Page 1 Operating Instructions Diesel Engine 12V4000Bx4 12V4000Gx4 16V4000Bx4 16V4000Gx4 MS15038/01E...
Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.
Page 3 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 Safety 4.15 Product data 16V4000B24F, application 3A; 16V4000B14S, application 3A; 1.1 Important provisions for all products 16V4000B24S, application 3A 1.2 Gendrive engines – Intended use 4.16 Product data 16V4000G14F, application 3B 1.3 Personnel and organizational requirements 4.17 Product data 16V4000G14F, application 3E 1.4 Safety regulations for initial start-up and 4.18 Product data 16V4000G14F, application 3F...
Page 6 5.11 After stopping the engine – Engine remains 8.8.4 Fuel prefilter (switchable) – Draining 8.8.5 Fuel prefilter (switchable) – Low pressure ready for operation indicator check 5.12 After stopping the engine – Putting the 8.8.6 Fuel prefilter (non-switchable) – Filter element engine out of operation replacement 5.13 Plant –...
Page 7 8.19.1 Engine mounting – Checking resilient element 8.19.2 Engine mounting – Checking securing screws 9.1 Abbreviations for firm seating 9.2 MTU Contact/Service Partners 8.19.3 Generator mounting – Check 8.19.4 Generator mounting – Securing screw firm 10 Appendix B seating check 8.20 Wiring (General) for Engine/Gearbox/Unit...
Page 8: 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 9 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 10: Gendrive Engines - Intended Use
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al- so applies to engine control/parameters) •...
Page 11: Personnel And Organizational Requirements
1.3 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.
Page 12: Safety Regulations For Initial Start-Up And Operation
1.4 Safety regulations for initial start-up and operation Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
Page 13 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 14: Safety Regulations For Assembly, Maintenance, And Repair Work
1.5 Safety regulations for assembly, maintenance, and repair work Safety regulations for work prior to assembly, maintenance, and repair Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants, risk of burning).
Page 15 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 16 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 17 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 18: 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 19 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 20: Standards For Warning Notices In The Text And Highlighted Information
1.7 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 21: Transport
Set system down on a firm, flat surface only. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set the engine down on its oil pan unless expressly authorized to do so by MTU. MS15038/01E 2018-11 | Transport | 19...
Page 22: Lifting Specifications
2.2 Lifting specifications Lifting specifications DANGER Suspended load. Danger to life! • Use suitable equipment and lifting devices. • Never stand beneath a suspended load and keep a safe distance. • Wear personal protective equipment (e.g. protective helmet, safety shoes). 1 Max.
Page 23: Crankshaft Transport Locking Device
2.3 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Engine oil Transport locking devices Note: The transport locking device on both sides protects the crankshaft bearings from shocks and vibration dam- age during engine transport.
Page 24 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 25 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 26: General Information
3 General Information 3.1 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite)
Page 27: Engine - Overview
3.2 Engine – Overview Engine overview, free end 1 Cylinder head cover 6 Fuel filter 11 Coolant distribution housing 2 Charge-air pipe 7 Fuel priming pump 12 Centrifugal oil filter (option) 3 Engine lifting eye 8 HP fuel pump 13 Crankcase breather 4 Oil filler neck 9 Vibration damper KGS Free end...
Page 28 Engine overview, driving end 1 Intercooler 6 LT thermostat housing 11 Starter 2 Air filter 7 HT thermostat housing 12 Flywheel 3 Exhaust outlet 8 Oil pan KS Driving end 4 Exhaust turbocharger 9 Crankcase 5 Oil heat exchanger 10 Engine Control Unit (ECU9) Illustration also applies to 12V engines.
Page 29: Sensors And Actuators - Overview
3.3 Sensors and actuators – Overview Illustrations are also applicable to 12V engines. Designation Monitors EIL (Engine Ident Label) Charge-air temperature Fuel pressure after filter Fuel temperature, low pressure B48.1 Fuel high pressure Y39.Ax-A1 Injectors, left engine side MS15038/01E 2018-11 | General Information | 27...
Page 30 Designation Monitors Camshaft speed B5.1 Lube oil pressure after filter Coolant temperature, engine outlet Lube oil temperature, engine inlet Charge air coolant temperature Crankcase pressure Lube oil pressure, replenishment pump XB54 Adaption for oil replenishment pump Fuel pump (control block) 28 | General Information | MS15038/01E 2018-11...
Page 31 Designation Monitors Charge air pressure B48.2 Fuel high pressure XF33 HT coolant level (remote expansion tank) XF57 LT coolant level (remote expansion tank) Y39.B1-Bx Injectors, right engine side MS15038/01E 2018-11 | General Information | 29...
Page 32 Designation Monitors Crankshaft speed 30 | General Information | MS15038/01E 2018-11...
Page 33 Designation Monitors B44 * Exhaust turbocharger speed * Installed on 60 Hz engines only MS15038/01E 2018-11 | General Information | 31...
Page 34: Technical Data
4 Technical Data 4.1 Product data 12V4000B14S, application 3A; 12V4000B24F, application 3A; 12V4000B24S, application 3A DL Reference value: Continuous power. continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations).
Page 35 1. Power-related data Rated engine speed 1800 1500 1800 Continuous power ISO 3046 (10% overload capability) 1190 1310 1420 (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1310 1440 1562 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 36 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas temperature) – m³/s Exhaust gas volume (at exhaust gas temperature) – m³/s Exhaust gas temperature after engine – DL °C 410 * Exhaust gas temperature after engine –...
Page 37 Fuel, engine side Liters Total engine oil capacity, initial filling (standard oil Liters system) (option: max. operating inclinations) Oil change quantity, max. (standard oil system) (op- Liters tion: max. operating inclinations) Oil pan capacity at dipstick mark “min.” (standard oil Liters system) (option: max.
Page 38: Product Data 12V4000G14F, Application 3B
4.2 Product data 12V4000G14F, application 3B DL Reference value: Continuous power. continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 39 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1420 1420 1420 1420 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1562 1562 1562 1562 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 40 Total displacement Liters 57.2 57.2 57.2 57.2 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s 1.95 1.95 Exhaust gas volume (at exhaust gas tem- m³/s perature) –...
Page 41 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 42 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 43: Product Data 12V4000G14F, Application 3E
4.3 Product data 12V4000G14F, application 3E DL Reference value: Continuous power. continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 44 1. Power-related data Rated engine speed 1500 1500 1500 Continuous power ISO 3046 (10% overload capability) 1420 1420 1420 (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1562 1562 1562 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 45 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s 1.95 Exhaust gas volume (at exhaust gas temperature) – m³/s Exhaust gas volume (at exhaust gas temperature) – m³/s Exhaust gas temperature after engine – DL °C Exhaust gas temperature after engine –...
Page 46 Fuel, engine side Liters Total engine oil capacity, initial filling (standard oil Liters system) (option: max. operating inclinations) Oil change quantity, max. (standard oil system) (op- Liters tion: max. operating inclinations) Oil pan capacity at dipstick mark “min.” (standard oil Liters system) (option: max.
Page 47: Product Data 12V4000G14F, Application 3F
4.4 Product data 12V4000G14F, application 3F DL Reference value: Continuous power. continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 48 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust gas overpressure mbar Exhaust gas overpressure, max. mbar Fuel temperature at engine inlet connection °C Fuel temperature at engine inlet connection, max. °C (w/o power reduction) Fuel temperature at engine inlet connection, max.
Page 49 Exhaust gas volume (at exhaust gas temperature) – m³/s Exhaust gas temperature after engine – DL °C Exhaust gas temperature after engine – BL °C 7. Coolant system (HT circuit) Coolant temperature (at engine connection: outlet to °C cooling system) Coolant temperature after engine, limit 1 °C Coolant temperature after engine, limit 2...
Page 50 Oil pan capacity at dipstick mark “min.” (standard oil Liters system) (option: max. operating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil Liters system) (option: max. operating inclinations) 19. Masses / main dimensions Engine mass, dry (basic engine configuration acc. to 6200 * 6200 * 6200 *...
Page 51: Product Data 12V4000G14F, Application 3G
4.5 Product data 12V4000G14F, application 3G DL Reference value: Continuous power. continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 52 1. Power-related data Rated engine speed 1500 1500 1500 Continuous power ISO 3046 (10% overload capability) 1420 1420 1420 (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1562 1562 1562 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 53 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s 1.95 Exhaust gas volume (at exhaust gas temperature) – m³/s Exhaust gas volume (at exhaust gas temperature) – m³/s Exhaust gas temperature after engine – DL °C Exhaust gas temperature after engine –...
Page 54 Fuel, engine side Liters Total engine oil capacity, initial filling (standard oil Liters system) (option: max. operating inclinations) Oil change quantity, max. (standard oil system) (op- Liters tion: max. operating inclinations) Oil pan capacity at dipstick mark “min.” (standard oil Liters system) (option: max.
Page 55: Product Data 12V4000G14Rf, Application 3B
4.6 Product data 12V4000G14RF, application 3B DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 56 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1205 1205 1205 1205 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1325 1325 1325 1325 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 57 Total displacement Liters 57.2 57.2 57.2 57.2 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s perature) –...
Page 58 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 59 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 60: Product Data 12V4000G14S, Applications 3B, 3F, 3G
4.7 Product data 12V4000G14S, applications 3B, 3F, 3G DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 61 Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level 0. Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut-in / cut-out control) 1. Power-related data Rated engine speed 1800 1800 1800 1800 1800 1800 Continuous power ISO 1520...
Page 62 3. Consumption Specific fuel consumption g/kWh (be) – 100% DL (+5%; EN 590; 42.8 MJ/kg) Specific fuel consumption g/kWh (be) – 100% BL (+5%; EN 590; 42.8 MJ/kg) Fuel consumption at zero kg/h 29.0 29.0 29.0 29.0 29.0 29.0 load 4.
Page 63 Exhaust gas temperature °C after engine – DL Exhaust gas temperature °C after engine – BL 7. Coolant system (HT circuit) Coolant temperature (at °C engine connection: outlet to cooling system) Coolant temperature after °C engine, limit 1 Coolant temperature after °C engine, limit 2 Coolant antifreeze con-...
Page 64 18. Capacities Engine coolant, engine Liters side (w/o cooling equip- ment) Charge-air coolant, en- Liters gine side Fuel, engine side Liters Total engine oil capacity, Liters initial filling (standard oil system) (option: max. op- erating inclinations) Oil change quantity, max. Liters (standard oil system) (op- tion: max.
Page 65 Exhaust noise, unsilenced dB(A) – BL (sound power level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) –...
Page 66: Product Data 12V4000G24F, Application 3B
4.8 Product data 12V4000G24F, application 3B DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 67 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1575 1575 1575 1575 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1733 1733 1732 1732 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 68 Total displacement Liters 57.2 57.2 57.2 57.2 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s 1.98 1.98 Combustion air volumetric flow – BL m³/s 2.10 2.10 Exhaust gas volume (at exhaust gas tem- m³/s 5.29 5.29...
Page 69 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 70 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 71: Product Data 12V4000G24F, Application 3E
4.9 Product data 12V4000G24F, application 3E DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 72 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1575 1575 1575 1575 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1733 1733 1732 1732 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 73 Total displacement Liters 57.2 57.2 57.2 57.2 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s 1.98 1.98 Combustion air volumetric flow – BL m³/s 2.10 2.10 Exhaust gas volume (at exhaust gas tem- m³/s 5.29 5.29...
Page 74 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 75 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 76: Product Data 12V4000G24F, Application 3F
4.10 Product data 12V4000G24F, application 3F DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 77 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1575 1575 1575 1575 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1733 1733 1732 1732 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 78 Total displacement Liters 57.2 57.2 57.2 57.2 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s 1.98 1.98 Combustion air volumetric flow – BL m³/s 2.10 2.10 Exhaust gas volume (at exhaust gas tem- m³/s 5.29 5.29...
Page 79 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 80 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 81: Product Data 12V4000G24F, Application 3G
4.11 Product data 12V4000G24F, application 3G DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 82 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1575 1575 1575 1575 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1733 1733 1732 1732 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 83 Total displacement Liters 57.2 57.2 57.2 57.2 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s 1.98 1.98 Combustion air volumetric flow – BL m³/s 2.10 2.10 Exhaust gas volume (at exhaust gas tem- m³/s 5.29 5.29...
Page 84 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 85 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 86: Product Data 12V4000G24S, Applications 3B, 3F, 3G
4.12 Product data 12V4000G24S, applications 3B, 3F, 3G DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 87 Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level 0. Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut-in / cut-out control) 1. Power-related data Rated engine speed 1800 1800 1800 1800 1800 1800 Continuous power ISO 1736...
Page 88 3. Consumption Specific fuel consumption g/kWh (be) – 100% DL (+5%; EN 590; 42.8 MJ/kg) Specific fuel consumption g/kWh (be) – 100% BL (+5%; EN 590; 42.8 MJ/kg) Fuel consumption at zero kg/h 29.0 29.0 29.0 29.0 29.0 29.0 load 4.
Page 89 Exhaust gas temperature °C after engine – DL Exhaust gas temperature °C after engine – BL 7. Coolant system (HT circuit) Coolant temperature (at °C engine connection: outlet to cooling system) Coolant temperature after °C engine, limit 1 Coolant temperature after °C engine, limit 2 Coolant antifreeze con-...
Page 90 18. Capacities Engine coolant, engine Liters side (w/o cooling equip- ment) Charge-air coolant, en- Liters gine side Fuel, engine side Liters Total engine oil capacity, Liters initial filling (standard oil system) (option: max. op- erating inclinations) Oil change quantity, max. Liters (standard oil system) (op- tion: max.
Page 91 Exhaust noise, unsilenced dB(A) – BL (sound power level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) –...
Page 92: Product Data 12V4000G74F, Application 3D; 12V4000G74S, Application 3D
4.13 Product data 12V4000G74F, application 3D; 12V4000G74S, application 3D DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value.
Page 93 0. Data-relevant engine specification Engine without sequential turbocharging (exhaust tur- bochargers without cut-in / cut-out control) 1. Power-related data Rated engine speed 1500 1500 1500 1800 1800 Fuel stop power ISO 3046 1575 1575 1575 1736 1736 2. General conditions (for maximum power) Intake depression (new filter) A mbar Intake depression, max.
Page 94 Combustion method: direct injection Cooling method: treated wa- Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V an- Degrees (°) Bore Stroke Cylinder displacement Liters 4.77 4.77 4.77 4.77 4.77 Total displacement Liters 57.2 57.2 57.2 57.2 57.2 Compression ratio...
Page 95 8. Coolant system (LT circuit) Coolant temperature (at en- °C gine connection: outlet to cooling system) Coolant temperature before °C intercooler, limit 1 Coolant temperature before °C intercooler, limit 2 Coolant antifreeze content, max. 10. Lube oil system Lube oil temperature before °C engine, limit 1 Lube oil temperature before...
Page 96 Oil pan capacity at dipstick Liters mark “min.” (standard oil system) (option: max. oper- ating inclinations) Oil pan capacity at dipstick Liters mark “max.” (standard oil system) (option: max. oper- ating inclinations) 19. Masses / main dimensions Engine mass, dry (basic en- 6200 * 6200 * 6200 *...
Page 97 Engine surface noise with at- dB(A) tenuated intake noise (filter) – BL (free-field sound pres- sure level Lp, 1 m distance, ISO 6798, +2 dB(A) toler- ance) Engine surface noise with at- dB(A) tenuated intake noise (filter) – BL (sound power level LW, ISO 6798, +2 dB(A) toler- ance) MS15038/01E 2018-11 | Technical Data | 95...
Page 98: Product Data 12V4000G84F, Application 3D; 12V4000G84S, Application 3D
4.14 Product data 12V4000G84F, application 3D; 12V4000G84S, application 3D DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value.
Page 99 0. Data-relevant engine specification Engine without sequential turbocharging (exhaust tur- bochargers without cut-in / cut-out control) 1. Power-related data Rated engine speed 1500 1500 1500 1800 1800 Fuel stop power ISO 3046 1750 1750 1750 1910 1910 2. General conditions (for maximum power) Intake depression (new filter) A mbar Intake depression, max.
Page 100 Combustion method: direct injection Cooling method: treated wa- Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V an- Degrees (°) Bore Stroke Cylinder displacement Liters 4.77 4.77 4.77 4.77 4.77 Total displacement Liters 57.2 57.2 57.2 57.2 57.2 Compression ratio...
Page 101 8. Coolant system (LT circuit) Coolant temperature (at en- °C gine connection: outlet to cooling system) Coolant temperature before °C intercooler, limit 1 Coolant temperature before °C intercooler, limit 2 Coolant antifreeze content, max. 10. Lube oil system Lube oil temperature before °C engine, limit 1 Lube oil temperature before...
Page 102 Oil pan capacity at dipstick Liters mark “min.” (standard oil system) (option: max. oper- ating inclinations) Oil pan capacity at dipstick Liters mark “max.” (standard oil system) (option: max. oper- ating inclinations) 19. Masses / main dimensions Engine mass, dry (basic en- 6200 * 6200 * 6200 *...
Page 103 Engine surface noise with at- dB(A) tenuated intake noise (filter) – BL (free-field sound pres- sure level Lp, 1 m distance, ISO 6798, +2 dB(A) toler- ance) Engine surface noise with at- dB(A) tenuated intake noise (filter) – BL (sound power level LW, ISO 6798, +2 dB(A) toler- ance) MS15038/01E 2018-11 | Technical Data | 101...
Page 104: Product Data 16V4000B24F, Application 3A; 16V4000B14S, Application 3A; 16V4000B24S, Application 3A
4.15 Product data 16V4000B24F, application 3A; 16V4000B14S, application 3A; 16V4000B24S, application 3A DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value.
Page 105 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust gas overpressure mbar Exhaust gas overpressure, max. mbar Fuel temperature at engine inlet connection °C Fuel temperature at engine inlet connection, max. °C (w/o power reduction) Fuel temperature at engine inlet connection, max.
Page 106 Exhaust gas volume (at exhaust gas temperature) – m³/s 4.9 * Exhaust gas volume (at exhaust gas temperature) – m³/s 5.4 * 7. Coolant system (HT circuit) Coolant temperature (at engine connection: outlet to °C cooling system) Coolant temperature after engine, limit 1 °C Coolant temperature after engine, limit 2 °C...
Page 107 Oil pan capacity at dipstick mark “min.” (standard oil Liters system) (option: max. operating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil Liters system) (option: max. operating inclinations) 19. Masses / main dimensions Engine mass, dry (basic engine configuration acc. to 7700 7700 7700...
Page 108: Product Data 16V4000G14F, Application 3B
4.16 Product data 16V4000G14F, application 3B DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 109 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1798 1798 1798 1798 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1978 1978 1978 1978 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 110 Total displacement Liters 76.3 76.3 76.3 76.3 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s 2.55 2.55 Exhaust gas volume (at exhaust gas tem- m³/s perature) –...
Page 111 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 112 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 113: Product Data 16V4000G14F, Application 3E
4.17 Product data 16V4000G14F, application 3E DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 114 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1798 1798 1798 1798 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1978 1978 1978 1978 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 115 Total displacement Liters 76.3 76.3 76.3 76.3 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s 2.55 2.55 Exhaust gas volume (at exhaust gas tem- m³/s perature) –...
Page 116 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 117 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 118: Product Data 16V4000G14F, Application 3F
4.18 Product data 16V4000G14F, application 3F DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 119 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1798 1798 1798 1798 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1978 1978 1978 1978 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 120 Total displacement Liters 76.3 76.3 76.3 76.3 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s 2.55 2.55 Exhaust gas volume (at exhaust gas tem- m³/s perature) –...
Page 121 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 122 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 123: Product Data 16V4000G14F, Application 3G
4.19 Product data 16V4000G14F, application 3G DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 124 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1798 1798 1798 1798 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 1978 1978 1978 1978 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 125 Total displacement Liters 76.3 76.3 76.3 76.3 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s 2.55 2.55 Exhaust gas volume (at exhaust gas tem- m³/s perature) –...
Page 126 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 127 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 128: Product Data 16V4000G14S, Applications 3B, 3F, 3G
4.20 Product data 16V4000G14S, applications 3B, 3F, 3G DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 129 Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level 0. Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut-in / cut-out control) 1. Power-related data Rated engine speed 1800 1800 1800 1800 1800 1800 Continuous power ISO 2020...
Page 130 3. Consumption Specific fuel consumption g/kWh (be) – 100% DL (+5%; EN 590; 42.8 MJ/kg) Specific fuel consumption g/kWh (be) – 100% BL (+5%; EN 590; 42.8 MJ/kg) Fuel consumption at zero kg/h 39.0 39.0 39.0 39.0 39.0 39.0 load 4.
Page 131 Exhaust gas temperature °C after engine – DL Exhaust gas temperature °C after engine – BL 7. Coolant system (HT circuit) Coolant temperature (at °C engine connection: outlet to cooling system) Coolant temperature after °C engine, limit 1 Coolant temperature after °C engine, limit 2 Coolant antifreeze con-...
Page 132 18. Capacities Engine coolant, engine Liters side (w/o cooling equip- ment) Charge-air coolant, en- Liters gine side Fuel, engine side Liters Total engine oil capacity, Liters initial filling (standard oil system) (option: max. op- erating inclinations) Oil change quantity, max. Liters (standard oil system) (op- tion: max.
Page 133 Exhaust noise, unsilenced dB(A) – BL (sound power level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) –...
Page 134: Product Data 16V4000G24F, Application 3B
4.21 Product data 16V4000G24F, application 3B DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 135 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1965 1965 1965 1965 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2162 2162 2162 2162 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 136 Total displacement Liters 76.3 76.3 76.3 76.3 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s perature) –...
Page 137 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 138 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 139: Product Data 16V4000G24F, Application 3E
4.22 Product data 16V4000G24F, application 3E DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 140 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1965 1965 1965 1965 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2162 2162 2162 2162 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 141 Total displacement Liters 76.3 76.3 76.3 76.3 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s perature) –...
Page 142 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 143 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 144: Product Data 16V4000G24F, Application 3F
4.23 Product data 16V4000G24F, application 3F DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 145 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1965 1965 1965 1965 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2162 2162 2162 2162 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 146 Total displacement Liters 76.3 76.3 76.3 76.3 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s perature) –...
Page 147 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 148 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 149: Product Data 16V4000G24F, Application 3G
4.24 Product data 16V4000G24F, application 3G DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 150 1. Power-related data Rated engine speed 1500 1500 1500 1500 Continuous power ISO 3046 (10% over- 1965 1965 1965 1965 load capability) (power range DIN 6280, ISO 8528) Fuel stop power ISO 3046 2162 2162 2162 2162 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max.
Page 151 Total displacement Liters 76.3 76.3 76.3 76.3 Compression ratio 16.4 16.4 16.4 16.4 5. Air / exhaust gas Combustion air volumetric flow – DL m³/s Combustion air volumetric flow – BL m³/s Exhaust gas volume (at exhaust gas tem- m³/s perature) –...
Page 152 12. General operating data High idling speed, max. (static) 1700 1700 1700 1700 Limit speed for overspeed alarm / emer- 1950 1950 1950 1950 gency shutdown Limit speed for overspeed message 1950 1950 1950 1950 Firing speed, from Firing speed, to 18.
Page 153 Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated in- dB(A) take noise (filter) – DL (sound power lev- el LW, ISO 6798, +2 db(A) tolerance) Engine surface noise with attenuated in- dB(A)
Page 154: Product Data 16V4000G24S, Applications 3B, 3F, 3G
4.25 Product data 16V4000G24S, applications 3B, 3F, 3G DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 155 Barometric pressure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level 0. Data-relevant engine specification Engine without sequential turbocharging (exhaust turbochargers without cut-in / cut-out control) 1. Power-related data Rated engine speed 1800 1800 1800 1800 1800 1800 Continuous power ISO 2280...
Page 156 3. Consumption Specific fuel consumption g/kWh (be) – 100% DL (+5%; EN 590; 42.8 MJ/kg) Specific fuel consumption g/kWh (be) – 100% BL (+5%; EN 590; 42.8 MJ/kg) Fuel consumption at zero kg/h 39.0 39.0 39.0 39.0 39.0 39.0 load 4.
Page 157 Exhaust gas temperature °C after engine – DL Exhaust gas temperature °C after engine – BL 7. Coolant system (HT circuit) Coolant temperature (at °C engine connection: outlet to cooling system) Coolant temperature after °C engine, limit 1 Coolant temperature after °C engine, limit 2 Coolant antifreeze con-...
Page 158 18. Capacities Engine coolant, engine Liters side (w/o cooling equip- ment) Charge-air coolant, en- Liters gine side Fuel, engine side Liters Total engine oil capacity, Liters initial filling (standard oil system) (option: max. op- erating inclinations) Oil change quantity, max. Liters (standard oil system) (op- tion: max.
Page 159 Exhaust noise, unsilenced dB(A) – BL (sound power level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) – DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with dB(A) attenuated intake noise (filter) –...
Page 160: Product Data 16V4000G74F, Application 3D; 16V4000G74S, Application 3D
4.26 Product data 16V4000G74F, application 3D; 16V4000G74S, application 3D DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value.
Page 161 0. Data-relevant engine specification Engine without sequential turbocharging (exhaust tur- bochargers without cut-in / cut-out control) 1. Power-related data Rated engine speed 1500 1500 1500 1800 1800 Fuel stop power ISO 3046 1965 1965 1965 2280 2280 2. General conditions (for maximum power) Intake depression (new filter) A mbar Intake depression, max.
Page 162 Combustion method: direct injection Cooling method: treated wa- Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V an- Degrees (°) Bore Stroke Cylinder displacement Liters 4.77 4.77 4.77 4.77 4.77 Total displacement Liters 76.3 76.3 76.3 76.3 76.3 Compression ratio...
Page 163 8. Coolant system (LT circuit) Coolant temperature (at en- °C gine connection: outlet to cooling system) Coolant temperature before °C intercooler, limit 1 Coolant temperature before °C intercooler, limit 2 Coolant antifreeze content, max. 10. Lube oil system Lube oil temperature before °C engine, limit 1 Lube oil temperature before...
Page 164 Oil pan capacity at dipstick Liters mark “min.” (standard oil system) (option: max. oper- ating inclinations) Oil pan capacity at dipstick Liters mark “max.” (standard oil system) (option: max. oper- ating inclinations) 19. Masses / main dimensions Engine mass, dry (basic en- 7700 7700 7700...
Page 165 Engine surface noise with at- dB(A) tenuated intake noise (filter) – BL (free-field sound pres- sure level Lp, 1 m distance, ISO 6798, +2 dB(A) toler- ance) Engine surface noise with at- dB(A) tenuated intake noise (filter) – BL (sound power level LW, ISO 6798, +2 dB(A) toler- ance) MS15038/01E 2018-11 | Technical Data | 163...
Page 166: Product Data 16V4000G84F, Application 3D; 16V4000G84S, Application 3D
4.27 Product data 16V4000G84F, application 3D; 16V4000G84S, application 3D DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value.
Page 167 0. Data-relevant engine specification Engine without sequential turbocharging (exhaust tur- bochargers without cut-in / cut-out control) 1. Power-related data Rated engine speed 1500 1500 1500 1800 1800 Fuel stop power ISO 3046 2185 2185 2185 2500 2500 2. General conditions (for maximum power) Intake depression (new filter) A mbar Intake depression, max.
Page 168 Combustion method: direct injection Cooling method: treated wa- Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V an- Degrees (°) Bore Stroke Cylinder displacement Liters 4.77 4.77 4.77 4.77 4.77 Total displacement Liters 76.3 76.3 76.3 76.3 76.3 Compression ratio...
Page 169 8. Coolant system (LT circuit) Coolant temperature (at en- °C gine connection: outlet to cooling system) Coolant temperature before °C intercooler, limit 1 Coolant temperature before °C intercooler, limit 2 Coolant antifreeze content, max. 10. Lube oil system Lube oil temperature before °C engine, limit 1 Lube oil temperature before...
Page 170 Oil pan capacity at dipstick Liters mark “min.” (standard oil system) (option: max. oper- ating inclinations) Oil pan capacity at dipstick Liters mark “max.” (standard oil system) (option: max. oper- ating inclinations) 19. Masses / main dimensions Engine mass, dry (basic en- 7700 7700 7700...
Page 171 Engine surface noise with at- dB(A) tenuated intake noise (filter) – BL (free-field sound pres- sure level Lp, 1 m distance, ISO 6798, +2 dB(A) toler- ance) Engine surface noise with at- dB(A) tenuated intake noise (filter) – BL (sound power level LW, ISO 6798, +2 dB(A) toler- ance) MS15038/01E 2018-11 | Technical Data | 169...
Page 172: Product Data 16V4000G94S, Application 3D
4.28 Product data 16V4000G94S, application 3D DL Reference value: Continuous power. Continuously attainable power at standard conditions. BL Reference value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value required to design an external system (plant). R Guideline value.
Page 173 2. General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust gas overpressure mbar Exhaust gas overpressure, max. mbar Fuel temperature at engine inlet connection °C Fuel temperature at engine inlet connection, max. (w/o power re- °C duction) Fuel temperature at engine inlet connection, max.
Page 174 7. Coolant system (HT circuit) Coolant temperature (at engine connection: outlet to cooling sys- °C tem) Coolant temperature after engine, limit 1 °C Coolant temperature after engine, limit 2 °C Coolant antifreeze content, max. 8. Coolant system (LT circuit) Coolant temperature (at engine connection: outlet to cooling sys- °C tem) Coolant temperature before intercooler, limit 1...
Page 175 19. Masses / main dimensions Engine mass, dry (basic engine configuration acc. to scope of de- 7700 7700 livery specification) 22. Acoustics Exhaust noise, unsilenced – DL (free-field sound pressure level dB(A) Lp, 1 m distance, ISO 6798, +3 dB(A) tolerance) Exhaust noise, unsilenced –...
Page 176: Product Data 12V4000B24X, Application 3A
4.29 Product data 12V4000B24X, application 3A; 12V4000G14X, application 3B; 12V4000G24X, application 3B; 12V4000G74X, application 3D; 12V4000G84X, application 3D Product type Application Speed Optimization 12V4000B24X 3A continuous op- 50 Hz Optimized fuel con- (→ Page 32), see Product data eration sumption 12V400B24F, 3A continuous op- eration, optimized fuel consump- tion...
Page 177: Product Data 16V4000B24X, Application 3A
4.30 Product data 16V4000B24X, application 3A; 16V4000G14X, application 3B; 16V4000G24X, application 3B; 16V4000G74X, application 3D; 16V4000G84X, application 3D Product type Application Speed Optimization 16V4000B24X 3A continuous op- 50 Hz Optimized fuel con- (→ Page 102), see Product data eration sumption 16V400B24F, 3A continuous op- eration, optimized fuel consump- tion...
Page 178: Firing Order
4.31 Firing order Cylinders Firing order A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 176 | Technical Data | MS15038/01E 2018-11...
Page 179: Main Engine Dimensions
4.32 Main engine dimensions Engine model Length (A) Width (B) Height (C) 12V4000Gx3 with 2-barrel HP fuel pump 2433.5 mm 1660.5 mm 2181.5 mm 12V4000Gx3 with 4-barrel HP fuel pump 2495 mm 1660.5 mm 2181.5 mm 16V4000Gx3 2981.3 mm 1660.5 mm 2181.5 mm MS15038/01E 2018-11 | Technical Data | 177...
Page 180: Operation
5.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications (A001070/..) available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item Action Engine Depreserve (→...
Page 181: Putting Into Operation After Scheduled Out-Of-Service-Period
5.2 Putting into operation after scheduled out-of-service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 285); Coolant circuit Check engine coolant level (→ Page 292). Check charge-air coolant level (→ Page 315). Coolant circuit Heat engine coolant with coolant preheater.
Page 182: Starting The Engine In Manual Mode (Test Run)
5.3 Starting the engine in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network ☑ External start interlock is not activated. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 183: Re-Starting The Engine Following An Automatic Safety Shutdown
5.4 Re-starting the engine following an automatic safety shutdown NOTICE Re-starting the engine following an automatic safety shutdown. Risk of severe engine damage! • Before starting the engine, make sure the root cause of the safety shutdown was eliminated. • If the root cause cannot be identified or eliminated, contact Service. Note: •...
Page 184: Safety System - Override
5.5 Safety system – Override NOTICE Safety functions and engine shutdown alarms will be disregarded. Severe material damage! • Initiate emergency start only in emergency situations. NOTICE Inadmissible operating status. Severe damage to property! • Use override function only in hazardous situations to ensure full capability in the event of engine faults.
Page 185: Emergency Engine Start (Override Mode)
5.6 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 186: Operational Monitoring
5.7 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 High level of engine noise when the engine is running.
Page 187: Emission Label - Check
5.8 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 188: Engine - Stopping In Manual Mode (Test Run)
5.9 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 189 After engine shutdown Item Action Coolant circulating pump Allow to run on for sufficient time after stopping. MS15038/01E 2018-11 | Operation | 187...
Page 190: Engine - Emergency Stop
5.10 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 191: After Stopping The Engine - Engine Remains Ready For Operation
5.11 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 MS15038/01E 2018-11 | Operation | 189...
Page 192: After Stopping The Engine - Putting The Engine Out Of Operation
5.12 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 296); Drain charge-air coolant (→ Page 318) if: •...
Page 193: Plant - Cleaning
5.13 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 194: Maintenance
6 Maintenance 6.1 Maintenance task reference table [QL1] The required maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a separate publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
Page 195 Task Item Maintenance tasks WM00106 CRANKCASE BREATHER Replace oil separator (→ Page 226) WM00119 CRANKCASE BREATHER Replace filter or filter element (→ Page 229) WM00110 CRANKCASE Perform endoscopic examination of cylinder liner (→ Page 222) WM00090 FUEL INJECTOR Replace fuel injection valve/injector (→...
Page 196: 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 197 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 198 Blue exhaust gas Cause Corrective action u Drain engine oil (→ Page 282). Too much engine oil in the engine u Replace filter (→ Page 226). Oil separator of crankcase breather contaminated Exhaust turbocharger, cylinder u Contact Service. head, piston rings or cylinder liner defective White exhaust gas Cause...
Page 199: Fault Messages Of Engine Control Unit Ecu9
7.2 Fault messages of Engine Control Unit ECU9 for Series 4000, genset applications Possible engine responses to yellow alarm: Warning, power limitation/reduction, speed limitation, engine shutdown Possible engine responses to red alarm: Engine shutdown, power limitation/reduction, speed limitation, warning Procedure following an automatic safety shutdown (→ Page 181) 3 –...
Page 200 10 – SS T-Coolant Intercooler Cause Corrective action The intercooler coolant 1. Reduce power. temperature measured at sensor 2. Check whether alarm 23 is signaled. B26 has violated limit value 2. The 3. Check cooler (plant) for contamination. intercooler coolant temperature is 4.
Page 201 27 – HI Level Leakage Fuel Cause Corrective action u Contact Service. Switch F46 in the collecting tank has been tripped. The HP fuel system is leaking. 30 – SS Engine Overspeed Cause Corrective action Engine speed has violated the 1.
Page 202 52 – SS T-Lube Oil Cause Corrective action The lube oil temperature at sensor 1. Check operation of cooler and fan (plant). B7 has exceeded limit value 2. 2. Check engine coolant level (→ Page 292). The lube oil temperature is too 3.
Page 203 67 – HI T-Coolant Cause Corrective action The coolant temperature at 1. Reduce power. sensor B6 has exceeded limit 2. Check operation of cooler and fan (plant). value 1. The coolant temperature 3. Check engine coolant level (→ Page 292). is too high.
Page 204 92 – SS Starter Speed Not Reached Cause Corrective action The engine has failed to reach the 1. Check pressure supply (plant) of starter. defined speed threshold within 2. Observe any other messages. the defined time. 3. Contact Service. 93 – SS T-Preheat Cause Corrective action The engine coolant temperature...
Page 205 120 – HI ECU Power Supply Voltage Cause Corrective action The supply voltage of the ECU has 1. Check condition of batteries (plant). violated set limit value 1. 2. Check plug connections to Engine Control Unit (→ Page 334). 3. Check battery charging-generator. 4.
Page 206 327 – AL Wiring Cylinder A7 Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 332). wiring for cylinder A7 or injector 2. Replace injector (→ Page 244). defective. 3. Contact Service. 328 –...
Page 207 334 – AL Wiring Cylinder B4 Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 332). wiring for cylinder B4 or injector 2. Replace injector (→ Page 244). defective. 3. Contact Service. 335 –...
Page 208 341 – AL Open Load Cylinder A1 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 332). to cylinder A1. 2. Contact Service. 342 – AL Open Load Cylinder A2 Cause Corrective action Disruption fault in injector wiring 1.
Page 209 349 – AL Open Load Cylinder A9 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 332). to cylinder A9. 2. Contact Service. 350 – AL Open Load Cylinder A10 Cause Corrective action Disruption fault in injector wiring 1.
Page 210 357 – AL Open Load Cylinder B7 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 332). to cylinder B7. 2. Contact Service. 358 – AL Open Load Cylinder B8 Cause Corrective action Disruption fault in injector wiring 1.
Page 211 454 – SS Power Reduction Active Cause Corrective action Power reduction activated. A main 1. Observe any other messages. alarm activating power reduction 2. Contact Service. has been tripped. 510 – AL Override applied Cause Corrective action The Override function was u No action required.
Page 212 834 – AL Gas Path Warning Cause Corrective action Summary emission fault alarm 1. Observe any other messages. 2. Contact Service. 835 – AL Gas Path Fault Cause Corrective action Summary emission fault alarm 1. Observe any other messages. 2. Contact Service. 1024 –...
Page 213 1036 – AL Inj. Drift Limit 1 Cyl. A5 Cause Corrective action u Schedule an injector replacement. The drift correction for energization (start and duration) of injector A5 has violated limit value 1. The injector will soon reach its maximum drift limit. 1037 –...
Page 214 1042 – AL Inj. Drift Limit 1 Cyl. B1 Cause Corrective action u Schedule an injector replacement. The drift correction for energization (start and duration) of injector B1 has violated limit value 1. The injector will soon reach its maximum drift limit. 1043 –...
Page 215 1048 – AL Inj. Drift Limit 1 Cyl. B7 Cause Corrective action u Schedule an injector replacement. The drift correction for energization (start and duration) of injector B7 has violated limit 1. The injector will soon reach its maximum drift limit. 1049 –...
Page 216 1054 – AL Inj. Drift Limit 2 Cyl. A3 Cause Corrective action u Replace injector (→ Page 244). The drift correction for energization (start and duration) of injector A3 has violated limit 2. The injector has reached its maximum drift limit. 1055 –...
Page 217 1060 – AL Inj. Drift Limit 2 Cyl. A9 Cause Corrective action u Replace injector (→ Page 244). The drift correction for energization (start and duration) of injector A9 has violated limit 2. The injector will soon reach its maximum drift limit. 1061 –...
Page 218 1066 – AL Inj. Drift Limit 2 Cyl. B5 Cause Corrective action u Replace injector (→ Page 244). The drift correction for energization (start and duration) of injector B5 has violated limit 2. The injector has reached its maximum drift limit. 1067 –...
Page 219 1170 – AL Permanent Injection Cause Corrective action u Contact Service. The ECU has detected continuous injection at one or more injectors based on the pressure gradient in the HP fuel system (B48). 1174 – HI T-Fuel f(T0) Cause Corrective action The charge-air pressure at sensor 1.
Page 220: Task Description
8 Task Description 8.1 Engine 8.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 221 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 222: Engine - Cranking On Starting System
8.1.2 Engine – Cranking on starting system DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before barring the engine, make sure that there are no persons in the engine's danger zone. •...
Page 223: Engine - Test Run
8.1.3 Engine – Test run DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Exhaust gases are harmful to health and may cause cancer.
Page 224: Cylinder Liner
8.2 Cylinder Liner 8.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 240). Remove injector (→...
Page 225 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 224). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...
Page 226: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination
8.2.2 Cylinder liner – Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina- tion report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
Page 227 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 228: Crankcase Breather
8.3 Crankcase Breather 8.3.1 Crankcase breather – Oil separator 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 Engine oil Filter element (→...
Page 229 Remove filter element (1) from housing (2). Insert new filter element in housing. Install cover with new O-ring. Tighten cover screws to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 6 Nm +2 Nm Replace further oil separator filter elements in the same way.
Page 230 Remove filter element (1) from oil separator housing (2). Insert new filter element in housing. Install cover with new O-ring. Tighten cover screws tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 8 Nm +1 Nm Replace further oil separator filter elements in the same way.
Page 231: Crankcase Breather - Filter Element Replacement
8.3.2 Crankcase breather – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Ratchet bit F30027340 Assembly compound (Kluthe Hakuform 30-10) X00067260 Engine oil Filter insert (→...
Page 232 Observe angular position of air filter covers. 230 | Crankcase Breather | MS15038/01E 2018-11...
Page 233: Valve Drive
8.4 Valve Drive 8.4.1 Valve protrusion – Measurement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Measuring jig 1 Y4350009 Depth gage, 200 mm Y20000918 Measuring jig 2, optional Y4350010 Preparatory steps Remove cylinder head covers (→...
Page 234 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 235 Release adjusting screw (1) and remove valve bridge. Do not remove rocker arm (2). Measure distance (A) between valve stem end and cylinder head top at the injector bore with depth gage. • The specified value for a new cylinder head: 93.8 mm.
Page 236 Note: Do not remove rocker arm (2). Release adjusting screw (1) and remove valve bridge. Place measuring unit 2 (2) on the cylinder head (3). Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specified torque using a torque wrench.
Page 237: Valve Gear - Lubrication
8.4.2 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication Remove cylinder head covers (→ Page 240). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjusting screws with oil.
Page 238: Valve Clearance - Check And Adjustment
8.4.3 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20098771 Valve setting gauge Y4349603...
Page 239 Note: Danger of confusion: There might be an addi- tional OT/A1 mark (1) on the outer perimeter of the flywheel. The additional OT/A1 mark (1) (if applicable) on the outer perimeter of the flywheel must not be used for reference. Diagram for 8V engines –...
Page 240 Diagram for 16V engines – Two crankshaft positions Diagram for 20V engines – Two crankshaft positions Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. •...
Page 241 Adjusting valve clearance Release locknut (1). Insert valve setting gauge (3) between valve bridge and rocker arm. Note: Replace or rectify adjusting screws and/or locknuts which do not move freely. Using angular screw driver, set adjusting screw (2) so that the specified valve clear- ance is provided.
Page 242: Cylinder Head Cover - Removal And Installation
8.4.4 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Assembly compound (Kluthe Hakuform 30-15) X00067260 Profile gasket (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal.
Page 243: Injection Pump / Hp Pump
8.5 Injection Pump / HP Pump 8.5.1 HP fuel pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Fuel suction pipe F30378207 Engine oil WARNING...
Page 244 Preparatory steps (two-cylinder HP pump) Undo nut (2) and remove oil line (1) from HP pump. Preparatory steps (four-cylinder HP pump) Undo nut (2) and remove oil line (1) from HP pump. Filling HP pump (two-cylinder HP pump) Remove union (1). Note: Excess engine oil runs into gear box.
Page 245 Screw in union (1) and use a torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Union M16x1.5 Tightening torque 40 Nm Filling HP pump (four-cylinder HP pump) Remove union (1). Note: Excess engine oil runs into gear box. Use fuel suction pipe to fill HP pump with 2 liters of clean engine oil.
Page 246: Injector
8.6 Injector 8.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 250). 244 | Injector | MS15038/01E 2018-11...
Page 247: Injector - Removal And Installation
8.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6789889 Milling cutter F30452739 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340...
Page 248 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 240). Removing injector Disconnect cable connector on injector.
Page 249 Install installation/removal jig on the cylinder head. Remove injector with installation/removal jig. Remove the installation/removal jig. Note: The sealing ring (2) for sealing the combus- tion chamber must only be used once. If the sealing ring (2) did not remain on the injector (1) when removed, use a self-made wire hook or magnet to extract it from the cylinder head and dispose accordingly.
Page 250 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 (2) with (Assembly com- pound (Molykote P 37)). Coat O-rings (3) and (5) with (Assembly com- pound (Kluthe Hakuform 30-15)).
Page 251 Use a torque wrench to tighten hold-down clamp screw (2) to specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 100 Nm+10 Nm Use a torque wrench and long socket to tighten adapter (3) to specified tightening torque. Name Size Type...
Page 252: Injector Rings - Replacement
8.6.3 Injector rings – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6789889 Milling cutter F30452739 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Torque wrench, 60–320 Nm...
Page 253 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 240). Removing injector, removing rings Disconnect cable connector at injector (ar- rowed).
Page 254 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 and dispose properly. Remove O-rings (5), O-ring (3) and damper ring (2) from injector (1) and dispose accord- ingly.
Page 255 Replacing rings, installing injec- 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. Note: • Replace sealing ring (1) between injector and water sleeve whenever the injector is disassembled.
Page 256 Press in injector with installation/removal jig. Remove installation/removal jig. Coat screw head mating face and thread of hold-down clamp (2) with engine oil. Fit hold-down clamp (1) in correct position, fit screw (2) and tighten by hand. Note: Make sure parts are perfectly clean. Apply engine oil to thread, sealing taper and thrust ring of adapter (3).
Page 257 Fit cable connector on injector (arrowed). Note: Do not reset drift correction (CDC) after re-in- stalling a used injector. After fitting new injectors (→ Page 245). Final steps Install cylinder head cover (→ Page 240). Open fuel supply to engine. MS15038/01E 2018-11 | Injector | 255...
Page 258: Fuel System
8.7 Fuel System 8.7.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 259 Note: See figure (a). Unlock hand pump: Hold sleeve (2). Turn han- dle (1) counterclockwise until sleeve can be moved back (arrowed). Note: • See figure (b). • After pulling the handle, wait briefly until the chamber is optimally filled. Operate pump with handle (1) until bubble- free fuel emerges from threaded vent plug.
Page 260: Fuel Cooler - External Contamination And Leak-Tightness Check
8.7.2 Fuel cooler – External contamination and leak-tightness check Preconditions ☑ Engine is stopped and starting disabled. ☑ All fuel cooler power sources are disconnected. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...
Page 261: Fuel Cooler - Cleaning
8.7.3 Fuel cooler – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ All fuel cooler power sources are disconnected. WARNING Hot components/surfaces. Risk of burns! • Allow the engine to cool down to below 50 °C before beginning work. •...
Page 262 Cleaning with a compressed-air pistol Blow out cooler elements with a jet of compressed air working against the direction of the cooling air parallel to the cooling fins. Remove and dispose of dirt before putting engine into operation. Use industrial high-pressure cleaner to clean fuel cooler in case of stubborn contamination. Cleaning with industrial high-pressure cleaner Note: •...
Page 263: Fuel Filter
8.8 Fuel Filter 8.8.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 264: Fuel Prefilter - Pressure Ratios
8.8.2 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 265: Fuel Prefilter (Non-Switchable) - Draining
8.8.3 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 266 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 267: Fuel Prefilter (Switchable) - Draining
8.8.4 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 268 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 269 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 270: Fuel Prefilter (Switchable) - Low Pressure Indicator Check
8.8.5 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 271: Fuel Prefilter (Non-Switchable) - Filter Element Replacement
8.8.6 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 272 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 273: Fuel Prefilter (Switchable) - Filter Element Replacement
8.8.7 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 274 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 275 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 276: Fuel Prefilter - Venting
8.8.8 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 277 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 278: Charge-Air Cooling
8.9 Charge-Air Cooling 8.9.1 Intercooler – Checking condensate drain for coolant leakage and obstruction DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
Page 279: Air Filter
8.10 Air Filter 8.10.1 Air filter ‒ Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Air filter ‒ Replacement Remove air filter and install new one (→ Page 279). Reset signal ring of service indicator (→ Page 280). MS15038/01E 2018-11 | Air Filter | 277...
Page 280: Air Filter - Check
8.10.2 Air filter – Check Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Checking air filter Check entire circumference of air filter for damage. Fit new air filter if damaged (→ Page 277). 278 | Air Filter | MS15038/01E 2018-11...
Page 281: Air Filter - Removal And Installation
8.10.3 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. DANGER Falling from great heights. Risk of serious injury – danger to life! • When working high on the equipment, always use suitable ladders or work platforms. •...
Page 282: Air Intake
8.11 Air Intake 8.11.1 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 283: Starting Equipment
8.12 Starting Equipment 8.12.1 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 284: Lube Oil System, Lube Oil Circuit
8.13 Lube Oil System, Lube Oil Circuit 8.13.1 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 285 Unscrew one of the drain plugs (1 to 8) and drain engine oil. Screw in drain plug (1 to 8) with new sealing ring. Engine oil treatment Check layer thickness of oil residues in the centrifugal oil filter, clean centrifugal oil filter and replace filter sleeve (→...
Page 286 Filling with new engine oil Open cover (1) on filler neck. Pour oil in at filler neck up to 'max.' mark at oil dipstick. Close cover (1) on filler neck. Check engine oil level (→ Page 285). Note: Observe the following instructions to avoid engine damage: Adequate oil pressure for an engine start is only provided when the quick- start function is deactivated.
Page 287: Engine Oil Level - Check
8.13.2 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 288: Engine Oil - Sample Extraction And Analysis
8.13.3 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 289 Screw Tightening torque (Engine oil) 20 Nm +2 Nm Use equipment and chemicals in MTU test kit to analyze engine oil for: • Dispersing capacity (spot test) • Proportion of water • Dilution by fuel MS15038/01E 2018-11 | Lube Oil System, Lube Oil Circuit | 287...
Page 290: Oil Priming Pump - Visual Inspection
8.13.4 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 291: Oil Filtration / Cooling
8.14 Oil Filtration / Cooling 8.14.1 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 292: Centrifugal Oil Filter - Cleaning And Filter Sleeve Replacement
8.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Ratchet bit F30027340...
Page 293 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 294: Coolant Circuit, General, High-Temperature Circuit
8.15 Coolant Circuit, General, High-Temperature Circuit 8.15.1 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 295: Engine Coolant Change
8.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 296). Fill with engine coolant (→ Page 294). MS15038/01E 2018-11 | Coolant Circuit, General, High-Temperature Circuit | 293...
Page 296: Engine Coolant - Filling
8.15.3 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 297 Filling with coolant from below using a pump Connect appropriate pump with hose to drain valve of engine coolant pump (arrowed). 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 (arrow) if coolant leaks out at loose union.
Page 298: Engine Coolant - Draining
8.15.4 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 299 Close all other open drain points. Position valve cover on filler neck and close. MS15038/01E 2018-11 | Coolant Circuit, General, High-Temperature Circuit | 297...
Page 300: Engine Coolant - Filling
8.15.5 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 301 Filling with coolant from below using a pump Connect appropriate pump with hose to drain valve of engine coolant pump (arrowed). 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 (arrow) if coolant leaks out at loose union.
Page 302: Engine Coolant Pump - Relief Bore Check
8.15.6 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 303: Engine Coolant - Sample Extraction And Analysis
8.15.7 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 304 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/..)). 302 | Coolant Circuit, General, High-Temperature Circuit | MS15038/01E 2018-11...
Page 305: Preheater - Overview
8.15.8 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 306: Preheater - Function And Leak Check
8.15.9 Preheater – Function and leak check Preconditions ☑ Preheater is switched on. WARNING Coolant is hot and highly pressurized. Risk of injury! Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Function check Note: The preheater operates properly if the measured value of the coolant temperature is within the control range...
Page 307: Preheater - Overhaul
8.15.10 Preheater – Overhaul Preconditions ☑ Engine is stopped and starting disabled. ☑ All preheater power sources are disconnected. Replacing solenoid switch Replace solenoid switch (→ Page 306). Cleaning heating element and replacing gasket Clean heating element and housing and check (→ Page 308). Replacing thermostat Replace thermostat (→...
Page 308: Preheater - Solenoid Switch Replacement
8.15.11 Preheater – Solenoid switch replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solenoid switch (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 309 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 310: Preheater - Heating Element And Housing Check
8.15.12 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 311 Open drain plug at coolant inlet (arrowed) 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 (1) with heating element out of housing.
Page 312 Final steps Connect preheater power sources. Switch on preheater. 310 | Coolant Circuit, General, High-Temperature Circuit | MS15038/01E 2018-11...
Page 313: Preheater Thermostats - Replacement
8.15.13 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 314 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 315 Final steps Connect preheater to power supply. Switch on preheater. MS15038/01E 2018-11 | Coolant Circuit, General, High-Temperature Circuit | 313...
Page 316: Coolant Expansion Tank Valve Cover - Replacement
8.15.14 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 317: Low-Temperature Circuit
8.16 Low-Temperature Circuit 8.16.1 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 318 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 320). 316 | Low-Temperature Circuit | MS15038/01E 2018-11...
Page 319: Charge-Air Coolant - Change
8.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 318). Fill with charge-air coolant (→ Page 320). MS15038/01E 2018-11 | Low-Temperature Circuit | 317...
Page 320: Charge-Air Coolant - Draining
8.16.3 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 321 Drain remaining coolant at intercooler (ar- rowed). Use a torque wrench to tighten drain valve on charge-air coolant pump to specified tightening torque. Name Size Type Lubricant Value/Standard Spindle A/F11 Tightening torque 12 Nm Screw in drain screws on thermostat housing and intercooler with new sealing rings. Position valve cover on filler neck at coolant expansion tank and close.
Page 322: Charge-Air Coolant - Filling
8.16.4 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 323 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 (arrow) if coolant leaks out at loose union.
Page 324 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 (arrow) if coolant leaks out at loose union.
Page 325: Charge-Air Coolant Pump - Relief Bore Check
8.16.5 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 326: Belt Drive
8.17 Belt Drive 8.17.1 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 327: Battery-Charging Generator
8.18 Battery-Charging Generator 8.18.1 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 328: Battery-Charging Generator Drive - Drive Belt Replacement
8.18.2 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 329: Engine Mounting / Support
8.19 Engine Mounting / Support 8.19.1 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 330: Engine Mounting - Checking Securing Screws For Firm Seating
8.19.2 Engine mounting – Checking securing screws for firm seating Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm F30452768 Torque wrench, 300–800 Nm F30047798 Ratchet bit F30027341 Engine oil Version A –...
Page 331 Version B – rigid engine mount- ing with standalone generator Check that securing screws (1, 2, 3) and base frame screw connections (arrowed) are tight. Use a torque wrench to tighten loose screw connections (1, 2) to specified tightening torque. Name Size Type...
Page 332: Generator Mounting - Check
8.19.3 Generator mounting – Check Special tools, Material, Spare parts Designation / Use Part No. Qty. Resilient element (→ Spare Parts Catalog) NOTICE Contamination of engine mounts made of natural rubber with fuel or oil. Engine mounts swell. Risk of shorter service life or destruction of the mounts! •...
Page 333: Generator Mounting - Securing Screw Firm Seating Check
8.19.4 Generator mounting – Securing screw firm seating check Preconditions ☑ Engine is stopped and starting disabled. Generator mounting, securing screw firm seating check Check securing screws for firm seating. Tighten loose screws. MS15038/01E 2018-11 | Engine Mounting / Support | 331...
Page 334: Wiring (General) For Engine/Gearbox/Unit
8.20 Wiring (General) for Engine/Gearbox/Unit 8.20.1 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 335: Accessories For (Electronic) Engine Governor / Control System
8.21 Accessories for (Electronic) Engine Governor / Control System 8.21.1 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 336: Engine Control Unit Plug Connections - Check
8.21.2 Engine Control Unit plug connections – Check Preconditions ☑ Engine is stopped and starting disabled. ☑ Electronic engine management system is de-energized. Checking plug connections at Engine Control Unit Check all plug connections for firm seating. Lock loose connectors. Check dust cap on ECU connectors for damage and correct seating.
Page 337: Engine Governor Ecu 9 - Removal And Installation
8.21.3 Engine governor ECU 9 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Protective cover over connectors on Heavy-Duty version removed. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.
Page 338: Parameters For Drift Correction (Cdc) - Resetting With Diasys
8.21.4 Parameters for drift correction (CDC) – Resetting with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Parameters for drift correction (CDC) – Resetting with DiaSys® Note: The engine will lose its emissions certification of the drift correction parameters (CDC) if not reset. Use DiaSys®...
Page 339: 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 340 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 341 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 342: 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 343: Special Tools
10 Appendix B 10.1 Special Tools Angular screw driver Part No.: F30002815 Qty.: Used in: 8.4.3 Valve clearance – Check and adjustment (→ Page 236) Barring tool Part No.: F6555766 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 218) Qty.: Used in: 8.2.1 Cylinder liner –...
Page 344 Crossbeam Part No.: T80092360 Qty.: Used in: 2.1 Transport (→ Page 19) Depth gage, 200 mm Part No.: Y20000918 Qty.: Used in: 8.4.1 Valve protrusion – Measurement (→ Page 231) Endoscope Part No.: Y20097353 Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→...
Page 345 Filter wrench Part No.: F30379104 Qty.: Used in: 8.8.1 Fuel filter – Replacement (→ Page 261) Qty.: Used in: 8.14.1 Engine oil filter – Replacement (→ Page 289) Fuel suction pipe Part No.: F30378207 Qty.: Used in: 8.5.1 HP fuel pump – Filling with engine oil (→ Page 241) High-pressure cleaner Part No.: Qty.:...
Page 346 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 245) Qty.: Used in: 8.6.3 Injector rings – Replacement (→ Page 250) MTU test kit Part No.: F6798833 Qty.: Used in: 8.13.3 Engine oil – Sample extraction and analysis (→...
Page 347 Oil filter wrench Part No.: F30455924 Qty.: Used in: 8.14.2 Centrifugal oil filter – Cleaning and filter sleeve re- placement (→ Page 290) Ratchet bit Part No.: F30027340 Qty.: Used in: 8.3.1 Crankcase breather – Oil separator element re- placement (→ Page 226) Qty.: Used in: 8.3.2 Crankcase breather –...
Page 348 Ratchet bit Part No.: F30027341 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 245) Qty.: Used in: 8.6.3 Injector rings – Replacement (→ Page 250) Qty.: Used in: 8.13.1 Engine oil – Change (→ Page 282) Qty.: Used in: 8.18.1 Battery-charging generator –...
Page 349 Torque screwdriver, 1–5 Nm Part No.: F30452774 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 245) Qty.: Used in: 8.6.3 Injector rings – Replacement (→ Page 250) Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 2.3 Crankshaft transport locking device (→...
Page 350 Torque wrench, 4–20 Nm Part No.: F30044239 Qty.: Used in: 8.3.1 Crankcase breather – Oil separator element re- placement (→ Page 226) Qty.: Used in: 8.3.2 Crankcase breather – Filter element replacement (→ Page 229) Qty.: Used in: 8.14.2 Centrifugal oil filter – Cleaning and filter sleeve re- placement (→...
Page 351 Valve setting gauge Part No.: Y4349603 Qty.: Used in: 8.4.3 Valve clearance – Check and adjustment (→ Page 236) MS15038/01E 2018-11 | Special Tools | 349...
Page 352: Index
10.2 Index Crankshaft – Transport locking device Abbreviations 337 – Installation/removal 21 Actuators Cylinder – Overview 27 – Designation 24 After stopping the engine Cylinder head cover – Engine remains ready for operation 189 – Installation 240 – Putting the engine out of operation 190 –...
Page 353 285 Engine overview 25 Main dimensions 177 Engine sides Maintenance Schedule – Designation 24 – Maintenance task reference table [QL1] 192 MTU contact persons 340 Fault messages – ECS with ECU9 197 Oil priming pump Firing order 176 – Visual inspection 288 Fuel cooler ...
Page 354 Preheater Product data 12V4000G14S – Check – 3B continuous operation – Heating element 308 – Optimized fuel consumption 58 – Housing 308 – 3F mains backup mode – Function check 304 – EPA Nonroad T2 Comp (40CFR89) 58 –...
Page 355 Product data 12V4000G74S Product data 16V4000G14S – 3D standby power – 3B continuous operation – EPA Nonroad T2 Comp (40CFR89) 90 – Optimized fuel consumption 126 – EPA Stationary EMERG T2 (40CFR60) 90 – 3F mains backup mode –...
Page 356 Product data 16V4000G74S Starting valve – 3D standby power – Manual operation 281 – EPA Nonroad T2 Comp (40CFR89) 158 – EPA Stationary EMERG T2 (40CFR60) 158 Thermostat – Optimized fuel consumption 158 – Replacement Product data 16V4000G74X –...

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12v4000gx4 16v4000bx4 16v4000gx4

MTU 12V4000Bx4 Operating Instructions Manual

1 Safety

2 Transport

3 General Information

4 Technical Data

5 Operation

6 Maintenance

7 Troubleshooting

8 Task Description

9 Appendix A

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