speed 1500 1800 1500 1500 1800 1800 Fuel stop power ISO 2420 2739 2662 2849 3014 3311 3046 General conditions (for maximum power) Intake depression (new mbar filter)
  • Page 52 Coolant temperature after °C engine, limit 2 Coolant antifreeze con- tent, max. Pressure loss in off-en- gine cooling system, max. Coolant system (LT circuit) Coolant temperature be- °C fore charge-air cooler (at engine inlet: from cooling equipment) Coolant antifreeze con- tent, max.
  • Page 53 General operating data Cold start capability: air °C temperature (w/o start aid. w/o preheating) - (case A) Coolant preheating: pre- °C heating temperature (min.) Firing speed, from Firing speed. to Capacities Engine coolant capacity, Liters 205 * 205 * 205 * 205 * 205 * 205 *...
  • Page 54 Sound Exhaust noise, unsilenced dB(A) - DL (power sound power level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) - DL (power sound power level LW, ISO 6798, +2dB (A) tolerance) 52 | Technical Data | MS150093/05E 2018-12...

  • Page 55: Product Data 20V4000Gx3X, Continuous Operation 3B, Optimized Exhaust Gas Emission (Ta-Luft)

    5.3 Product data 20V4000Gx3x, continuous operation 3B, optimized exhaust gas emission (TA-Luft) Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 56 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 4.77 4.77 4.77 Displacement, total Liters 95.4 95.4 95.4 Compression ratio 16.4 16.4...
  • Page 57 Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min. (when -0.1 -0.1 -0.1 engine is starting) Fuel pressure at engine inlet connection, max.

  • Page 58: (40Cfr60) And Epa Nonroad T2 Comp (40Cfr89)

    5.4 Product data 20V4000Gx3x, continuous operation 3B, EPA stationary EMERG T2 (40CFR60) and EPA Nonroad T2 Comp (40CFR89) Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 59 Performance data Rated engine speed 1800 1800 1800 Fuel stop power ISO 3046 2739 3014 3311 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore...
  • Page 60 Lube oil system Lube-oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube-oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min.
  • Page 61 Sound Exhaust noise, unsilenced - DL (power sound power dB(A) level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with attenuated intake noise (fil- dB(A) ter) - DL (power sound power level LW, ISO 6798, +2 dB (A) tolerance) MS150093/05E 2018-12 | Technical Data | 59...

  • Page 62: China Nonroad Mobile Machinery Stage

    5.5 Product data 20V4000Gx3x, continuous operation 3B, NEA Singapore for ORDE and China Nonroad Mobile Machinery Stage III Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 63 Performance data Rated engine speed 1500 1500 1500 Fuel stop power ISO 3046 2420 2670 2849 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore...
  • Page 64 Lube oil system Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min.
  • Page 65 Sound Exhaust noise, unsilenced - DL (power sound power dB(A) level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (fil- dB(A) ter) - DL (power sound power level LW, ISO 6798, +2dB (A) tolerance) MS150093/05E 2018-12 | Technical Data | 63...

  • Page 66: Product Data 20V4000Gx3X, Standby Operation 3D, Optimized Fuel Consumption

    5.6 Product data 20V4000Gx3x, standby operation 3D, optimized fuel consumption Legend DL Ref. value: Continuous output. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 67 Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level Performance data Rated engine speed 1500 1800 1500 1500 1800 1800 Fuel stop power ISO 2420 2740 2670 2850 3010 3490 3046 General conditions (for maximum power) Intake depression (new mbar filter)
  • Page 68 Coolant antifreeze con- tent, max. Pressure loss in off-en- gine cooling system, max. Coolant system (LT circuit) Coolant temperature be- °C fore charge-air cooler (at engine inlet: from cooling equipment) Coolant antifreeze con- tent, max. Pressure loss in off-en- gine cooling system, max. Lube oil system Lube-oil operating tem- °C...
  • Page 69 General operating data Cold start capability: air °C temperature (w/o start aid. w/o preheating) - (case A) Coolant preheating: pre- °C heating temperature (min.) Firing speed, from Firing speed. to Capacities Engine coolant capacity, Liters 205 * 205 * 205 * 205 * 205 * 205 *...
  • Page 70 Sound Exhaust noise, unsilenced dB(A) - BL (sound power level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) - BL (sound power level LW, ISO 6798, +2dB (A) tolerance) 68 | Technical Data | MS150093/05E 2018-12...

  • Page 71: Product Data 20V4000Gx3X, Standby Operation 3D, Epa Stationary Emerg T2

    5.7 Product data 20V4000Gx3x, standby operation 3D, EPA Stationary EMERG T2 (40CFR60) and EPA Nonroad T2 Comp (40CFR89) Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 72 Performance data Rated engine speed 1800 1800 1800 Fuel stop power ISO 3046 2740 3010 3490 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore...
  • Page 73 Lube oil system Lube-oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube-oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min.
  • Page 74 Sound Exhaust noise, unsilenced - BL (sound power level dB(A) LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with attenuated intake noise (fil- dB(A) ter) - BL (sound power level LW, ISO 6798, +2 dB (A) tolerance) 72 | Technical Data | MS150093/05E 2018-12...

  • Page 75: Product Data 20V4000Gx3X, Standby Operation Mode 3D, Nea Singapore For Orde And China Nonroad Mobile Machinery Stage

    5.8 Product data 20V4000Gx3x, standby operation mode 3D, NEA Singapore for ORDE and China Nonroad Mobile Machinery Stage III Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 76 Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level Performance data Rated engine speed 1500 1500 1500 1500 1500 Fuel stop power ISO 3046 2420 2670 2670 2850 2850 General conditions (for maximum power) Intake depression (new filter) A mbar Intake depression, max.
  • Page 77 Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. Coolant system (LT circuit) Coolant temperature before °C charge-air cooler (at engine inlet: from cooling equip- ment) Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. Lube oil system Lube oil operating tempera- °C ture before engine, from...
  • Page 78 Firing speed, from Firing speed. to Capacities Engine coolant capacity, en- Liters 205 * 205 * 205 * 205 * 205 * gine side (without cooling equipment) Charge-air coolant, engine Liters side Engine oil capacity, initial fill- Liters 390 * 390 * 390 * 390 *...

  • Page 79: Product Data 20V4000Gx3X, Standby Operation 3E, Optimized Fuel Consumption

    5.9 Product data 20V4000Gx3x, standby operation 3E, optimized fuel consumption Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 80 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 4.77 4.77 4.77 Displacement, total Liters 95.4 95.4 95.4 Compression ratio 16.4 16.4...
  • Page 81 Lube oil temperature before engine, limit 1 °C Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube-oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min. (when -0.1 -0.1 -0.1...

  • Page 82: Product Data 20V4000Gx3X, Standby Operation 3E, Optimized Exhaust Gas Emission (Ta-Luft)

    5.10 Product data 20V4000Gx3x, standby operation 3E, optimized exhaust gas emission (TA-Luft) Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 83 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 4.77 4.77 4.77 Displacement, total Liters 95.4 95.4 95.4 Compression ratio 16.4 16.4...
  • Page 84 Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube-oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min. (when -0.1 -0.1 -0.1 engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) General operating data Cold start capability: air temperature (w/o start aid.

  • Page 85: Product Data 20V4000Gx3X, Standby Operation 3E, Nea Singapore For Orde And China Nonroad Mobile Machinery Stage

    5.11 Product data 20V4000Gx3x, standby operation 3E, NEA Singapore for ORDE and China Nonroad Mobile Machinery Stage III Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 86 Performance data Rated engine speed 1500 1500 1500 Fuel stop power ISO 3046 2420 2670 2849 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore...
  • Page 87 Lube oil system Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min.
  • Page 88 Sound Exhaust noise, unsilenced - DL (power sound power dB(A) level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (fil- dB(A) ter) - DL (power sound power level LW, ISO 6798, +2dB (A) tolerance) 86 | Technical Data | MS150093/05E 2018-12...

  • Page 89: Product Data 20V4000Gx3X, Standby Operation Mode 3F, Optimized Fuel Consumption

    5.12 Product data 20V4000Gx3x, standby operation mode 3F, optimized fuel consumption Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 90 Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level Performance data Rated engine speed 1500 1800 1500 1500 1800 1800 Fuel stop power ISO 2420 2739 2662 2849 3014 3311 3046 General conditions (for maximum power) Intake depression (new mbar filter)
  • Page 91 Coolant temperature after °C engine, limit 2 Coolant antifreeze con- tent, max. Pressure loss in off-en- gine cooling system, max. Coolant system (LT circuit) Coolant temperature be- °C fore charge-air cooler (at engine inlet: from cooling equipment) Coolant antifreeze con- tent, max.
  • Page 92 General operating data Cold start capability: air °C temperature (w/o start aid. w/o preheating) - (case A) Coolant preheating: pre- °C heating temperature (min.) Firing speed, from Firing speed. to Capacities Engine coolant capacity, Liters 205 * 205 * 205 * 205 * 205 * 205 *...
  • Page 93 Sound Exhaust noise, unsilenced dB(A) - DL (power sound power level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) - DL (power sound power level LW, ISO 6798, +2dB (A) tolerance) MS150093/05E 2018-12 | Technical Data | 91...

  • Page 94: Product Data 20V4000Gx3X, Standby Operation Mode 3F, Optimized Exhaust Gas Emission (Ta-Luft)

    5.13 Product data 20V4000Gx3x, standby operation mode 3F, optimized exhaust gas emission (TA-Luft) Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 95 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 4.77 4.77 4.77 Displacement, total Liters 95.4 95.4 95.4 Compression ratio 16.4 16.4...
  • Page 96 Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min. (when -0.1 -0.1 -0.1 engine is starting) Fuel pressure at engine inlet connection, max.

  • Page 97: Product Data 20V4000Gx3X, Standby Operation Mode 3F, Epa Stationary Emerg T2 (40Cfr60) And Epa Nonroad T2 Comp (40Cfr89)

    5.14 Product data 20V4000Gx3x, standby operation mode 3F, EPA Stationary EMERG T2 (40CFR60) and EPA Nonroad T2 Comp (40CFR89) Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 98 Performance data Rated engine speed 1800 1800 1800 Fuel stop power ISO 3046 2739 3014 3311 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore...
  • Page 99 Lube oil system Lube-oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min.
  • Page 100 Sound Exhaust noise, unsilenced - DL (power sound power dB(A) level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with attenuated intake noise (fil- dB(A) ter) - DL (power sound power level LW, ISO 6798, +2 dB(A) tolerance) 98 | Technical Data | MS150093/05E 2018-12...

  • Page 101: Product Data 20V4000Gx3X, Standby Operation Mode 3F, Nea Singapore For Orde And China Nonroad Mobile Machinery Stage

    5.15 Product data 20V4000Gx3x, standby operation mode 3F, NEA Singapore for ORDE and China Nonroad Mobile Machinery Stage III Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 102 Performance data Rated engine speed 1500 1500 1500 Fuel stop power ISO 3046 2420 2670 2849 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore...
  • Page 103 Lube oil system Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min.
  • Page 104 Sound Exhaust noise, unsilenced - DL (power sound power dB(A) level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (fil- dB(A) ter) - DL (power sound power level LW, ISO 6798, +2dB (A) tolerance) 102 | Technical Data | MS150093/05E 2018-12...

  • Page 105: Product Data 20V4000Gx3X, Continuous Operation 3G, Optimized Fuel Consumption

    5.16 Product data 20V4000Gx3x, continuous operation 3G, optimized fuel consumption Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 106 Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level Performance data Rated engine speed 1500 1800 1500 1500 1800 1800 Fuel stop power ISO 2420 2739 2662 2849 3014 3311 3046 General conditions (for maximum power) Intake depression (new mbar filter)
  • Page 107 Coolant temperature after °C engine, limit 2 Coolant antifreeze con- tent, max. Pressure loss in off-en- gine cooling system, max. Coolant system (LT circuit) Coolant temperature be- °C fore charge-air cooler (at engine inlet: from cooling equipment) Coolant antifreeze con- tent, max.
  • Page 108 General operating data Cold start capability: air °C temperature (w/o start aid. w/o preheating) - (case A) Coolant preheating: pre- °C heating temperature (min.) Firing speed, from Firing speed. to Capacities Engine coolant capacity, Liters 205 * 205 * 205 * 205 * 205 * 205 *...
  • Page 109 Sound Exhaust noise, unsilenced dB(A) - DL (power sound power level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) - DL (power sound power level LW, ISO 6798, +2dB (A) tolerance) MS150093/05E 2018-12 | Technical Data | 107...

  • Page 110: Product Data 20V4000Gx3X, Continuous Operation 3G, Optimized Exhaust Gas Emission (Ta-Luft)

    5.17 Product data 20V4000Gx3x, continuous operation 3G, optimized exhaust gas emission (TA-Luft) Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 111 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 4.77 4.77 4.77 Displacement, total Liters 95.4 95.4 95.4 Compression ratio 16.4 16.4...
  • Page 112 Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min. (when -0.1 -0.1 -0.1 engine is starting) Fuel pressure at engine inlet connection, max.

  • Page 113: Product Data 20V4000Gx3X, Continuous Operation 3G, Epa Nonroad T2 Comp (40Cfr89)

    5.18 Product data 20V4000Gx3x, continuous operation 3G, EPA Nonroad T2 Comp (40CFR89) Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 114 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 4.77 4.77 4.77 Displacement, total Liters 95.4 95.4 95.4 Compression ratio 16.4 16.4...
  • Page 115 Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube-oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min. (when -0.1 -0.1 -0.1 engine is starting) Fuel pressure at engine inlet connection, max. (when engine is starting) General operating data Cold start capability: air temperature (w/o start aid.

  • Page 116: China Nonroad Mobile Machinery Stage

    5.19 Product data 20V4000Gx3x, continuous operation 3G, NEA Singapore for ORDE and China Nonroad Mobile Machinery Stage III Legend DL Ref. value: Continuous power. Continuous drivable power under standard conditions BL Ref. value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applica- tions (adjustment reserve) A Design value.
  • Page 117 Performance data Rated engine speed 1500 1500 1500 Fuel stop power ISO 3046 2420 2670 2849 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore...
  • Page 118 Lube oil system Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C Lube oil temperature before engine, limit 2 °C Lube oil operating pressure upstream of engine, from R Lube oil operating pressure before engine, to Fuel system Fuel pressure at engine inlet connection, min.
  • Page 119 Sound Exhaust noise, unsilenced - DL (power sound power dB(A) level LW, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake noise (fil- dB(A) ter) - DL (power sound power level LW, ISO 6798, +2dB (A) tolerance) MS150093/05E 2018-12 | Technical Data | 117...

  • Page 120: Final Compression Pressure

    5.20 Final compression pressure Final compression pressure At 120 rpm 24 bar to 28 bar 118 | Technical Data | MS150093/05E 2018-12...

  • Page 121: Firing Order

    5.21 Firing order Firing order Number of cylinders Firing order A1-B4-A4-A2-B3-A3-B2-B1 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 A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 MS150093/05E 2018-12 | Technical Data | 119...

  • Page 122: Engine - Main Dimensions

    5.22 Engine – Main dimensions Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 20V4000Gx3 3560 mm 1671 mm 2163 mm 120 | Technical Data | MS150093/05E 2018-12...

  • Page 123: 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 124: 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 242); Coolant circuit Check engine coolant level (→ Page 252). Check charge-air coolant level (→ Page 274). Coolant circuit Heat engine coolant with coolant preheater.

  • Page 125: 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 126: 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 127: 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 128: Emergency Engine Start (Override Mode)

    6.6 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 129: Operational Monitoring

    6.7 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 A high level of noise is produced when the engine is running.

  • Page 130: Emission Label - Check

    6.8 Emission label – Check Emission label – Check Note: If there are any irregularities, notify your MTU contact person/service partner without delay. Check that emission labels are present (there can be more than one). Check emission label for intactness.

  • Page 131: Engine - Stopping In Manual Mode (Test Run)

    6.9 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 132 After engine shutdown Item Action Coolant circulating pump Allow to run on for sufficient time after stopping. 130 | Operation | MS150093/05E 2018-12...

  • Page 133: Engine - Emergency Stop

    6.10 Engine – Emergency stop NOTICE An emergency stop subjects the engine system to an extremely high load. Risk of overheating, damage to components! • Trigger an emergency stop only in emergency situations. Emergency engine stop from LOP Item Action Emergency stop pushbutton Press pushbutton.

  • Page 134: After Stopping The Engine - Engine Remains Ready For Operation

    6.11 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 132 | Operation | MS150093/05E 2018-12...

  • Page 135: After Stopping The Engine - Putting The Engine Out Of Operation

    6.12 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 254); Drain charge-air coolant (→ Page 277) if: •...

  • Page 136: Plant - Cleaning

    6.13 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 137: 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 138 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 139 Blue exhaust gas Cause Corrective action u Drain engine oil (→ Page 240). Too much engine oil in the engine u Replace filter (→ Page 197). Oil separator of crankcase breather contaminated Exhaust turbocharger, cylinder u Contact Service. head, piston rings or cylinder liner defective White exhaust gas Cause...

  • Page 140: Engine Control Unit Adec (Ecu 7) For Series 4000 Genset Engines - Fault Messages

    7.2 Engine Control Unit ADEC (ECU 7) for Series 4000 genset engines – Fault messages Possible engine responses to yellow alarm: Warning, power limitation/reduction, speed limitation, engine stop Possible engine responses to red alarm: Engine stop, power limitation/reduction, speed limitation, warning Procedure following an automatic safety shutdown (→...
  • Page 141 009 – HI T-Coolant Intercooler ZKP-Number: 2.0124.931 Limit value 1 Cause Corrective action Coolant temperature in u Reduce power. intercooler too high 010 – SS T-Coolant Intercooler ZKP-Number: 2.0124.932 Limit value 2 Cause Corrective action Coolant temperature in u Reduce power. intercooler too high.
  • Page 142 021 – HI T-Exhaust B ZKP-Number: 2.0127.931 Limit value 1 Cause Corrective action Exhaust gas temperature (B side) 1. Check cabling (→ Page 287). too high 2. Contact Service. 022 – SS T-Exhaust B ZKP-Number: 2.0127.932 Limit value 2 Cause Corrective action Exhaust gas temperature (B side) 1.
  • Page 143 029 – HI ETC2 Idle Speed too High ZKP-Number: 1.8004.206 Cause Corrective action ETC 2 idling speed too high u Contact Service. 030 – SS Engine Overspeed ZKP-Number: 2.2510.932 Limit value 2 Cause Corrective action Engine overspeed. Automatic 1. Acknowledge alarm. engine emergency stop.
  • Page 144 036 – HI ETC2 Overspeed ZKP-Number: 2.3013.931 Limit value 1 Cause Corrective action Speed of 1st secondary 1. Reduce power. turbocharger too high 2. Contact Service. 037 – SS ETC2 Overspeed ZKP-Number: 2.3013.912 Limit value 2 Cause Corrective action Speed of 1st secondary 1.
  • Page 145 052 – SS T-Lube Oil ZKP-Number: 2.0125.932 Limit value 2 Cause Corrective action Lube oil temperature too high. 1. Reduce power. Engine stop. 2. Check engine oil level (→ Page 242). 057 – LO P-Coolant ZKP-Number: 2.0101.921 Limit value 1 Cause Corrective action Coolant pressure too low...
  • Page 146 063 – HI P-Crankcase ZKP-Number: 2.0106.931 Limit value 1 Cause Corrective action Crankcase pressure too high 1. Reduce power. 2. Replace oil separator element (→ Page 197). 064 – SS P-Crankcase ZKP-Number: 2.0106.932 Limit value 2 Cause Corrective action Crankcase pressure too high. u Engine must not be started (risk of engine failure), contact Service.
  • Page 147 068 – SS T-Coolant ZKP-Number: 2.0120.932 Limit value 2 Cause Corrective action Coolant temperature too high. 1. Allow engine to cool down. Engine stop. 2. Check engine coolant cooler, clean if dirty. 3. Restart engine (→ Page 123). 4. Contact Service. 081 –...
  • Page 148 086 – HIHI T-Umblasen ZKP-Number: 2.0128.932 Limit value 2 Cause Corrective action Recirculation temperature too u Reduce power. high 089 – SS Engine Speed too Low ZKP-Number: 2.2500.030 Cause Corrective action Engine speed too low u Observe any other messages. 090 –...
  • Page 149 094 – LO T-Preheat ZKP-Number: 2.1090.921 Limit value 1 Cause Corrective action Preheating temperature too low. u Check preheater. Coolant temperature too low for engine start. 095 – AL Prelubrication Fault ZKP-Number: 2.1090.920 Cause Corrective action u Check priming system. Oil priming fault 102 –...
  • Page 150 120 – HI ECU Power Supply Voltage ZKP-Number: 2.0140.931 Limit value 1 Cause Corrective action Supply voltage too high 1. Check Engine Control Unit supply voltage. 2. Contact Service. 121 – HIHI ECU Power Supply Voltage ZKP-Number: 2.0140.932 Limit value 2 Cause Corrective action Supply voltage too high...
  • Page 151 176 – AL LifeData not available ZKP-Number: 2.4000.004 Cause Corrective action No (appropriate) LifeData backup u Contact Service. system available, ECU reset on expiry of timeout period 177 – AL LifeData Restore Incomplete ZKP-Number: 2.4000.006 Cause Corrective action u Contact Service. This fault message is generated if a CRC is faulty during a data upload to ADEC (indicated for...
  • Page 152 184 – AL CAN PU-Data Flash Error ZKP-Number: 2.0500.684 Cause Corrective action A programming error occurred u Contact Service. when attempting to copy a received PU data module into the Flash module 186 – AL CAN1 Bus Off ZKP-Number: 2.0500.686 Cause Corrective action CAN controller 1 is in “Bus-Off”...
  • Page 153 201 – SD T-Coolant ZKP-Number: 1.8004.570 Cause Corrective action Coolant temperature sensor u Check sensor and cabling (B6), replace as necessary. faulty. Short circuit or wire break. Error cleared after restarting the engine. 202 – SD T-Fuel ZKP-Number: 1.8004.572 Cause Corrective action Fuel temperature sensor faulty.
  • Page 154 207 – SD T-Exhaust B ZKP-Number: 18.004.577 Cause Corrective action Exhaust temperature sensor on B u Check sensor and cabling (B4.22), replace as necessary. side faulty. Short circuit or wire break. 208 – SD P-Charge Air ZKP-Number: 1.8004.566 Cause Corrective action u Check sensor and cabling (B10), replace as necessary.
  • Page 155 215 – SD P-HD ZKP-Number: 1.8004.567 Cause Corrective action Rail pressure sensor faulty. High- u Check sensor and cabling (B48), replace as necessary. pressure regulator in emergency Error cleared after restarting the engine. mode ==> Short circuit or wire break 216 –...
  • Page 156 223 – SD Level Coolant Intercooler ZKP-Number: 1.8004.583 Cause Corrective action Sensor for intercooler coolant u Check sensor and cabling (F57), replace as necessary. level faulty. Short circuit or wire Error cleared after restarting the engine. break. 227 – SD P-Oil before Filter ZKP-Number: 1.8004.620 Cause Corrective action...
  • Page 157 232 – SD Charger 1 Speed ZKP-Number: 1.3011.128 Cause Corrective action Speed sensor of primary u Check sensor and cabling (B44.1), replace as necessary. turbocharger faulty. Short circuit Error cleared after restarting the engine. or wire break. 233 – SD Charger 2 Speed ZKP-Number: 1.3011.129 Cause Corrective action...
  • Page 158 244 – SD P-Lube Oil (R) ZKP-Number: 1.8004.621 Cause Corrective action Redundant lube oil pressure u Check sensor and cabling, replace as necessary. sensor faulty. Short circuit or wire Error cleared after restarting the engine. break. 245 – SD ECU Power Supply Voltage ZKP-Number: 2.8006.589 Cause Corrective action...
  • Page 159 301 – AL Timing Cylinder A1 ZKP-Number: 1.8004.500 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears frequently injector: Time-of-flight measured (→ Page 210). value extremely low or extremely high. 302 – AL Timing Cylinder A2 ZKP-Number: 1.8004.501 Cause Corrective action...
  • Page 160 306 – AL Timing Cylinder A6 ZKP-Number: 1.8004.505 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears frequently injector: Time-of-flight measured (→ Page 210). value extremely low or extremely high 307 – AL Timing Cylinder A7 ZKP-Number: 1.8004.506 Cause Corrective action...
  • Page 161 311 – AL Timing Cylinder B1 ZKP-Number: 1.8004.510 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears frequently injector: Time-of-flight measured (→ Page 210). value extremely low or extremely high 312 – AL Timing Cylinder B2 ZKP-Number: 1.8004.511 Cause Corrective action...
  • Page 162 316 – AL Timing Cylinder B6 ZKP-Number: 1.8004.515 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears frequently injector: Time-of-flight measured (→ Page 210). value extremely low or extremely high. 317 – AL Timing Cylinder B7 ZKP-Number: 1.8004.516 Cause Corrective action...
  • Page 163 321 – AL Wiring Cylinder A1 ZKP-Number: 1.8004.520 Cause Corrective action Short circuit in injector cabling to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 322 – AL Wiring Cylinder A2 ZKP-Number: 1.8004.521 Cause Corrective action Short circuit in injector cabling to 1.
  • Page 164 328 – AL Wiring Cylinder A8 ZKP-Number: 1.8004.527 Cause Corrective action Short circuit in injector cabling to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 329 – AL Wiring Cylinder A9 ZKP-Number: 1.8004.528 Cause Corrective action Short circuit in injector cabling to 1.
  • Page 165 335 – AL Wiring Cylinder B5 ZKP-Number: 1.8004.534 Cause Corrective action Short circuit in injector cabling to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 336 – AL Wiring Cylinder B6 ZKP-Number: 1.8004.535 Cause Corrective action Short circuit in injector cabling to 1.
  • Page 166 342 – AL Open Load Cylinder A2 ZKP-Number: 1.8004.541 Cause Corrective action Open circuit in injector wiring to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 343 – AL Open Load Cylinder A3 ZKP-Number: 1.8004.542 Cause Corrective action Open circuit in injector wiring to 1.
  • Page 167 349 – AL Open Load Cylinder A9 ZKP-Number: 1.8004.548 Cause Corrective action Open circuit in injector wiring to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 350 – AL Open Load Cylinder A10 ZKP-Number: 1.8004.549 Cause Corrective action Open circuit in injector wiring to 1.
  • Page 168 356 – AL Open Load Cylinder B6 ZKP-Number: 1.8004.555 Cause Corrective action Open circuit in injector wiring to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 357 – AL Open Load Cylinder B7 ZKP-Number: 1.8004.556 Cause Corrective action Open circuit in injector wiring to 1.
  • Page 169 362 – AL Power Stage High ZKP-Number: 1.8004.497 Cause Corrective action Internal electronic fault 1. Check solenoid valve cabling. (electronics possibly faulty: start 2. Replace Engine Control Unit. ITS). Check additional messages if ITS indicates diagnosis “Electronics OK” (e.g. cabling faulty).
  • Page 170 373 – AL Wiring TO 3 ZKP-Number: 1.8004.636 Cause Corrective action Short circuit or wire break at transistor output 3 (TO 3) 374 – AL Wiring TO 4 ZKP-Number: 1.8004.637 Cause Corrective action Short circuit or wire break at transistor output 4 (TO 4) 381 –...
  • Page 171 390 – AL MCR exceeded ZKP-Number: 1.1085.009 Cause Corrective action DBR/MCR feature: MCR 1. No action required if alarm only applied temporarily. exceeded. 2. Contact Service if alarm applied constantly. 392 – HI T-Coolant Red ZKP-Number: 2.0129.931 Limit value 1 Cause Corrective action Redundant coolant temperature...
  • Page 172 397 – TD P-Oil Sensor Deviation ZKP-Number: 1.0480.293 Cause Corrective action Maximum lube oil pressure 1. Check wiring and sensor. deviation 2. Contact Service. 400 – AL Open Load Digital Input 1 ZKP-Number: 2.8006.625 Cause Corrective action Line disruption on digital input 1. 1.
  • Page 173 405 – AL Open Load Digital Input 6 ZKP-Number: 2.8006.630 Cause Corrective action Line disruption on digital input 6. 1. Check cabling. Cabling faulty or no resistance 2. Check target device input. over switch 3. Contact Service. 406 – AL Open Load Digital Input 7 ZKP-Number: 2.8006.631 Cause Corrective action...
  • Page 174 412 – HI U-PDU ZKP-Number: 2.0141.931 Limit value 1 Cause Corrective action Injector voltage too high 1. Check cabling. 2. Check supply. 3. Contact Service. 413 – HIHI U-PDU ZKP-Number: 2.0141.932 Limit value 2 Cause Corrective action Injector voltage too high 1.
  • Page 175 417 – SD Level Water Fuel Prefilter ZKP-Number: 1.8004.594 Cause Corrective action Water level sensor in fuel prefilter u Check sensor and cabling, replace as necessary. faulty. Short circuit or wire break. Error cleared after restarting the engine. 419 – SD T-Coolant before Engine ZKP-Number: 18.004.604 Cause Corrective action...
  • Page 176 431 – SS P-Coolant before Engine ZKP-Number: 20.168.922 Limit value 2 Cause Corrective action Coolant pressure too low u Check coolant circuit. 434 – HI T-Coolant before Engine ZKP-Number: 20.173.931 Limit value 1 Cause Corrective action Coolant temperature too high u Check coolant circuit.
  • Page 177 445 – SD P-Ambient Air ZKP-Number: 1.8004.580 Cause Corrective action Ambient air pressure sensor faulty u Replace Engine Control Unit. 448 – HI P-Charge Air ZKP-Number: 2.0103.931 Limit value 1 Cause Corrective action Charge-air pressure too high u Contact Service. 449 –...
  • Page 178 456 – AL L2 Aux1 Plant ZKP-Number: 2.8006.651 Limit value 2 Cause Corrective action Input signal of Aux 1 (plant side) u Determine cause of limit value violation and rectify fault. has violated limit value 2, depending on configuration 460 – HI T-Exhaust EMU ZKP-Number: 2.8006.652 Limit value 1 Cause...
  • Page 179 467 – AL L2 T-Aux 1 ZKP-Number: 2.0130.922 Limit value 2 Cause Corrective action Temperature signal of Aux 1 has u Determine cause of limit value violation and rectify fault. violated limit value 2, depending on configuration 468 – SD T-AUX 1 ZKP-Number: 1.8004.579 Cause Corrective action...
  • Page 180 473 – AL Wiring PWM_CM2 ZKP-Number: 1.8004.593 Cause Corrective action Cable break or short circuit on 1. Check cabling. channel PWM_CM2 2. Contact Service. 474 – AL Wiring FO ZKP-Number: 2.8006.655 Cause Corrective action Cable break or short circuit on 1.
  • Page 181 482 – SD T-Exhaust C ZKP-Number: 18.004.596 Cause Corrective action Exhaust temperature sensor on A u Check sensor and cabling (B4.23), replace as necessary. side faulty. Short circuit or wire break. 483 – SD T-Exhaust D ZKP-Number: 18.004.597 Cause Corrective action u Check sensor and cabling (B4.24), replace as necessary.
  • Page 182 488 – HI ETC3 Overspeed ZKP-Number: 23.014.931 Limit value 1 Cause Corrective action Speed of 2nd secondary u Reduce power. turbocharger too high 489 – SS ETC3 Overspeed ZKP-Number: 23.014.932 Limit value 2 Cause Corrective action Speed of 2nd secondary u Reduce power.
  • Page 183 500 – AL Wiring POM Starter 1 ZKP-Number: 14.500.900 Cause Corrective action A cabling fault in connection of u Check connection between POM and starter. starter 1 of CPM has been detected. This may be due to a missing consumer, wire break or a short circuit.
  • Page 184 507 – AL POM Error ZKP-Number: 14.500.907 Cause Corrective action A general POM fault occurred u Replace POM. 508 – AL Wrong POM-ID ZKP-Number: 14.500.908 Cause Corrective action POM transmits an unexpected ID u Check POM wiring harness. number. 510 – AL Override applied ZKP-Number: 27.002.010 Cause Corrective action...
  • Page 185 523 – SS T-Coolant Red Mid Val ZKP-Number: 20.480.189 Limit value 2 Cause Corrective action Average coolant temperature u Reduce power. value from three sources is too high 524 – SS Engine Overspeed Mid Val ZKP-Number: 20.480.089 Limit value 2 Cause Corrective action Average engine overspeed value...
  • Page 186 529 – SS T-Coolant Red2 ZKP-Number: 20.480.195 Limit value 2 Cause Corrective action 2nd redundant coolant u Check coolant circuit. temperature reading too high 530 – SS P-Lube Oil Red2 ZKP-Number: 20.480.295 Limit value 2 Cause Corrective action 2nd redundant lube-oil pressure u Check oil level, top up as necessary.
  • Page 187 Limit value 2 Cause Corrective action Camshaft overspeed 1. Acknowledge alarm. 2. Attempt to restart engine. 555 – AL Call MTU Field Service ZKP-Number: 20.555.001 Cause Corrective action u Request enabling code via internet. This fault becomes active if a...
  • Page 188 578 – AL L1 T-Lube Oil Pan ZKP-Number: 20.137.921 Limit value 1 Cause Corrective action L1 T-Lube oil in oil pan violated limit 1 579 – AL MD CAN Request Idle Speed ZKP-Number: 21.063.511 Cause Corrective action MD forced idle demand => node failure (node 3, 4 or 5) 580 –...

  • Page 189: Maintenance

    8 Maintenance 8.1 Maintenance task reference table [QL1] The required maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a separate publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
  • Page 190 Task Measures W1713 Injector: Reset drift correction parameters (CDC). (→ Page 211) W1828 Check preheater for leaks and operation. (→ Page 263) W1864 Check and clean oil indicator filter. (→ Page 247) W4172 Check general condition of rubber mounts (visual inspection). (→...

  • Page 191: 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 192 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 193: Engine - Turning On Starting System

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

  • Page 194: 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 195: 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 207). Remove injector (→...
  • Page 196 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 195). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 197: 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 198 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 199: 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 200: Crankcase Breather - Filter Element Replacement

    9.3.2 Crankcase breather – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Ratchet bit F30027340 Assembly compound (Kluthe Hakuform 30-15) X00067260 Engine oil Filter element (→...

  • Page 201: 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 202 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 203 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 204 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 205: 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 207). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjusting screws with oil.

  • Page 206: 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 gage Y20098771 Torque wrench, 60–320 Nm F30452768...
  • Page 207 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 208 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 209: 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 210: Injection Pump / Hp Pump

    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 device F30378207 Engine oil WARNING...
  • Page 211 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 212: Injector

    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 211). 210 | Injector | MS150093/05E 2018-12...

  • Page 213: Injector - Removal And Installation

    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 214 NOTICE Contamination of components. Damage to component! • Observe manufacturer's instructions. • Check components for special cleanliness. Preparatory steps Allow HP system to cool down. Shut off fuel supply to engine. Remove cylinder head cover (→ Page 207). Removing injector Disconnect cable connector at injector (ar- rowed).
  • Page 215 Install installation/removal jig on the cylinder head. Remove injector with installation/removal jig. Remove the installation/removal jig. Remove sealing ring (4) from injector or use a self-made wire hook or magnet to take it out of the cylinder head. Note: The sealing ring (4) for sealing the combus- tion chamber must only be used once.
  • Page 216 Note: Remove plugs on HP line only before installa- tion of the adapter. Remove plug. Use milling cutter to remove oil carbon from sealing face on cylinder head and protective sleeve. Coat damper ring (1) with (Assembly com- pound (Molykote P 37)). Coat O-rings (3) and (2) with (Assembly com- pound (Kluthe Hakuform 30-15)).
  • Page 217 Using a torque wrench, tighten screw (2) to specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 100 Nm+10 Nm Using a torque wrench, tighten adapter (3) to specified tightening torque. Name Size Type Lubricant Value/Standard Adapter Tightening torque (Engine oil)
  • Page 218 Fit cable connector on injector. Note: Failure to reset drift compensation (CDC) will void the emissions certification of the engine. Reset drift compensation (CDC) with Dia- Sys® (→ Dialog system DiaSys® E531920/..). If DiaSys® is not available, con- tact Service. Final steps Install cylinder head cover (→...

  • Page 219: Fuel System

    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 F30044239 Ratchet bit F30027340 Diesel fuel Engine oil WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
  • Page 220 Turn handle (2) clockwise to screw it in. Verify that fuel priming pump is locked: Handle (2) must be tightened firmly. 218 | Fuel System | MS150093/05E 2018-12...

  • Page 221: Fuel Filter

    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 222: Fuel Prefilter - Pressure Ratios

    9.8.2 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 223: Fuel Prefilter (Non-Switchable) - Draining

    9.8.3 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 224 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 225: Fuel Prefilter (Switchable) - Draining

    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 226 During engine operation, turn the switchover level as far as the stop (arrow) to cut out the filter module to be serviced. Result: • Filter module (1) is cut in • Filter module (2) is cut out Open threaded vent plug (1) of filter to be serviced.
  • Page 227 Draining fuel prefilter in case of gauge 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 228: Fuel Prefilter (Switchable) - Low Pressure Indicator Check

    9.8.5 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 229: Fuel Prefilter (Non-Switchable) - Filter Element Replacement

    9.8.6 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 230 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 231: Fuel Prefilter (Switchable) - Filter Element Replacement

    9.8.7 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 232 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 233 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 234: Fuel Prefilter - Venting

    9.8.8 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 235 Loosen threaded vent plugs (2, 3) and un- screw at least one rotation. Note: • Only operate the fuel priming pump man- ually! • Move the piston of the pump only vertical- ly to avoid damaging the pump! Unlock fuel priming pump, screw out han- dle (1).

  • Page 236: Charge-Air Cooling

    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 237: 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 237). Reset signal ring of service indicator (→ Page 238). MS150093/05E 2018-12 | Air Filter | 235...

  • Page 238: Air Filter - Check

    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 235). 236 | Air Filter | MS150093/05E 2018-12...

  • Page 239: Air Filter - Removal And Installation

    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 240: Air Intake

    9.11 Air Intake 9.11.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. WARNING The engine draws in large volumes of ambient air for combustion. This air intake results in a strong vac- uum. Risk of injury if body parts are drawn in! There is also a danger if opening of the entrance door can be prevented! •...

  • Page 241: Starting Equipment

    9.12 Starting Equipment 9.12.1 Air starter – Manual operation 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 242: Lube Oil System, Lube Oil Circuit

    9.13 Lube Oil System, Lube Oil Circuit 9.13.1 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 243 Draining residual oil from equip- ment carrier (only with un- scheduled engine oil change) Provide a suitable container in which to col- lect the engine oil. Remove drain plug (1) and drain engine oil from engine oil heat exchanger and from en- gine oil filter.

  • Page 244: Engine Oil Level - Check

    9.13.2 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 245: Engine Oil - Sample Extraction And Analysis

    9.13.3 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 246 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 244 | Lube Oil System, Lube Oil Circuit | MS150093/05E 2018-12...

  • Page 247: Oil Priming Pump - Visual Inspection

    9.13.4 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 248: Oil Filtration / Cooling

    9.14 Oil Filtration / Cooling 9.14.1 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 249: Oil Indicator Filter - Cleaning And Check

    9.14.2 Oil indicator filter – Cleaning and check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner (Snow-White 11-0) X00054118 Cleaner (Hakupur 50/136) X00056700 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
  • Page 250 Cleaning strainer Shake coarse contamination out of strainer (6). Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136). Note: Do not damage the fabric of the strainer. Use a soft brush to remove stubborn deposits from strainer as necessary. Blow out strainer (6) with compressed air from outside to inside.
  • Page 251 Checking strainer Item Findings Task Strainer Metallic residues • Clean • Monitor engine operation • Check strainer daily • Contact Service. Strainer Damaged Replace Square section ring Damaged Replace Spring Damaged Replace O-ring Damaged Replace Installing strainer Coat square section ring on basket strainer (5) with engine oil and install basket strainer (5). Coat O-ring (3) with engine and install in filter housing.

  • Page 252: Centrifugal Oil Filter - Cleaning And Filter Sleeve Replacement

    9.14.3 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 253 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 254: Coolant Circuit, General, High-Temperature Circuit

    9.15 Coolant Circuit, General, High-Temperature Circuit 9.15.1 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 255: Engine Coolant Change

    9.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 254). Fill with engine coolant (→ Page 256). MS150093/05E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 253...

  • Page 256: Engine Coolant - Draining

    9.15.3 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 257 Close all other open drain points. Position valve cover on filler neck and close. MS150093/05E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 255...

  • Page 258: Engine Coolant - Filling

    9.15.4 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 WARNING Coolant is hot and under pressure.
  • Page 259 Note: An empty engine must always filled with coolant from below, i.e. using the drain valve connection of the en- gine coolant pump. Filling with coolant from below using a pump Connect appropriate pump with hose to drain valve of engine coolant pump (arrow). Loosen vent line union at distributor (arrow).
  • Page 260 Alternatively: Filling coolant through filler neck Loosen vent line union at distributor (arrow). Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. Tighten union (arrow) if coolant leaks out at loose union.

  • Page 261: Engine Coolant Pump - Relief Bore Check

    9.15.5 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 A high level of noise is produced when the engine is running.

  • Page 262: Engine Coolant - Sample Extraction And Analysis

    9.15.6 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 263 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/..)). MS150093/05E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 261...

  • Page 264: Preheater - Overview

    9.15.7 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 265: Preheater - Function And Leak Check

    9.15.8 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 266: Preheater - Overhaul

    9.15.9 Preheater – Overhaul Preconditions ☑ Engine is stopped and starting disabled. ☑ All preheater power sources are disconnected. Replacing solenoid switch Replace solenoid switch (→ Page 265). Cleaning heating element and replacing gasket Clean heating element and housing and check (→ Page 267). Replacing thermostat Replace thermostat (→...

  • Page 267: Preheater - Solenoid Switch Replacement

    9.15.10 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 268 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 269: Preheater - Heating Element And Housing Check

    9.15.11 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 270 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 271 Final steps Connect preheater power sources. Switch on preheater. MS150093/05E 2018-12 | Coolant Circuit, General, High-Temperature Circuit | 269...

  • Page 272: Preheater Thermostats - Replacement

    9.15.12 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 273 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 274 Final steps Connect preheater to power supply. Switch on preheater. 272 | Coolant Circuit, General, High-Temperature Circuit | MS150093/05E 2018-12...

  • Page 275: Coolant Expansion Tank Valve Cover - Replacement

    9.15.13 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 276: Low-Temperature Circuit

    9.16 Low-Temperature Circuit 9.16.1 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 277 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 279). MS150093/05E 2018-12 | Low-Temperature Circuit | 275...

  • Page 278: Charge-Air Coolant - Change

    9.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 277). Fill with charge-air coolant (→ Page 279). 276 | Low-Temperature Circuit | MS150093/05E 2018-12...

  • Page 279: Charge-Air Coolant - Draining

    9.16.3 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 280 Drain remaining coolant at intercooler (ar- row). Tighten drain valve to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Spindle 11A/F Tightening torque 12 Nm Close the remaining drain valves and screw in drain plugs with new sealing rings. Position valve cover on filler neck and close.

  • Page 281: Charge-Air Coolant - Filling

    9.16.4 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 282 Filling coolant using a pump Connect appropriate pump with hose to drain valve (1). Loosen the vent line union at the distributor piece (arrow). Open drain valve and pump coolant into en- gine at 0.5 bar minimum. Tighten union (arrowed) if coolant leaks out at loose union.
  • Page 283 Alternatively: Filling coolant through filler neck Loosen the vent line union at the distributor piece (arrow). Fill in 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 284: Charge-Air Coolant Pump - Relief Bore Check

    9.16.5 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 A high level of noise is produced when the engine is running.

  • Page 285: Belt Drive

    9.17 Belt Drive 9.17.1 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 286: Battery-Charging Generator

    9.18 Battery-Charging Generator 9.18.1 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 287: Battery-Charging Generator Drive - Drive Belt Replacement

    9.18.2 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 288: Engine Mounting / Support

    9.19 Engine Mounting / Support 9.19.1 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 289: Wiring (General) For Engine/Gearbox/Unit

    9.20 Wiring (General) for Engine/Gearbox/Unit 9.20.1 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 290: Accessories For (Electronic) Engine Governor / Control System

    9.21 Accessories for (Electronic) Engine Governor / Control System 9.21.1 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 291: Engine Governor Plug Connections - Check

    9.21.2 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 292: Engine Governor Ecu 7 - Removal And Installation

    9.21.3 Engine governor ECU 7 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine electronics is powered off. 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 293: Abbreviations

    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 294 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 295 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 296: Mtu Contact/Service Partners

    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 297: Special Tools

    11 Appendix B 11.1 Special Tools Barring tool Part No.: F6555766 Qty.: Used in: 9.1.1 Engine – Barring manually (→ Page 189) Qty.: Used in: 9.2.1 Cylinder liner – Endoscopic examination (→ Page 193) Crossbeam Part No.: T80091826 Qty.: Used in: 3.1 Transport (→...
  • Page 298 Depth gauge, 200 mm Part No.: Y20000918 Qty.: Used in: 9.4.1 Valve protrusion – Measurement (→ Page 199) Endoscope Part No.: Y20097353 Qty.: Used in: 9.2.1 Cylinder liner – Endoscopic examination (→ Page 193) Feeler gage Part No.: Y20098771 Qty.: Used in: 9.4.3 Valve clearance –...
  • Page 299 Fuel suction device Part No.: F30378207 Qty.: Used in: 9.5.1 HP fuel pump – Filling with engine oil (→ Page 208) High-pressure cleaner Part No.: Qty.: Used in: 6.13 Plant – Cleaning (→ Page 134) Installation/removal jig Part No.: F6789889 Qty.: Used in: 9.6.2 Injector –...
  • Page 300 9.4.1 Valve protrusion – Measurement (→ Page 199) Milling cutter Part No.: F30452739 Qty.: Used in: 9.6.2 Injector – Removal and installation (→ Page 211) MTU test kit Part No.: F6798833 Qty.: Used in: 9.13.3 Engine oil – Sample extraction and analysis (→ Page 243) Qty.:...
  • Page 301 Ratchet bit Part No.: F30027340 Qty.: Used in: 9.3.2 Crankcase breather – Filter element replacement (→ Page 198) Qty.: Used in: 9.6.2 Injector – Removal and installation (→ Page 211) Qty.: Used in: 9.7.1 Fuel system – Venting (→ Page 217) Qty.: Used in: 9.8.6 Fuel prefilter (non-switchable) –...
  • Page 302 Ratchet with extension Part No.: F30006212 Qty.: Used in: 9.1.1 Engine – Barring manually (→ Page 189) Qty.: Used in: 9.2.1 Cylinder liner – Endoscopic examination (→ Page 193) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 9.4.3 Valve clearance – Check and adjustment (→...
  • Page 303 Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 3.4 Crankshaft transport locking device (→ Page 23) Qty.: Used in: 9.5.1 HP fuel pump – Filling with engine oil (→ Page 208) Qty.: Used in: 9.6.2 Injector – Removal and installation (→ Page 211) Qty.: Used in: 9.14.3 Centrifugal oil filter –...
  • Page 304 Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 3.4 Crankshaft transport locking device (→ Page 23) Qty.: Used in: 9.4.3 Valve clearance – Check and adjustment (→ Page 204) Qty.: Used in: 9.6.2 Injector – Removal and installation (→ Page 211) Qty.: Used in: 9.13.1 Engine oil –...

  • Page 305: Index

    11.2 Index Crankshaft  – Transport locking device   Abbreviations 291 – Installation/removal  23 Actuators  Cylinder  – Overview  41 – Designation  39 ADEC (ECU 7)  Cylinder head cover  – Fault messages  138 – Installation  207 After stopping the engine  – Removal  207 –...
  • Page 306 Lifting instructions 21 Engine mounting  – Check  286 Engine oil  Maintenance task reference table [QL1] 187 – Change  240 MTU contact persons 294 – Sample extraction and analysis  243 Engine oil filter  – Replacement  246 Oil indicator filter  Engine oil level  – Check  247...
  • Page 307 Product data 20V4000G23  Product data 20V4000G63  – Continuous operation 3B   – Continuous operation 3A   – China Nonroad Mobile Machinery Stage III  60 – Optimized fuel consumption  44 – NEA Singapore for ORDE  60 – Continuous operation 3B   –...
  • Page 308 Product data 20V4000G83  – Continuous operation 3A   Safety regulations  – Optimized fuel consumption  44 – Assembly work  13 – Continuous operation 3B   – Auxiliary materials  17 – EPA Nonroad T2 Comp (40CFR89)  56 – Environmental protection  17 – EPA Stationary EMERG T2 (40CFR60)  56 –...
  • Page 309 Valve cover  – Replacement  273 Valve gear  – Lubrication  203 Valve protrusion  – Measurement  199 Warning notices, standards 19 MS150093/05E 2018-12 | Index | 307...

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