Page 1 Operating Instructions Diesel engine 12V4000Cx5 16V4000Cx5 MS15041/03E...
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 5: Table Of Contents
Table of Contents 1 Safety 5.3 Re-starting the engine following an automatic safety shutdown 1.1 Important provisions for all products 5.4 Operational checks 1.2 Correct use of all products 5.5 Emission label – Check 1.3 Personnel and organizational requirements 5.6 Engine – Starting in manual mode 1.4 Initial start-up and operation –...
Page 6 8.15.7 Coolant expansion tank valve cover – 10 Appendix A Replacement 10.1 Abbreviations 8.16 Low-Temperature Circuit 10.2 MTU Contact/Service Partners 8.16.1 Charge-air coolant level – Check 8.16.2 Charge-air coolant – Change 11 Appendix B 8.16.3 Charge-air coolant – Draining 8.16.4 Charge-air coolant – Filling 11.1 Special Tools...
Page 7: Safety
Nameplates, model designation or serial number can be found on the product. All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv- ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system is not visible without the removal of components, the system integrator must install the second nameplate in a clearly visible area on the vehicle/system.
Page 8 Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life. Exception: Engines used exclusively in land-based, military applications other than by US government agen- cies.
Page 9: Correct Use Of All Products
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al- so applies to engine control/parameters) •...
Page 10: 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 11: Initial Start-Up And Operation - Safety Regulations
1.4 Initial start-up and operation – Safety regulations Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
Page 12 Do not inhale the exhaust gases of the product. The following requirements must be fulfilled before the product is started: • Wear ear protectors. • Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent. Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live.
Page 13: Assembly, Maintenance, And Repair Work - Safety Regulations
1.5 Assembly, maintenance, and repair work – Safety regulations Safety regulations for work prior to assembly, maintenance, and repair Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants, risk of burning).
Page 14 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. Completely wipe up escaped fluids and lubricants due to the risk of slipping.
Page 15 Welding work Welding operations on the product or mounted units are not permitted. Cover the product when welding in its vicinity. Before starting welding work: • Switch off the power supply master switch. • Disconnect the battery cables or actuate the battery isolating switch. •...
Page 16 Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur- ing operation by: • Contact with sharp edges • Chafing on components • Contact with hot surfaces. Do not secure cables on lines carrying fluids. Do not use cable ties to secure lines.
Page 17: Fire And Environmental Protection, Fluids And Lubricants
Process materials can also be or contain hazardous or toxic substances. When using process materials and other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi- cations must be used.
Page 18 Particularly hazardous substances used with our products are named in a list: www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products Compressed air • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion.
Page 19: 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 20: Transport
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set the engine down on its oil pan unless expressly authorized to do so by MTU. 18 | Transport | MS15041/03E 2018-08...
Page 21: Lifting Requirements
2.2 Lifting requirements Lifting requirements DANGER Suspended load. Danger to life! • Use suitable equipment and lifting devices. • Never stand beneath a suspended load and keep a safe distance. • Wear personal protective equipment (e.g. protective helmet, safety shoes). 1 Max.
Page 22: Crankshaft - Transport Locking Device
2.3 Crankshaft – Transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Ratchet adapter F30027340 Engine oil Transport locking device Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine trans- port.
Page 23 Installing transport locking de- vice on driving end (KS), variant Screw retainer (4) with spacer sleeves (5) and screws (6) on crankshaft. Spacer sleeves (5) are optional. Tighten screws (6) to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard...
Page 24 Install guard plate (3) with screws (2) and spacer sleeves (1) on flywheel housing. Store the removed parts of the transport locking device carefully for possible reuse. Installing transport locking device on driving end (KS), variant B Note: Keep guard plate and screws on the engine. They must be reinstalled when the transport locking device has been removed.
Page 25: General Information
3 General Information 3.1 Tightening specifications for screws, nuts and bolts Tightening torques for setscrew and connections as per MTN 5008 standard This standard applies to setscrews not subject to dynamic loads and the associated nuts according to: • MMN 384 •...
Page 26 Hand-tightening Machine-tightening Thread 8.8 M (Nm) 10.9 M (Nm) 8.8 M (Nm) 10.9 M (Nm) M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5 M24 x 2 1250 1175 M27 x 2 1350 1275 1200 1700 1100 1600 M30 x 2 1350...
Page 27 Tightening torque for self-locking hex nuts (Nm) Thread Lubricants 7.5 +1 – 17 +2 – 35 +4 – 59 +6 – 100 +10 – 140 +14 – 290 +29 – = tightening torques Tightening torque for stress bolt connections as per MTN 5007 standard This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of strength class 10.9 as well as to the associated nuts.
Page 28 Not torsion-protected M (Nm) Torsion-protected M (Nm) Thread 1250 1575 *Protect screw shaft from torsion when tightening. = tightening torques. Tightening torques for plug screws as per MTN 5183-1 standard This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852 Form A (sealed with sealing ring to DIN 7603-Cu).
Page 29 Tightening torques M are given for screw plugs made of steel (St) with surface protected by a phosphate coating and oiled or galvanized. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
Page 30 screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M64 x 2 = tightening torques Tightening torque for plug screws DIN 7604C (with long screwed end) screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M8 x 1 M22 x 1.5...
Page 31 The stated tightening torques M apply to steel (St) banjo screws with a phosphatized surface and oiled or galvanized and for copper-aluminum alloy. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
Page 32 Tightening torques for male connectors as per MTN 5183-3 standard This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by sealing ring to DIN 7603-Cu). Tightening torques M are given for male unions made of steel (St) with phosphatized surface coating and oiled, or galvanized.
Page 33 Tightening torques for union nuts as per DIN 3859-2 1 Union nut 2 Screw fixture 3 O-ring 4 Linear ball bearing Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase in force), it should be tightened another 1/4 turn (90°) past this point. Tightening torques for spigot unions with O-ring to ISO 6149-2 Thread Torque (Nm) +10%...
Page 34 Thread Torque (Nm) +10% M27 x 2 M33 x 2 M42 x 2 M48 x 2 M60 x 2 Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789) Tightening torques for screwed plugs with O-ring as per ISO 6149-3 Thread Torque (Nm) +10% M8 x 1...
Page 35 Tightening torques for plug screw joints as per MTN 5183-6 screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M10 x 1 10 +2 M12 x 1.5 14 +2 M14 x 1.5 15 +3 M16 x 1.5 18 +3 M18 x 1.5 23 +3...
Page 36 Sealing head/sealing cone with metric union nut Metric thread Pipe outer dia. Torque (Nm) M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5 M26 x 1.5 M30 x 2 M36 x 2 M42 x 2 M45 x 2 M52 x 2 Sealing head with BSP union nut...
Page 37 ORFS – flat sealing with union nut UNF thread Size Torque (Nm) 9/16–18 –4 14 +2 11/16–16 –6 24 +3 13/16–16 –8 43 +4 1–14 –10 60 +8 1.3/16–12 –12 90 +5 1.3/16–12 –14 90 +5 1.7/16–12 –16 125 +10 1.11/16–12 –20 170 +20...
Page 38: Engine Side And Cylinder Designations
3.2 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite) Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
Page 39: Engine Layout - 12V4000Cx5
3.3 Engine layout ‒ 12V4000Cx5 Engine overview – Free end 1 Oil heat exchanger 8 Engine mounting bracket 15 HP fuel pump 2 Crankcase breather 9 Engine governor ECU9 16 Vibration damper 3 Exhaust outlet 10 Additional fuel filter 17 Fan drive 4 Air intake 11 Fuel filter 18 Belt tensioner...
Page 40 Engine overview – Driving end 1 EGR cooler 6 Cylinder head 11 Flywheel 2 Intercooler (low pressure) 7 Battery-charging generator 12 EGR system after EGR cool- 3 Exhaust turbocharger (high 8 Oil priming pump pressure) 9 Engine lifting equipment 13 Intercooler (high pressure) 4 Exhaust turbocharger (low 10 Oil filler neck pressure)
Page 41: Engine Layout - 16V4000Cx5
3.4 Engine layout ‒ 16V4000Cx5 Engine overview – Free end 1 Oil heat exchanger 7 Starter 13 HP fuel pump 2 Crankcase breather 8 Engine governor ECU9 14 Automatic oil filter 3 Exhaust outlet 9 Oil pan 15 Vibration damper 4 Air intake 10 Additional fuel filter 16 Fan drive...
Page 42 Engine overview – Driving end 1 EGR cooler 6 Cylinder head 11 Oil filler neck 2 Intercooler (low pressure) 7 Battery-charging generator 12 Flywheel 3 Exhaust turbocharger (high 8 Engine mounting bracket 13 EGR system after EGR cool- pressure) 9 Oil priming pump 4 Exhaust turbocharger (low 10 Engine lifting equipment 14 Intercooler (high pressure)
Page 43: Overview Of Sensors, Actuators And Injectors - 12V4000Cx5
3.5 Overview of sensors, actuators and injectors – 12V4000Cx5 1 B10.2 - Charge-air pressure, 2 B16 - Coolant pressure 12 Y39 - Injector (B1-B6) B side MS15041/03E 2018-08 | General Information | 41...
Page 44 1 B5.3 - Lube oil pressure be- 7 A19 - Electronic engine 13 B34.3 - Fuel pressure be- fore filter identification label (EIL) fore optional filter 2 M52 - HP turbine bypass 8 B9 - Charge air temperature 14 F34.2 - Fuel pressure before flap 9 F57 - Charge-air coolant filter...
Page 45 1 B50 - Crankcase pressure 4 B33 - Fuel temperature 7 B43 - Charge-air coolant 2 Y44 - Fan control valve (Rail) pressure 3 B5.1 - Lube oil pressure af- 5 B48 - Fuel pressure (Rail) 8 B26 - Charge-air coolant ter filter 6 B1 - Camshaft speed temperature...
Page 46 1 B13 - Crankskaft speed 44 | General Information | MS15041/03E 2018-08...
Page 47 1 B44.3 - Turbocharger speed 4 B89 - LAMBDA (Bosch) 7 B88.2 - LAMBDA NOx (Con- (high pressure) 5 B7 - Lube oil temperature ti) B side 2 B44.1 - Turbocharger speed 6 B91.3 - Exhaust pressure 8 B44.2 - Turbocharger speed (low pressure) A side LAMDA (low pressure) B side...
Page 48 Injectors A1 Injector Y39A1 A5 Injector Y39A5 B3 Injector Y39B3 A2 Injector Y39A2 A6 Injector Y39A6 B4 Injector Y39B4 A3 Injector Y39A3 B1 Injector Y39B1 B5 Injector Y39B5 A4 Injector Y39A4 B2 Injector Y39B2 B6 Injector Y39B6 The injectors are numbered in ascending order and located below the cylinder head covers. Injector replace- ment and necessary activities (→...
Page 49: Overview Of Sensors, Actuators And Injectors - 16V4000Cx5
3.6 Overview of sensors, actuators and injectors – 16V4000Cx5 1 B10.2 - Charge-air pressure, 2 B16 - Coolant pressure 12 Y39 - Injector (B1-B8) B side MS15041/03E 2018-08 | General Information | 47...
Page 50 1 B5.3 - Lube oil pressure be- 8 A19 - Electronic engine 15 F34.2 - Fuel pressure before fore filter identification label (EIL) filter 2 B5.1 - Lube oil pressure af- 9 B9 - Charge air temperature 16 B33 - Fuel temperature ter filter 10 F57 - Charge-air coolant (Rail)
Page 51 1 B50 - Crankcase pressure 4 B1 - Camshaft speed 7 B6 - Coolant temperature 2 Y44 - Fan control valve 5 B43 - Charge-air coolant 3 B48 - Fuel pressure (Rail) pressure 6 B26 - Charge-air coolant temperature 1 B13 - Crankskaft speed MS15041/03E 2018-08 | General Information | 49...
Page 52 1 B44.3 - Turbocharger speed 4 B89 - LAMBDA (Bosch) 7 B88.2 - LAMBDA NOx (Con- (high pressure) 5 B4 - Exhaust temperature ti) B side 2 B44.1 - Turbocharger speed 6 B91.3 - Exhaust pressure 8 B44.2 - Turbocharger speed (low pressure) A side LAMDA (low pressure) B side...
Page 53 Injectors A1 Injector Y39A1 A7 Injector Y39A7 B5 Injector Y39B5 A2 Injector Y39A2 A8 Injector Y39A8 B6 Injector Y39B6 A3 Injector Y39A3 B1 Injector Y39B1 B7 Injector Y39B7 A4 Injector Y39A4 B2 Injector Y39B2 B8 Injector Y39B8 A5 Injector Y39A5 B3 Injector Y39B3 A6 Injector Y39A6 B4 Injector Y39B4...
Page 54: Technical Data
4 Technical Data 4.1 Product data 12V4000C15 12V4000C25 12V4000C35 Legend 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 55 2. General conditions (for maximum power) Identifier Intake depression (new filter) mbar Intake depression, max. (total pressure referenced to mbar atmosphere) Exhaust gas overpressure (total pressure referenced mbar to atmosphere) Exhaust gas overpressure, max. mbar Maximum admissible deviation between intake air °C temperature measured at the engine and ambient air temperature (measured in the shade at a distance of...
Page 56 8. Coolant system (low-temperature circuit) Identifier Coolant temperature before intercooler (at engine °C connection: inlet from cooling equipment) Coolant antifreeze content, max. Thermostat: Starts to open °C Thermostat: Fully open °C 10. Lube oil system Identifier Lube-oil operating temperature before engine, to °C Lube-oil temperature before engine, limit 1 °C...
Page 57 22. Acoustics Identifier Exhaust noise, unsilenced – BL (free-field sound pres- dB(A) sure level Lp, 1 m distance, ISO 6798, +3dB(A) toler- ance) Exhaust noise, unsilenced – BL (sound power level dB(A) LW, ISO 6798, +3dB(A) tolerance) MS15041/03E 2018-08 | Technical Data | 55...
Page 58: Product Data 12V4000C55 12V4000C65 12V4000C65
4.2 Product data 12V4000C55 12V4000C65 12V4000C65 Legend 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 59 2. General conditions (for maximum power) Identifier Intake depression (new filter) (total pressure refer- mbar enced to atmosphere) Intake depression, max. (total pressure referenced to mbar atmosphere) Exhaust gas overpressure (total pressure referenced mbar to atmosphere) Exhaust gas overpressure, max. (total pressure refer- mbar enced to atmosphere) Maximum admissible deviation between intake air...
Page 60 8. Coolant system (low-temperature circuit) Identifier Coolant temperature before intercooler (at engine °C connection: inlet from cooling equipment) Coolant antifreeze content, max. Thermostat: Starts to open °C Thermostat: Fully open °C 10. Lube oil system Identifier Lube-oil operating temperature before engine, to °C Lube-oil temperature before engine, limit 1 °C...
Page 61 19. Masses / main dimensions Identifier Engine mass, dry (standard scope of supply) 8320 ** 8320 ** 8320 ** 22. Acoustics Identifier Exhaust noise, unsilenced – BL (free-field sound pres- dB(A) sure level Lp, 1m distance, ISO 6798, +3dB(A) toler- ance) Exhaust noise, unsilenced –...
Page 62: Product Data 16V4000C45 16V4000C45 16V4000C55 16V4000C55 16V4000C65
4.3 Product data 16V4000C45 16V4000C45 16V4000C55 16V4000C55 16V4000C65 Legend 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 63 1. Power-related data Identifier Rated engine speed 1800 1900 1800 1900 1800 Effective power (w/o fan) 2000 2000 2240 2240 2400 (Fuel stop power ISO 3046) 2. General conditions (for maximum power) Identifier Intake depression (new filter) A mbar Intake depression, max. (to- mbar tal pressure referenced to at- mosphere)
Page 64 5. Air / exhaust gas Identifier Charge-air pressure before bar abs cylinder 7. Coolant system (high-temperature circuit) Identifier Coolant temperature at am- °C bient temperature up to 40 °C (at engine connection: outlet to cooling system) Coolant temperature after °C engine, limit 1 Coolant temperature after °C...
Page 65 11. Fuel system Identifier Fuel pressure at engine inlet -0.3 -0.3 -0.3 -0.3 -0.3 connection, min. (when en- gine is starting) Fuel pressure at engine inlet -0.5 -0.5 -0.5 -0.5 -0.5 connection, min. (when en- gine is running) Fuel pressure at engine inlet connection, max.
Page 66: Firing Order
4.4 Firing order Firing order Number of cylinders Firing order A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 64 | Technical Data | MS15041/03E 2018-08...
Page 67: Main Engine Dimensions - 12V4000Cx5
4.5 Main engine dimensions ‒ 12V4000Cx5 Main engine dimensions Item Dimensions Length (A) approx. 2878 mm Width (B) approx. 1685.5 mm Height (C) approx. 1992 mm MS15041/03E 2018-08 | Technical Data | 65...
Page 68: Main Engine Dimensions - 16V4000Cx5
4.6 Main engine dimensions ‒ 16V4000Cx5 Main engine dimensions Item Dimensions Length (A) approx. 3348 mm Width (B) approx. 1685.5 mm Height (C) approx. 1992 mm 66 | Technical Data | MS15041/03E 2018-08...
Page 69: 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/..) are available. Putting the engine into operation after extended out-of-service periods (>3 months) Item...
Page 70: Putting The Engine Into Operation After Scheduled Out-Of-Service Period
5.2 Putting the engine into operation after scheduled out-of- service period Preconditions ☑ Engine is stopped and starting disabled. WARNING In case of out-of-service periods of more than one week: Possible corrosion of components carrying air or exhaust gas due to weather conditions, e.g. rain or snow. Risk of injury by flying debris when putting the engine into operation! •...
Page 71: Re-Starting The Engine Following An Automatic Safety Shutdown
5.3 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 72: Operational Checks
5.4 Operational checks 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 73: Emission Label - Check
5.5 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 74: Engine - Starting In Manual Mode
5.6 Engine – Starting in manual mode Preconditions ☑ Engine is not under load. ☑ 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 75: Engine - Stopping In Manual Mode
5.7 Engine – Stopping in manual mode Preconditions ☑ Engine is not under load. ☑ Engine is running in manual mode. NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress- Overheating of and, therefore, damage to components is possible! •...
Page 76: After Stopping The Engine - Putting The Engine Out Of Operation
5.8 After stopping the engine – Putting the engine out of operation Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. NOTICE Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at temperatures below 0 °C.
Page 77: Plant - Cleaning
5.9 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 78: Maintenance
6 Maintenance 6.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte- nance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
Page 79 Task Maintenance tasks W1675 Replace fuel prefilter or its filter element. (→ Page 70) (→ Page 263) (→ Page 275) W1689 Measure valve protrusion. (→ Page 166) W1716 Clean battery-charging generator. (→ Page 238) W1817 Check coupling rods of EGR flaps for clearance. (→...
Page 80: Troubleshooting
7 Troubleshooting 7.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery/UltraCaps low or u Charge or replace (→ manufacturer's documentation) defective u Check cable connections for secure seating (→ manufacturer's Cable connections faulty documentation) Starter: plant starter controller or 1.
Page 81 2. Contact Service PTOs Charge air temperature too high Cause Corrective action u Check (→ MTU test kit) Incorrect coolant concentration u Contact Service Intercooler clogged u Contact Service EGR cooler clogged u Check fans and air supply/exhaust ducts...
Page 82 Charge-air pressure too low Cause Corrective action u Check, clean as necessary (→ manufacturer's documentation) Air filter clogged u Contact Service Intercooler clogged u Contact Service Exhaust turbocharger defective Coolant discharge at intercooler Cause Corrective action u Contact Service Intercooler: Leaking, major coolant discharge Blue exhaust gas Cause...
Page 83: Fault Messages
7.2 Fault messages Possible engine reactions to yellow alarm: Warning, power limitation / reduction, speed limitation, engine stop Possible engine reactions to red alarm: Engine stop, power limitation / reduction, speed limitation, warning 3 – HI T-Fuel Cause Corrective action The fuel temperature at sensor 1.
Page 84: Engine
10 – SS T-Coolant Intercooler Cause Corrective action The intercooler coolant 1. Reduce power. temperature measured at sensor 2. Check whether alarm 23 is pending. B26 has violated limit value 2. 3. Check cooler (plant side) for contamination. Coolant temperature in 4.
Page 85 25 – HI P-Diff-Lube Oil Cause Corrective action The differential oil pressure at 1. Replace engine oil filter. sensors B5.1 and B5.3 has 2. Contact Service. violated limit value 1. The differential oil pressure is too high. 26 – SS P-Diff-Lube Oil Cause Corrective action The differential oil pressure at...
Page 86 32 – SS ETC1 Overspeed Cause Corrective action The speed of the A side LP 1. Reduce power. turbocharger at sensor B44.1 has 2. Contact Service. violated limit value 2. The exhaust turbocharger speed is too high. Cause: Fault or malfunction of another exhaust turbocharger.
Page 87 44 – LO Coolant Level Intercooler Cause Corrective action Coolant level in LT circuit at 1. Check charge-air coolant level (→ Page 227). switch F57 is too low. 2. Check relief bore of charge-air coolant pump (→ Page 236). 3. Visually check coolant circuit for leaks. 4.
Page 88 64 – SS P-Crank Case Cause Corrective action The crankcase pressure at sensor 1. Stop engine. B50 has violated upper limit value 2. Contact Service. 2. The crankcase pressure is too high. 65 – LO P-Fuel Cause Corrective action The fuel pressure at sensor B34.1 1.
Page 89 83 – LO P-Fuel (Common Rail) Cause Corrective action The HP fuel pressure at sensor u Contact Service. B48 has violated the limit value. Fuel pressure is too low. 89 – SS Engine Speed too Low Cause Corrective action The engine speed has violated the 1.
Page 90 94 – LO T-Preheat Cause Corrective action Engine coolant temperature has u Contact Service. not reached the specified limit value 1. Preheating is not functioning. 95 – AL Prelubrication Fault Cause Corrective action The oil pressure at sensor B5.1 1. Check engine wiring (→ Page 251). has violated the specified value.
Page 91 3. Contact Service. 186 – AL CAN1 Bus Off Cause Corrective action CAN bus 1 for MTU Automation 1. Check plug connectors for engine governor (→ Page 256). (e.g. ECU/MAU/SAM) disrupted 2. Contact Service. or faulty. MS15041/03E 2018-08 | Troubleshooting | 89...
Page 92 188 – AL CAN2 Bus Off Cause Corrective action CAN bus 2 to plant-side 1. Check connection between plant automation system and MTU automation (e.g. Murphy Display) automation system. disrupted or faulty. 2. Contact Service. 201 – SD T-Coolant...
Page 93 206 – SD T-Exhaust A Cause Corrective action The signal from the exhaust gas 1. Check engine wiring (→ Page 251). temperature sensor (B4) in the A 2. Contact Service. side exhaust pipe is faulty or missing. 208 – SD P-Charge Air Cause Corrective action The signal from the charge-air...
Page 94 216 – SD T-Lube Oil Cause Corrective action The signal from he lube oil 1. Check engine wiring (→ Page 251). temperature sensor (B7) is faulty 2. Contact Service. or missing. 220 – SD Level Coolant Water Cause Corrective action The signal from the coolant level 1.
Page 95 229 – AL Stop Camshaft Sensor Defect Cause Corrective action Emergency engine stop following u Contact Service. failure of the crankshaft sensor (B13) and camshaft sensor (B1). 230 – SD Crankshaft Speed Cause Corrective action The signal from the crankshaft 1.
Page 96 245 – SD ECU Power Supply Voltage Cause Corrective action The signal from the internal 1. Check engine wiring (→ Page 251). voltage sensor in the ECU is faulty 2. Contact Service. or missing. 266 – SD Speed Demand Cause Corrective action Signal of analog speed setting 1.
Page 97 325 – AL Wiring Cylinder A5 Cause Corrective action Short circuit fault in the injector 1. Check wiring of relevant injector (→ Page 251). wiring for cylinder A5 or injector 2. Replace injector (→ Page 176). faulty. 3. Contact Service. 326 –...
Page 98 332 – AL Wiring Cylinder B2 Cause Corrective action Short circuit fault in the injector 1. Check wiring of relevant injector (→ Page 251). wiring for cylinder B2 or injector 2. Replace injector (→ Page 176). faulty. 3. Contact Service. 333 –...
Page 99 339 – AL Wiring Cylinder B9 Cause Corrective action Short circuit fault in injector 1. Check wiring of relevant injector (→ Page 251). wiring cylinder B9 or injector 2. Replace injector (→ Page 176). faulty. 3. Contact Service. 340 – AL Wiring Cylinder B10 Cause Corrective action Short circuit fault in the injector...
Page 100 347 – AL Open Load Cylinder A7 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of relevant injector (→ Page 251). for cylinder A7. 2. Contact Service. 348 – AL Open Load Cylinder A8 Cause Corrective action Disruption fault in injector wiring 1.
Page 101 355 – AL Open Load Cylinder B5 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of relevant injector (→ Page 251). to cylinder B5. 2. Contact Service. 356 – AL Open Load Cylinder B6 Cause Corrective action Disruption fault in injector wiring 1.
Page 102 363 – AL Stop Power Stage Cause Corrective action The output stage voltage to 1. Check power supply (plant). control the injectors is too low. 2. Contact Service. Engine stop 365 – AL Stop MV-Wiring Ground Cause Corrective action Short circuit of injector positive 1.
Page 103 401 – AL Open Load Digital Input 2 Cause Corrective action Open load detected at digital 1. Check cabling (→ Page 251). input 2 of the ECU. 2. Contact Service. 402 – AL Open Load Digital Input 3 Cause Corrective action Open load detected at digital 1.
Page 104 410 – LO U-PDU Cause Corrective action The ECU voltage to control the 1. Check power supply (plant). injectors has violated lower limit 2. Check cabling (→ Page 251). value 1. 3. Contact Service. 411 – LOLO U-PDU Cause Corrective action The ECU voltage to control the 1.
Page 105 416 – SS P-Coolant Intercooler Cause Corrective action The charge-air coolant pressure in 1. Check relief bore of charge-air coolant pump (→ Page 236). the intercooler at sensor B43 has 2. Check intercooler for coolant discharge (→ Page 191). violated limit value 2. Charge-air 3.
Page 106 454 – SS Power Reduction Active Cause Corrective action Power reduction activated. A main 1. Check for additional messages. alarm activating power reduction 2. Contact Service. has been tripped. 470 – SD T-ECU Cause Corrective action The signal from the temperature 1.
Page 107 549 – AL Power Cut-Off detected Cause Corrective action ECU operating voltage was 1. If the voltage supply was not disconnected manually, check engine switched off while the engine was wiring (→ Page 251). running. Only disconnect the 2. Contact Service. voltage supply when the engine is stationary.
Page 108 608 – AL Wiring PWM_CM6 Cause Corrective action Open circuit or short circuit in 1. Check engine wiring (→ Page 251). wiring to fan oil priming pump M2. 2. Contact Service. 609 – AL Wiring PWM_CM7 Cause Corrective action Wire break or short circuit in the 1.
Page 109 627 – AL Wiring PWM_CM9 Cause Corrective action Disruption or short circuit in 1. Check engine wiring (→ Page 251). wiring to servomotor of dispenser 2. Contact Service. flap M55. 628 – AL Wiring PWM_CM10 Cause Corrective action Disruption or short circuit in 1.
Page 110 647 – SD P-Exhaust Lambda Cause Corrective action The signal from the exhaust gas 1. Check engine wiring (→ Page 251). sensor (B91.3) is faulty or 2. Contact Service. missing. 648 – SD P-Charge Air B Cause Corrective action The signal from the charge-air 1.
Page 111 833 – AL Emission Warning Cause Corrective action Emission fault summary alarm 1. Check for additional messages. 2. Contact Service. 834 – AL Gas Path Warning Cause Corrective action Emission fault summary alarm 1. Check for additional messages. 2. Contact Service. 835 –...
Page 112 877 – AL Bypass FlpA Wear Limit3 Cause Corrective action Fast reference run of bypass flap 1. Check state of charge of batteries (plant side). (M52) faulty (executed after every 2. Check operation of the bypass flap (→ Page 195). ECU restart).
Page 113 956 – AL p5 ctrlvar limit min active Cause Corrective action The charge-air pressure regulator 1. Check operation of the bypass flap (→ Page 195). attempts to adjust its set value 2. Contact Service. but has reached its lower limit. The bypass flap (M52) is fully open.
Page 114 960 – AL NOx p5 min BOI max active Cause Corrective action Emission-related alarm. The 1. Check operation of the bypass flap (→ Page 195). charge-air pressure has reached 2. Contact Service. the minimum value defined in the performance map. The advanced start of injection has reached its maximum value.
Page 115 973 – AL Check Sum IIG Cause Corrective action The IIG value entered does not 1. Check the IIG input in DiaSys, repeat as necessary. match the defined input format. 2. Contact Service. 974 – AL CAN3 Bus Off Cause Corrective action The first engine CAN (CAN 3) for 1.
Page 116 985 – AL NOx ATO2 Communication Lost Cause Corrective action The ECU cannot detect the NOx 1. Check engine wiring (→ Page 251). sensor (B88.2) after LP 2. Check NOx sensor and replace as necessary (→ Page 257). turbocharger B side on the bus. 3.
Page 117 1034 – AL Inj. Drift Limit 1 Cyl. A3 Cause Corrective action The drift correction for u Schedule an injector replacement. energization (start and duration) of injector A3 has violated limit 1. The injector has soon reached its maximum drift limit. 1035 –...
Page 118 1039 – AL Inj. Drift Limit 1 Cyl. A8 Cause Corrective action The drift correction for u Schedule an injector replacement. energization (start and duration) of injector A8 has violated limit 1. The injector has soon reached its maximum drift limit. 1040 –...
Page 119 1044 – AL Inj. Drift Limit 1 Cyl. B3 Cause Corrective action The drift correction for u Schedule an injector replacement. energization (start and duration) of injector B3 has violated limit 1. The injector has soon reached its maximum drift limit. 1045 –...
Page 120 1049 – AL Inj. Drift Limit 1 Cyl. B8 Cause Corrective action The drift correction for u Schedule an injector replacement. energization (start and duration) of injector B8 has violated limit 1. The injector has soon reached its maximum drift limit. 1050 –...
Page 121 1054 – AL Inj. Drift Limit 2 Cyl. A3 Cause Corrective action The drift correction for u Replace injector (→ Page 176). energization (start and duration) of injector A3 has violated limit 2. The injector has reached its maximum drift limit. 1055 –...
Page 122 1059 – AL Inj. Drift Limit 2 Cyl. A8 Cause Corrective action The drift correction for u Replace injector (→ Page 176). energization (start and duration) of injector A8 has violated limit 2. The injector has reached its maximum drift limit. 1060 –...
Page 123 1064 – AL Inj. Drift Limit 2 Cyl. B3 Cause Corrective action The drift correction for u Replace injector (→ Page 176). energization (start and duration) of injector B3 has violated limit 2. The injector has reached its maximum drift limit. 1065 –...
Page 124 1069 – AL Inj. Drift Limit 2 Cyl. B8 Cause Corrective action The drift correction for u Replace injector (→ Page 176). energization (start and duration) of injector B8 has violated limit 2. The injector has reached its maximum drift limit. 1070 –...
Page 125 1103 – AL Flap BypassA Communication Lost Cause Corrective action The ECU can no longer detect the 1. Check engine wiring (→ Page 251). bypass flap (M52) on the bus. 2. Contact Service. 1104 – AL Act BypasA Temperature Warning Cause Corrective action The internal servomotor...
Page 126 1115 – AL Difference P0 P1 Intake Air L1 Cause Corrective action The differential pressure at sensor 1. Check air filter (plant side) for contamination. B90 and the ambient air pressure 2. Contact Service. sensor integrated in the ECU have violated limit value 1.
Page 127 1124 – AL Flap Dispenser Calibr Drive Err Cause Corrective action The ECU has detected a u Contact Service. calibration run error in the dispenser flap (M55). Cause: The learned rotation range (angle) during the calibration run was not plausible. The learned angle is not between a minimum and maximum permissible limit.
Page 128 1172 – AL Implausible NOx High Limit2 Cause Corrective action NOx emissions too high. The NOx u Contact Service. emissions from the engine have violated limit value 2 cumulatively. 1173 – AL Implausible NOx Low Limit2 Cause Corrective action u Contact Service. NOx emissions too low.
Page 129 1183 – AL Invalid Measurement Config Cause Corrective action Selected measuring point not u Contact Service. activated or configured incorrectly. 1186 – AL EGR FlpA Wear Limit2 Cause Corrective action Fast reference run of EGR shutoff 1. Check state of charge of batteries (plant side). flap (M53) faulty (executed after 2.
Page 130 1372 – AL Exhaust gas inclusion Cause Corrective action The pressure differential between u Contact Service. exhaust gas pressure after cylinder (P6) measured at sensor B98, and charge-air pressure (P5) measured at sensor B10.1, has violated the limit. A fault has occurred in the exhaust gas path.
Page 131 1380 – AL Act Byp A Ref-Drv EngStop Cause Corrective action This alarm is set in the fault 1. Check state of charge of batteries (plant side). memory if homing the bypass flap 2. Check plug connectors for engine governor (→ Page 256). (M52) was not successful when 3.
Page 132 1392 – AL Flap Byp A Wear Limit 1 Cause Corrective action The range of rotation on homing u Replace linkage rod at next scheduled maintenance interval the bypass flap (M52) has violated (→ Page 197). limit 1. The flap mechanism is beginning to wear.
Page 133 1404 – AL Flap Byp A linkage failure Cause Corrective action The range of rotation on homing 1. Check exhaust flap for damage (→ Page 192). the bypass flap (M52) has violated 2. Replace the linkage rod if it is damaged (→ Page 192). the limit.
Page 134 1416 – AL Flap Byp A restricted Limit 2 Cause Corrective action The range of rotation on homing 1. Check smooth operation of the exhaust flap mechanism. the bypass flap (M52) has violated 2. Contact Service. limit 2. Flap travel is restricted. 1418 –...
Page 135 1432 – AL Act Byp A Temperature Alert Cause Corrective action The internal electronics of the 1. Check for high temperatures in the vicinity of the servomotor, e.g. servomotor of the bypass flap resulting from faulty insulation, defective seals, signs of sooting (M52) signals that temperature is (→...
Page 136 1450 – AL ECU Comm Lost to Act Byp A Cause Corrective action The ECU is no longer able to 1. Check engine wiring (→ Page 251). detect the bypass flap (M52) on 2. Contact Service. the CAN bus. 1452 – AL ECU Comm Lost to Act Dispenser Cause Corrective action The ECU is no longer able to...
Page 137 1552 – AL LSU Stop Cal Delta Factor Cause Corrective action Calibration of lambda sensor 1. Replace lambda sensor (→ Page 259). failed. Sensor defective. 2. Contact Service. 1553 – AL Act Agr A Targetpos Blocked Cause Corrective action The servomotor of the EGR u Contact Service.
Page 138 5001 – AL HI T-EXU Device Cause Corrective action The temperature limit measured u Contact Service. at the device-internal temperature sensor of the EXU has been violated. The temperature of the EXU device is too high. 5002 – AL Sensordefect EXU Power Supply Cause Corrective action The signal from the EXU internal...
Page 139 3. Contact Service. monitoring. 5018 – AL CAN1 error passive Cause Corrective action CAN bus 1 for plant-side MTU u Contact Service. automation (e.g. MAU/SAM) faulty. Alarm 5019 follows if fault persists. 5019 – AL CAN1 bus off...
Page 140 5021 – AL CAN2 bus off Cause Corrective action CAN bus 2 to customer u Contact Service. automation (e.g. Murphy display) disrupted/failed. 5022 – AL CAN1 Node Lost Cause Corrective action u Contact Service. Connection to a node on CAN bus 1 lost.
Page 141 5028 – AL SD Crankshaft Speed Cause Corrective action The signal from the crankshaft 1. Check engine wiring (→ Page 251). speed sensor (B13) is faulty or 2. Contact Service. missing. 5029 – AL Synchronization Lost Cause Corrective action Unable to synchronize crankshaft 1.
Page 142 5202 – AL IAP Sensor Cyl A2 Defect Cause Corrective action The signal from the single u Contact Service. accumulator pressure sensor (B97.A2) in injector A2 is faulty or missing. 5203 – AL IAP Sensor Cyl A3 Defect Cause Corrective action The signal from the single u Contact Service.
Page 143 5208 – AL IAP Sensor Cyl A8 Defect Cause Corrective action The signal from the single u Contact Service. accumulator pressure sensor (B97.A8) in injector A8 is faulty or missing. 5209 – AL IAP Sensor Cyl A9 Defect Cause Corrective action The signal from the single u Contact Service.
Page 144 5214 – AL IAP Sensor Cyl B4 Defect Cause Corrective action The signal from the single u Contact Service. accumulator pressure sensor (B97.B4) in injector B4 is faulty or missing. 5215 – AL IAP Sensor Cyl B5 Defect Cause Corrective action The signal from the single u Contact Service.
Page 145 5220 – AL IAP Sensor Cyl B10 Defect Cause Corrective action The signal from the single u Contact Service. accumulator pressure sensor (B97.B10) in injector B10 is faulty or missing. 5221 – AL No Injection Detected CylA1 Cause Corrective action The pressure variation measured 1.
Page 146 5225 – AL No Injection Detected CylA5 Cause Corrective action The pressure variation measured 1. Check whether alarm 5205 is signaled. If so, contact Service. at sensor B97A5 and evaluated by 2. Replace injector (→ Page 176). the EXU indicates that despite 3.
Page 147 5230 – AL No Injection Detected CylA10 Cause Corrective action The pressure variation measured 1. Check whether alarm 5210 is signaled. If so, contact Service. at sensor B97A10 and evaluated 2. Replace injector (→ Page 176). by the EXU indicates that despite 3.
Page 148 5235 – AL No Injection Detected CylB5 Cause Corrective action The pressure variation measured 1. Check whether alarm 5215 is signaled. If so, contact Service. at sensor B97B5 and evaluated by 2. Replace injector (→ Page 176). the EXU indicates that despite 3.
Page 149 5240 – AL No Injection Detected CylB10 Cause Corrective action The pressure variation measured 1. Check whether alarm 5220 is signaled. If so, contact Service. at sensor B97B10 and evaluated 2. Replace injector (→ Page 176). by the EXU indicates that despite 3.
Page 150 5246 – AL Implausible BOI CylA6 Cause Corrective action The beginning of injection u Contact Service. measured by sensor B97A6 and evaluated by the EXU is outside the controllable tolerance. 5247 – AL Implausible BOI CylA7 Cause Corrective action The beginning of injection u Contact Service.
Page 151 5252 – AL Implausible BOI CylB2 Cause Corrective action The beginning of injection u Contact Service. measured by sensor B97B2 and evaluated by the EXU is outside the controllable tolerance. 5253 – AL Implausible BOI CylB3 Cause Corrective action The beginning of injection u Contact Service.
Page 152 5258 – AL Implausible BOI CylB8 Cause Corrective action The beginning of injection u Contact Service. measured by sensor B97B8 and evaluated by the EXU is outside the controllable tolerance. 5259 – AL Implausible BOI CylB9 Cause Corrective action The beginning of injection u Contact Service.
Page 153 5264 – AL Implausible EOI CylA4 Cause Corrective action The end of injection measured by u Contact Service. sensor B97A4 and evaluated by the EXU is outside the controllable tolerance. 5265 – AL Implausible EOI CylA5 Cause Corrective action The end of injection measured by u Contact Service.
Page 154 5270 – AL Implausible EOI CylA10 Cause Corrective action The end of injection measured by u Contact Service. sensor B97A10 and evaluated by the EXU is outside the controllable tolerance. 5271 – AL Implausible EOI CylB1 Cause Corrective action The end of injection measured by u Contact Service.
Page 155 5276 – AL Implausible EOI CylB6 Cause Corrective action The end of injection measured by u Contact Service. sensor B97B6 and evaluated by the EXU is outside the controllable tolerance. 5277 – AL Implausible EOI CylB7 Cause Corrective action The end of injection measured by u Contact Service.
Page 156: 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 F6787910 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 157: Engine - Barring With Starting System
8.1.2 Engine – Barring with 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 158: 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 159: Auxiliary Pto
8.2 Auxiliary PTO 8.2.1 Auxiliary PTO – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Assembly compound (Kluthe Hakuform 30-15) X00067260 Engine oil O-ring (→ Spare Parts Catalog) Screw (→ Spare Parts Catalog) NOTICE Contamination of components. Damage to component! •...
Page 160 Remove screws (5, 6) and take off retain- ers (3, 4). Remove screws (7) and washers (8). Remove auxiliary PTO (2) with O-ring (1). Install new auxiliary PTO (2) with new O- ring (1). Install screws (8) with washers (7). Install retainers (3, 4) with screws (5, 6).
Page 161: Cylinder Liner
8.3 Cylinder Liner 8.3.1 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 172). Remove injector (→...
Page 162 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 161). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...
Page 163: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination
8.3.2 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 164 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 165: Crankcase Breather
8.4 Crankcase Breather 8.4.1 Oil mist fine separator – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Engine oil Oil mist fine separator (→...
Page 166 Unscrew locknut (1) and remove together with washer (2). Remove filter cover (3), cover (4) and sealing ring (5). Remove threaded rod (6). Replace oil mist fine separator (7). Replace sealing ring (5) if necessary. Install sealing ring (5), cover (4) and filter cover (3).
Page 167: Valve Drive
8.5 Valve Drive 8.5.1 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 upper section (→ Page 172). Fill oil chambers of valve bridges with oil.
Page 168: Valve Protrusion - Measurement
8.5.2 Valve protrusion – Measurement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Depth gauge, 200 mm Y20000918 Preparatory steps Remove cylinder head cover upper section (→ Page 172). Remove injector (→...
Page 169 Loosen adjusting screw (1, 2) and take off valve bridges (4, 5). Do not remove rocker arm (3). Measure distance between valve stem end and cylinder head top at the injector bore with depth gauge (see figure). • Specified value for a new cylinder head: 93.8 mm.
Page 170: Valve Clearance - Check And Adjustment
8.5.3 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20098771 Valve adjusting gauge Y4349603 Allen key...
Page 171 Note: Pointer (1) in lower opening of flywheel hous- ing (arrow). Use barring device to turn crankshaft in en- gine direction of rotation until marking OT-A1 on the rear side of the flywheel and point- er (1) are aligned. Diagram for 12V engines – Two crankshaft positions Diagram for 16V engines –...
Page 172 Diagram for 20V engines – Two crankshaft positions Valve clearance at two crankshaft positions – Check Check TDC position of piston in cylinder A1: • If rocker arms on cylinder A1 are unloaded, the piston is in firing TDC. • If rocker arms on cylinder A1 are loaded, the piston is in overlap TDC. Check valve clearance with cold engine: •...
Page 173 Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2) to prevent it from turning. Name Size Type Lubricant Value/Standard Locknut M16x1.5 Tightening torque (Engine oil) 90 Nm +9 Nm hand tightening Locknut M16x1.5 Tightening torque (Engine oil) 95 Nm ±9 Nm ma-...
Page 174: Cylinder Head Cover - Removal And Installation
8.5.4 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Assembly compound (Kluthe Hakuform 30-15) X00067260 Gasket (→ Spare Parts Catalog) O-ring (→...
Page 175 Installing cylinder head cover Clean installation surface. Check gasket (1) for damage, replace as nec- essary. Coat gasket (1) with assembly compound. Place gasket (1) and cylinder head cover low- er section (2) on cylinder head. Install cylinder head cover lower section (2) with screws (4, 5) and washers (3, 6).
Page 176: Injection Pump / Hp Pump
8.6 Injection Pump / HP Pump 8.6.1 HP fuel pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. ☑ HP pump is installed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Fuel suction device F30378207...
Page 177 Preparatory steps Loosen nut (2) and remove oil line (1) from HP pump. HP pump – Filling Remove union (1). Note: Excess engine oil runs into gear box. Use fuel suction device to fill HP pump with 2 liters of clean engine oil. Screw in union (1) and use torque wrench to tighten to specified tightening torque.
Page 178: Injector
8.7 Injector 8.7.1 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 177). 176 | Injector | MS15041/03E 2018-08...
Page 179: Injector - Removal And Installation
• Seal off components with suitable covers. • Check components for special cleanliness prior to installation/assembly and clean if necessary. Label 1 DMC - Data Matrix Code 2 L'Orange part number 3 MTU part number 4 EMI-ID 5 Serial number 6 Date of manufacture Preparatory steps Close off fuel supply to engine.
Page 180 Removing injector Note: The cable connectors feature a latch, which is released by pulling the black connector housing backwards. Disconnect connectors on injector (arrowed). Unscrew union nuts (2, 5) and remove HP line (3) from rail (4) and cylinder head. Note: When the adapter is unscrewed, the stored volume of the injector is emptied.
Page 181 Install installation/removal jig (2) on cylinder head. Remove injector (1) and hold-down clamp with installation/removal jig (2). Remove installation/removal jig (2). Clean all mating and sealing surfaces. If carbon residue is present, clean sealing face on cylinder head and protective sleeve with milling cutter.
Page 182 Press in injector (1) and hold-down clamp with installation/removal jig (2). Remove the installation/removal jig. Coat screw head mating face on hold-down clamp (1) and screw head mating face and thread of screw (2) with engine oil. Insert screw (2) and tighten hand-tight. Note: Ensure immaculate cleanliness.
Page 183 Tighten screw on hold-down clamp (→ Step 9) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 100 Nm +10 Nm Tighten adapter (1) tighten to specified torque using a torque wrench. Name Size Type...
Page 184: Fuel System
8.8 Fuel System 8.8.1 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 185 Note: See figure (a). Unlock hand pump: Hold sleeve (2) firmly. Turn handle (1) counterclockwise until the sleeve can be pushed backwards (arrow). Note: See figure (b). Operate the pump with the handle (1) until bubble-free fuel escapes from the vent plug. Close vent plug.
Page 186 Note: See (a). Unlock hand pump: Hold sleeve (2) firmly. Turn handle (1) counterclockwise until the sleeve can be pushed backwards (arrow). Note: See (b). Operate the pump with the handle (1) until bubble-free fuel escapes from the vent plug. Close vent plug.
Page 187: Fuel Filter
8.9 Fuel Filter 8.9.1 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 188: Fuel Prefilter With Internal Electrical Priming
8.9.2 Fuel prefilter with internal electrical priming pump – Draining 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 189 8.9.3 Fuel prefilter with internal electrical priming pump – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) O-ring (→...
Page 190 Use collar wrench to remove clear cover (1) with spring (2) and discard the O-ring from the cover. Remove filter elements (3) by pulling them upwards. Install new O-ring (supplied with new filter el- ements.) in cover. Insert new filter elements (4) in filter housing. Use collar wrench to tighten clear cover (2) with spring (3).
Page 191 Venting when the whole filter chain is replaced (prefilter, pri- mary filter, secondary filter) Note: If only the primary and secondary filters are replaced, the pump of the prefilter can be used instead of the hand pump to vent the primary and secondary filters.
Page 192 8.9.4 Additional fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 193: Charge-Air Cooling
8.10 Charge-Air Cooling 8.10.1 Charge-air cooler – Leak check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
Page 194: Exhaust Gas Recirculation
8.11 Exhaust Gas Recirculation 8.11.1 Exhaust flaps overview ‒ 12V and 16V Exhaust flaps overview ‒ 12V 1 Dispenser cylinder flap 2 EGR shutoff flap 192 | Exhaust Gas Recirculation | MS15041/03E 2018-08...
Page 195 1 Bypass flap Exhaust flaps overview ‒ 16V 1 Dispenser cylinder flap 2 EGR shutoff flap MS15041/03E 2018-08 | Exhaust Gas Recirculation | 193...
Page 196 1 Bypass flap 194 | Exhaust Gas Recirculation | MS15041/03E 2018-08...
Page 197: Exhaust Flaps – Checking Coupling Rod
8.11.2 Exhaust flaps – Checking coupling rod clearance and function Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage applied. WARNING Actuation mechanism in the exhaust and intake area closes automatically. Risk of crushing hands! • To carry out the teach-in routine, keep clear of the safety zone of the actuation mechanism in the intake and exhaust area.
Page 198 Check operability and ease of movement of coupling rod (1) by moving it at the specified points (arrows) and make sure that there is no excessive play. Result: Replace coupling rod (1) if it is jamming, slug- gish or features excessive play (→ Page 197). 196 | Exhaust Gas Recirculation | MS15041/03E 2018-08...
Page 199 Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 Ratchet adapter F30027340 Assembly paste (Ultra-Therm MTU) 50547 Coupling rod (→ Spare Parts Catalog) Coupling rod (→ Spare Parts Catalog) Locknut (→ Spare Parts Catalog) Locking screw (→...
Page 200 Tighten lever (2) with locknut (1) on output shaft to the specified tightening torque. Name Size Type Lubricant Value/Standard Tightening torque (Assembly paste (Ul- 16 Nm ±2 Nm tra-Therm MTU)) Tighten washers and locknuts (3) to the specified tightening torque. Name Size Type Lubricant Value/Standard Tightening torque (Assembly paste (Ul- 16 Nm ±2 Nm...
Page 201 Screw Tightening torque (Assembly paste (Ul- 10 Nm ±1 Nm tra-Therm MTU)) Note: After every change to the exhaust gas recirculation mechanical system, the DiaSys® must be used to carry out an actuator test (learning run) (→ Dialog system E531920/..).
Page 202: Starting Equipment
8.12 Starting Equipment 8.12.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Starter – Condition check Check securing screws of starter and nut on cable connection for secure seating and tighten if required. Check cabling (→ Page 251). 200 | Starting Equipment | MS15041/03E 2018-08...
Page 203: Lube Oil System, Lube Oil Circuit
8.13 Lube Oil System, Lube Oil Circuit 8.13.1 Engine oil level – Check at sight glass Preconditions ☑ Engine is stopped and starting disabled. Engine oil level check at sight glass Make a preliminary visual check of oil lev- el (2) at the sight glass (1). A proper engine oil level check must always be carried out using the oil dipstick (→...
Page 204 8.13.2 Engine oil – Level check with oil dipstick Checking oil level prior to en- gine start – Variant A Remove oil dipstick from guide tube and wipe it clean. Insert dipstick into guide tube up to the stop, pull out after approx. 10 seconds. Check oil level on oil dipstick side marked “5 Min.
Page 205 Checking engine oil level after engine has stopped 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it. Insert dipstick into guide tube up to the stop, pull out after approx. 10 seconds. Check oil level on oil dipstick side marked “5 Min.
Page 206 8.13.3 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. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm...
Page 207 Oil change using semirotary hand pump: Extracting engine oil Provide a suitable container in which to collect the engine oil. Extract all engine oil from oil pan using the semirotary hand pump. Draining residual oil from equip- ment carrier (only with un- scheduled engine oil change) Provide a suitable container in which to col- lect the engine oil.
Page 208 8.13.4 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 5605892099/00 DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 209 Drain approx. 1 liter engine oil into a clean container. Close screw (1). Using the equipment and chemicals of the MTU test kit, examine oil for: • Dispersing capacity (spot test); • Water content; • Dilution by fuel. MS15041/03E 2018-08 | Lube Oil System, Lube Oil Circuit | 207...
Page 210: Oil Filtration / Cooling
8.14 Oil Filtration / Cooling 8.14.1 Engine oil filter – Replacement Preconditions ☑ Run engine to reach operating temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) Sealing ring (→...
Page 211 Remove engine oil filter using the filter wrench. Clean sealing surface on connecting piece. Note: Only install engine oil filter with an integrated safety valve. Check condition of the new oil filter sealing ring and coat it with engine oil. Screw the engine oil filter on and tighten by hand.
Page 212 8.14.2 Oil indicator filter – Cleaning and check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner (Snow-White 11-0) X00054118 Cleaner (Hakupur 50/136) X00056700 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
Page 213 Cleaning strainer Shake coarse contamination out of strainer (6). Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136). Note: Do not damage the fabric of the strainer. Use a soft brush to remove stubborn deposits from strainer as necessary. Blow out strainer (6) with compressed air from outside to inside.
Page 214 Checking strainer Item Findings Task Strainer Metallic residues • Clean • Monitor engine operation • Check strainer daily • Contact Service. Strainer Damaged Replace Square section ring Damaged Replace Spring Damaged Replace O-ring Damaged Replace Installing strainer Coat square section ring on basket strainer (5) with engine oil and install basket strainer (5). Coat O-ring (3) with engine and install in filter housing.
Page 215: Centrifugal Oil Filter – Cleaning And Filter
8.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Cold cleaner (Hakutex 60) X00070585...
Page 216 Centrifugal oil filter, cleaning and filter-sleeve replacement on 12V engines Release screw (1) and remove. Remove clamp (3) and take off hood (2). Carefully remove rotor assembly (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7). Take off rotor cap (8).
Page 217 Centrifugal oil filter, cleaning and filter-sleeve replacement on 16V engines Remove clamp (17). Release cover screw (2) and remove cov- er (1). Carefully lift rotor (14), allow oil to drain and remove from housing. Holding the rotor (14) firmly, release rotor cover nut (3).
Page 218: Coolant Circuit, General, High-Temperature
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 219 Checking engine coolant level at sight glass Check coolant level (coolant level must be between “min.” and “max.” mark). Top up coolant if necessary (→ Page 221). MS15041/03E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 217...
Page 220 8.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 219). Fill with engine coolant (→ Page 221). 218 | Coolant Circuit, General, High-Temperature Circuit | MS15041/03E 2018-08...
Page 221 8.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench 10–60 Nm F30452769 WARNING Coolant is hot and highly pressurized. Risk of injury! Risk of scalding! •...
Page 222 Drain remaining engine coolant at EGR cool- er, A and B side (arrow). Final steps Tighten all open drain valves to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Spindle 11A/F Tightening torque 12 Nm Fit cover on filler neck and close it. 220 | Coolant Circuit, General, High-Temperature Circuit | MS15041/03E 2018-08...
Page 223 8.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench 10-60 Nm F30452769 Engine coolant WARNING Coolant is hot and highly pressurized.
Page 224 Filling with engine coolant using pump Connect appropriate pump with hose to drain valve (1). Open vent points on EGR cooler (1, 8), dis- tributors (2, 5), exhaust turbochargers (3, 4, 7) and oil heat exchanger (6). Open drain valve and pump coolant into en- gine at 0.5 bar minimum.
Page 225 Alternatively: Filling with cool- ant through filler neck Open vent points on EGR cooler (1, 8), dis- tributors (2, 5), exhaust turbochargers (3, 4, 7) and oil heat exchanger (6). Fill engine coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant.
Page 226 8.15.5 Engine coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
Page 227: Engine Coolant – Sample Extraction And
11 A/F Tightening torque 12 Nm Using the equipment and chemicals of the MTU test kit, examine engine coolant for: • Concentration of engine coolant additives • pH value Engine coolant change intervals (→ MTU Fluids and Lubricants Specifications (A001061/..)).
Page 228: Coolant Expansion Tank Valve Cover
8.15.7 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 229: 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 230 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 233). 228 | Low-Temperature Circuit | MS15041/03E 2018-08...
Page 231 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 230). Fill with charge-air coolant (→ Page 233). MS15041/03E 2018-08 | Low-Temperature Circuit | 229...
Page 232 8.16.3 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench 10–60 Nm...
Page 233 Drain remaining charge-air coolant at charge- air cooler (high pressure) (arrowed). Drain remaining charge-air coolant at charge- air cooler (low pressure) A side (arrowed). Drain remaining charge-air coolant at charge- air cooler (low pressure) B side (arrowed). MS15041/03E 2018-08 | Low-Temperature Circuit | 231...
Page 234 Note: • The procedure is only described for one exhaust flap, but also applies to the re- maining exhaust flaps. Exhaust flap over- view (→ Page 192). • Collect emerging engine coolant in a suita- ble container. Loosen the union nut (4) of the lower coolant line (3).
Page 235 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. Torque wrench 10-60 Nm F30452769 Charge-air coolant WARNING Coolant is hot and highly pressurized.
Page 236 Filling with charge-air coolant through filler neck Open vent points at intercooler (high pres- sure) (4), intercooler (low pressure) (1, 3) and distributor (2, ). Fill in charge-air coolant at expansion tank via filler neck until coolant level at top edge of filler neck remains constant.
Page 237 Open vent points at intercooler (high pres- sure) (4), intercooler (low pressure) (1, 3) and distributor (2, ). Open drain valve and pump charge-air cool- ant into engine at 0.5 bar minimum. Fill expansion tank until overflow edge is reached. Tighten drain valve to specified torque using a torque wrench.
Page 238 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 High level of engine noise when the engine is running.
Page 239: 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 240: Battery-Charging Generator
8.18 Battery-Charging Generator 8.18.1 Battery-charging generator – Check Preconditions ☑ Engine is stopped and starting disabled. 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 241: Battery-Charging Generator Drive – Drive Belt
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. Drive belt (→ Spare Parts Catalog) WARNING Spring/circlip/tensioning roller preload. Risk of injury! •...
Page 242: Replacement
Hold measuring tip of belt tension tester over belt drive. Tap drive belt (arrow) with a suita- ble tool. Hold belt tension tester over belt drive until the measured value is indicated. Initial assembly at MTU Initial operation with fan Re-tensioning None 60 Hz ±1 Hz 52 Hz ±1 Hz...
Page 243 Hold measuring tip of belt tension tester over belt drive. Tap drive belt (arrow) with a suita- ble tool. Hold belt tension tester over belt drive until the measured value is indicated. Initial assembly at MTU Initial operation with fan Re-tensioning 36 Hz ±5 Hz 49 Hz ±2 Hz...
Page 244 8.19.2 Fan drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Preparatory steps Remove protective cover. Remove fan. Replacing drive belt Release screws (2).
Page 245: Fan Drive – Drive Belt Tension Check
8.19.3 Fan drive – Drive belt tension check / adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Optibelt TT belt tension tester Y4345711 Torque wrench, 60–320 Nm F30452768 Preparatory steps Remove protective cover.
Page 246 Adjusting drive belt tension Loosen hex nuts (3). Tension belt (1) by turning the tie rod (2) until the required frequency (→ Table 3) is at- tained. Turn crankshaft by minimum two rotations. Tension belt (1) by turning the tie rod (2) until the required frequency (→...
Page 247: Fan Drive – Drive Belt Replacement
8.19.4 Fan 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 Drive belt (→ Spare Parts Catalog) Preparatory steps Remove protective cover. Remove fan.
Page 248 Turn tensioning lever (1) inwards. Install tie rod (4) with swivel heads (3, 5) and hex nuts (2). Adjust fan height (→ Page 246). Adjust belt tension (→ Page 240). Tighten hex nuts (2) with torque wrench to specified tightening torque. Name Size Type...
Page 249: Engine Mounting / Support
8.20 Engine Mounting / Support 8.20.1 Engine mounting – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 300–800 Nm F30047798 Ratchet F30450902 Engine oil NOTICE Contamination of engine mounts made of natural rubber with fuel or oil. Engine mounts swell.
Page 250 Information on screws to connect engine mounting ( 6 x Ø21 or 8 x M22) to vehicle frame of vehicle manu- facturer, system manufacturer or OEM must be obtained on the basis of the specific requirements. These screws must also be checked for firm seating. 248 | Engine Mounting / Support | MS15041/03E 2018-08...
Page 251: Engine Mounting – Resilient Mount Check
8.20.2 Engine mounting – Resilient mount check Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine filled with coolant and engine oil. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y20098771 Calipers Y20001743 Box wrench F30379609 Torque wrench 300-800 Nm F30047798...
Page 252 Engine mounts – Checking buf- fer clearance Check dimension (A) with feeler gage on measuring groove (arrowed). Adjust buffer clearance if dimension (A) is not 4.0 mm +0.5 mm. Engine mounts – Adjusting buf- fer clearance Take off protective cap (1). Undo nut (3).
Page 253: Wiring (General) For Engine/Gearbox/Unit
8.21 Wiring (General) for Engine/Gearbox/Unit 8.21.1 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 254: Accessories For (Electronic) Engine
8.22 Accessories for (Electronic) Engine Governor / Control System 8.22.1 Resetting CDC parameter and entering IIG with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Note: The engine will lose its emissions certification of the drift correction parameters (CDC) if not reset. Parameters for drift correction (CDC) –...
Page 255: Governor / Control System
8.22.2 Actuators – Visual inspection and test Preconditions ☑ Engine is stopped and starting disabled. WARNING Actuation mechanism in the exhaust and intake area closes automatically. Risk of crushing hands! • To carry out the teach-in routine, keep clear of the safety zone of the actuation mechanism in the intake and exhaust area.
Page 256 Item Findings Measure Connector (1) Damaged Replace actuator. Actuator cable connection (2) Damaged Replace actuator. Protective cap not correctly Mount protective cap correctly. mounted. Actuator general condition Heavily contaminated by black ex- Replace actuator. haust. Checking actuators with DiaSys® Note: For installation position of exhaust flaps, refer to overview (→...
Page 257: Engine Governor And Connector – Cleaning
8.22.3 Engine governor and connector – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! •...
Page 258: Engine Governor Plug Connections – Check
8.22.4 Engine governor plug connections – Check Preconditions ☑ Engine stopped and starting disabled. ☑ Electronic engine management system is de-energized. NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! • Carry out check of plug connection only with test connectors. Checking plug connections at engine governor Check all plug connections for secure seating.
Page 259: Nox Sensor – Replacement
8.22.5 NOx sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Power supply to electronic engine management system is switched off. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 10–60 Nm F30452769 Ratchet bit...
Page 260 Removing NOx sensor Note: Observe arrangement and position of sensor (→ Page 41). Disconnect and remove male connector (2) from control unit (1). Unscrew control unit (1) at the eyelets. Remove sensor (3). Installing NOx sensor Note: Note the following: •...
Page 261: Lambda Sensor – Replacement
8.22.6 Lambda sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Power supply to electronic engine management system is switched off. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Assembly compound (Molykote P 37)
Page 262 Removing Lambda sensor Observe the following general information: • Layout and position of sensor (→ Page 41). Unplug and remove male connector (1). Remove sensor (2). Installing Lambda sensor Note: When the sensor was subjected to shock or impact load, it is deemed to be defective and may not be used.
Page 263: Manufacturer's Documentation
9 Manufacturer's Documentation Prefilter Installation, Operation ................................Prefilter Installation Instructions ................................MS15041/03E 2018-08 | Manufacturer's Documentation | 261...
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Page 277 Collar Wrench WIF Plug (not shown) Electric Heaters (optional) WIF (optional) MTU America 39525 MacKenzie Drive, Novi, MI 48377 Customer support: 248-560-8200 F1862MTU REV 9 MS15041/03E 2018-08 | Manufacturer's Documentation | 275...
Page 278 Industrial Pro Installation Instructions “SEEING IS BELIEVING” ® • See when NOT to change the fuel filter. • See the condition of the fuel. Seeing what collects on the filter media or what’s happening inside the clear cover can help diagnose many fuel and mechanical conditions. •...
Page 279 Industrial Pro Installation Instructions Fuel Processor Installation Installation Steps This system must be installed between the fuel tank and 1. With the engine shut down and at ambient tempera- the transfer fuel pump on the suction side of the fuel sys- ture, close the fuel shutoff valve (if equipped) and tem.
Page 280 Industrial Pro Installation Instructions 5. Securely mount the Industrial Pro using twelve bolts . If the fuel hoses are made up to length on the (3/8"-24UNF or M10). (See Figure 1) job, be sure that the inner liner of the fuel hose is not cut by the fitting, creating potential check valve effects.
Page 281 Industrial Pro Installation Instructions Installing a WIF (Water In Fuel) Sensor With Optional Indicator (LED) E WARNING: Fuels are combusible. 5. Connect the XF70 plug of the WIF sensor harness (Figure 4) (5) to the XF70 connector on the engine and •...
Page 282 Industrial Pro Installation Instructions Priming Pump Electrical Specifications Supply Voltage: 24V Maximum Current 6A@24V Recommended Fuse: 10 Amp A (+) RED WIRE 24VDC B (-) BLACK WIRE DEUTSCH CONNECTOR #DT04-2P FUEL IN M12 X 1.5-6H THD. FUEL OUT M12 X 1.5-6H THD. Figure 5 - Priming Pump Electrical Connections 280 | Manufacturer's Documentation | MS15041/03E 2018-08...
Page 283 Industrial Pro Installation Instructions Primer Pump Service Assembly E WARNING: Fuels are combusible. 1. Install the new primer pump with fuel flow arrow aimed • RISK OF FIRE OR EXPLOSION: towards fuel outlet. (See Figure 7) • Avoid open flames, electrical sparks or igni- tion sources •...
Page 284 Industrial Pro Installation Instructions Installing an Optional Electric Heater E WARNING: Fuels are combusible. Note: When wiring the electric preheater, use a fuse NOT a circuit breaker. • RISK OF FIRE OR EXPLOSION: Industrial Pro 25 A • Avoid open flames, electrical sparks or igni- Fuse* tion sources 30/51...
Page 285 Industrial Pro Installation Instructions Filter Change Procedure E WARNING: Fuels are combusible. • RISK OF FIRE OR EXPLOSION: • Avoid open flames, electrical sparks or igni- tion sources Keyway Note: Do not smoke. Change the filter only when the fuel level reaches and remains at the top of the black band on the filter.
Page 286 Industrial Pro Installation Instructions Draining Contaminants Torque Values 1. Turn off the engine and open the vent cap. Application Torque 2. Place a suitable container under the drain valve at the ft-lb base of the Industrial Pro and open the drain valve. WIF Probe to Housing 3.
Page 287 Industrial Pro Installation Instructions Dimensions 6 . 0 0 1 5 2 . 4 R E C O M M E N D E D 4 . 2 0 M IN . S E R V IR E H E IG H T 5 .
Page 288 286 | Manufacturer's Documentation | MS15041/03E 2018-08...
Page 289 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 290 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 291 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 292: 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 293: Appendix B
11 Appendix B 11.1 Special Tools Optibelt TT belt tension tester Part No.: Y4345711 Qty.: Used in: 8.19.1 Fan drive – Drive belt tension check / adjustment (→ Page 240) Qty.: Used in: 8.19.3 Fan drive – Drive belt tension check / adjustment (→...
Page 294 Barring tool Part No.: F6555766 Qty.: Used in: 8.3.1 Cylinder liner – Endoscopic examination (→ Page 159) Box wrench Part No.: F30379609 Qty.: Used in: 8.20.2 Engine mounting – Resilient mount check (→ Page 249) Calipers Part No.: Y20001743 Qty.: Used in: 8.20.2 Engine mounting –...
Page 295 Crossbeam Part No.: T80092360 Qty.: Used in: 2.1 Transportation (→ Page 18) Depth gauge, 200 mm Part No.: Y20000918 Qty.: Used in: 8.5.2 Valve protrusion – Measurement (→ Page 166) Endoscope Part No.: Y20097353 Qty.: Used in: 8.3.1 Cylinder liner – Endoscopic examination (→...
Page 296 Feeler gauge Part No.: Y20098771 Qty.: Used in: 8.5.3 Valve clearance – Check and adjustment (→ Page 168) Filter wrench Part No.: F30379104 Qty.: Used in: 8.9.1 Fuel filter – Replacement (→ Page 185) Qty.: Used in: 8.9.4 Additional fuel filter – Replacement (→ Page 190) Qty.: Used in: 8.14.1 Engine oil filter –...
Page 297 8.7.2 Injector – Removal and installation (→ Page 177) Milling cutter Part No.: F30452739 Qty.: Used in: 8.7.2 Injector – Removal and installation (→ Page 177) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 8.13.4 Engine oil – Sample extraction and analysis (→ Page 206) Ratchet Part No.:...
Page 298 Ratchet adapter Part No.: F30027340 Qty.: Used in: 2.3 Crankshaft – Transport locking device (→ Page 20) Qty.: Used in: 8.11.3 Exhaust flaps – Coupling rod replacement (→ Page 197) Ratchet bit Part No.: F30027341 Qty.: Used in: 8.13.3 Engine oil – Change (→ Page 204) Ratchet bit Part No.: F30450902...
Page 299 Ratchet with extension Part No.: F30006212 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 154) Qty.: Used in: 8.3.1 Cylinder liner – Endoscopic examination (→ Page 159) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 8.5.3 Valve clearance – Check and adjustment (→...
Page 300 Torque wrench 300-800 Nm Part No.: F30047798 Qty.: Used in: 8.20.2 Engine mounting – Resilient mount check (→ Page 249) Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 2.3 Crankshaft – Transport locking device (→ Page 20) Qty.: Used in: 8.6.1 HP fuel pump –...
Page 301 Torque wrench, 4–20 Nm Part No.: F30044239 Qty.: Used in: 8.4.1 Oil mist fine separator – Replacement (→ Page 163) Qty.: Used in: 8.5.4 Cylinder head cover – Removal and installation (→ Page 172) Qty.: Used in: 8.7.2 Injector – Removal and installation (→ Page 177) Qty.: Used in: 8.14.3 Centrifugal oil filter –...
Page 302 Torque wrench 10–60 Nm Part No.: F30452769 Qty.: Used in: 8.15.3 Engine coolant – Draining (→ Page 219) Qty.: Used in: 8.15.6 Engine coolant – Sample extraction and analysis (→ Page 225) Qty.: Used in: 8.16.3 Charge-air coolant – Draining (→ Page 230) Valve adjusting gauge Part No.: Y4349603...
Page 303: Index
11.2 Index Cylinder head cover – Removal and installation 172 Abbreviations 287 Cylinder liner Actuators – Endoscopic examination 159 – Function test 253 – Endoscopic inspection – Overview 41, 47 – Instructions and comments on endoscopic and visu- – Visual inspection 253 al examination 161...
Page 304 – Check with oil dipstick 202 Engine overview 37, 39 Maintenance Schedule Engine sides – Maintenance task reference table [QL1] 76 – Designation 36 MTU contact persons 290 Exhaust flaps – Check – Coupling rods 195 NOx sensor – Overview 192 – Replacement 257...
Page 305 Safety regulations – Assembly work 11 – Auxiliary materials 15 – Environmental protection 15 – Fire prevention 15 – Fluids and lubricants 15 – Important provisions 5, 7 – Initial start-up 9 – Maintenance work 11 – Operation 9 – Organizational requirements 8 –...

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12v4000c55 12v4000c65 16v4000c45 16v4000c55 16v4000c65 12v4000c15 ... Show all

MTU 12V4000C*5 series Operating Instructions Manual

1 Safety

2 Transport

3 General Information

4 Technical Data

5 Operation

6 Maintenance

7 Troubleshooting

8 Task Description

9 Manufacturer's Documentation

11 Appendix B

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