Page 1 Operating Instructions Diesel Engine with Exhaust Gas Aftertreatment 12V4000Gx5S MS15065/01E...
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 4.2.11 Cooling system 4.2.12 Engine management and monitoring 1.1 Important provisions for all products 4.2.13 Sensors and actuators – Overview 1.2 Important requirements for Power 4.3 Exhaust Gas Aftertreatment Generation application products 4.3.1 Exhaust gas aftertreatment system – Overview 1.3 Gendrive engines –...
Page 6 6.11 After stopping the engine – Engine remains 9.8.5 Fuel prefilter (switchable) – Draining 9.8.6 Fuel prefilter (switchable) – Low pressure ready for operation indicator check 6.12 After stopping the engine – Putting the 9.8.7 Fuel prefilter (non-switchable) – Filter element engine out of operation replacement 6.13 Plant –...
Page 7 10.1 Abbreviations 9.18.2 Battery-charging generator drive – Drive belt replacement 10.2 Conversion tables 10.3 MTU Contact/Service Partners 9.19 Engine Mounting / Support 9.19.1 Engine mounting – Checking resilient element 11 Appendix B 9.19.2 Engine mounting – Checking securing screws for firm seating 11.1 Special Tools...
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: Important Requirements For Power Generation Application Products
1.2 Important requirements for Power Generation application products Project-specific operational environment During integration and use of the diesel engine, all currently valid and relevant standards and guidelines on safety and specified operation must be implemented and observed. This applies to persons responsible for: •...
Page 11 Chemical resistance Only use hoses, pipes, fittings, etc. that can tolerate the fluids and lubricants in accordance with the Fluids and Lubricants Specifications. Only use options that are resistant to the fluids and lubricants in accordance with the Fluids and Lubricants Specifications. Electrical devices The IP protection class of the electrical devices required by the manufacturer must be observed.
Page 12: 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 13: Personnel And Organizational Requirements
1.4 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.
Page 14: Safety Regulations For Initial Start-Up And Operation
1.5 Safety regulations for initial start-up and operation Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
Page 15 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 16: Safety Regulations For Assembly, Maintenance, And Repair Work
1.6 Safety regulations for assembly, maintenance, and repair work Safety regulations for work prior to assembly, maintenance, and repair Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants, risk of burning).
Page 17 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 18 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 19 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 20: 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 21 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 22: Standards For Warning Notices In The Text And Highlighted Information
1.8 Standards for warning notices in the text and highlighted information DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...
Page 23: Guards On The Engine - Overview
1.9 Guards on the engine – Overview 1 Throttle flap guard plate 2 Flywheel housing guard 3 Generator guard cover plate MS15065/01E 2019-01 | Safety | 21...
Page 24 1 Generator guard cover 2 Flywheel housing guard 3 Throttle flap guard plate plate The engine may only be operated with the protective guards installed. 22 | Safety | MS15065/01E 2019-01...
Page 25: 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. Set down the exhaust gas aftertreatment system in such a way that only the mounts, not the main body, touch the ground.
Page 26: Lifting Specifications
2.2 Lifting specifications DANGER Suspended load. Danger to life! • Use suitable equipment and lifting devices. • Never stand beneath a suspended load and keep a safe distance. • Wear personal protective equipment (e.g. protective helmet, safety shoes). DANGER Falling from great heights. Risk of serious injury –...
Page 27 The figure applies to engines with other cylinder configurations as well. * Max. permissible diagonal pull. Observe requirements specified in MTN5194. Taking note of the engine center of gravity Refer to the engine installation drawings for details of the center of gravity of the engine. Lifting the engine Follow the instructions below when lifting the engine: •...
Page 28 Take note of the center of gravity Refer to the exhaust gas aftertreatment system installation drawings for details of the center of gravity of the SCR system. DPF system lifting points A Distance between lifting C Distance between center of E Distance between center of points gravity and outer edge of...
Page 29 Lifting points of exhaust gas aftertreatment SCR system and DPF system on module frame A Distance between lifting C Distance between center of E Distance between center of points gravity and lifting point gravity and bottom edge of B Distance between lifting D Distance between center of module frame points...
Page 30: Ra Tank (Optional) - Transport
2.3 RA tank (optional) – Transport 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). DANGER Falling from great heights.
Page 31: Crankshaft Transport Locking Device
2.4 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Ratchet bit F30027340 Engine oil Transport locking device Note: The locking device on both ends protects the crankshaft bearings from shocks and vibration damage during engine transport.
Page 32 Note: Attach plate (6) only to the upper part of the openings. 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. Name Size Type...
Page 33 Install guard plate (3) on flywheel housing (4). Install screws (2) with washers (1) and tight- MS15065/01E 2019-01 | Transport | 31...
Page 34: Engine Mount Shipping Lock
2.5 Engine mount shipping lock Preconditions ☑ Engine coolant and engine oil must be filled. Shipping lock Note: The shipping lock protects the engine mount from damage resulting from shock and vibration during engine transportation. For installation and removal of the transport locking device, follow the in- structions below: Remove the transport locking device from all resilient mounts before putting the engine into operation.
Page 35: 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 36: Product Summary
3.2 Product summary Diesel engine with exhaust gas aftertreatment 1 Jacketed DPF system 4 Reducing agent lines 7 Reducing Agent Tank (op- 2 Exhaust pipe bellows be- 5 Cabling (available in prede- tional) tween SCR and DPF system fined lengths for customer 8 Tank sensors 3 Jacketed SCR system selection)
Page 37: High-Pressure Points On Exhaust Gas Aftertreatment System - Overview
3.3 High-pressure points on exhaust gas aftertreatment system – Overview 1 Dosing unit 3 Supply unit 2 HP reducing agent line 4 Pressure relief valve The operating pressure in the reducing agent supply lines between supply unit and dosing unit is 10 bar. The pressure relief valve opens at 12.5 bar.
Page 38: Functional Description
(DPF) with a diesel oxidation catalyst (DOC) and an SCR system (selective catalytic reduction) to moder- ate emissions. The use of approved fuels, lube oils and reducing agents as listed in the MTU Fluids and Lubricants Specifica- tions prevents premature failure of the SCR catalyst and DOC as a result of contamination.
Page 39 EGAT system Main components: • DPF system (DPF) including diesel oxidation catalyst (DOC) • SCR system (SCR) with downstream ammonia slip catalyst (ASC) and integrated mixing channel • Reducing agent dosing system (RA) comprising pre-feed module (PFM), supply unit (SU) and dosing unit (DU) •...
Page 40: Diesel Engine With Egat - Standard Scope Of Supply
3 Jacketed DOC/DPF selection) 4 Module frame for EGAT sys- Standard scope of supply MTU Series 4000 engine: • Rated speed 1800 rpm (60 Hz) • Electronic engine management system • Electrical starter on the left and right (A and B sides) Exhaust gas aftertreatment system: •...
Page 41: Diesel Engine With Egat - Nameplate And Designation
4.1.3 Diesel engine with EGAT – Nameplate and designation Nameplates on diesel engine The illustration applies similarly to other cylinder configurations. 1 Emissions label (EPA) 2 Engine nameplate 3 Instruction plate MS15065/01E 2019-01 | Diesel Engine with Exhaust Gas Aftertreatment | 39...
Page 42 Nameplate 1 Engine model designation 2 Serial number (product (product type) number) Engine model designation Key to the engine model designation Number of cylinders Cylinder arrangement: V engine 4000 Series Application (G = Genset) Application segment Design index Additional feature (S = 60 Hz) 40 | Diesel Engine with Exhaust Gas Aftertreatment | MS15065/01E 2019-01...
Page 43: Series 4000 Engines
4.2 Series 4000 Engines 4.2.1 Engine layout Engine overview, free end 1 Exhaust turbocharger 6 Fuel filter 11 Coolant distribution housing 2 Air system 7 HP fuel pump 12 Thermostat housing 3 Throttle flap after intercool- 8 Lube oil filter KGS Free end 9 Vibration damper 4 Cylinder head cover...
Page 44 Engine overview, driving end 1 Intercooler 5 Oil heat exchanger 9 Engine Control Unit ECU9 2 Air filter 6 Engine mounting 10 Throttle flap after intercool- 3 Exhaust pipe bellows 7 Charge-air pipe 4 Crankcase breather 8 Flywheel KS Driving end Series 4000Gx5S engines These engines are compact, powerful, reliable, maintenance-friendly and economical.
Page 45 Technology Application group Engine Power rating Speed Displacement 3D, standby power, fuel stop 12V4000G75S 1638 kW/cyl. 1800 rpm 57.24 l power, IFN 137 kW/cyl. 4.77 l/cyl. 3D, standby power, fuel stop 12V4000G85S 1919 kW/cyl. 1800 rpm 57.24 l power, IFN 160 kW/cyl.
Page 46: Crankcase With Oil Pan
4.2.2 Crankcase with oil pan 1 Crankcase 7 Coolant transfer 13 Crankshaft bearing 2 Main oil gallery 8 Oil dipstick 14 Oil spray nozzle for piston 3 Upper end cover 9 Oil filler neck cooling 4 Coolant chamber 10 Inspection port cover 15 Camshaft bearing 5 Cylinder liner 11 Oil pan...
Page 47 Benefits • High level of rigidity • Low noise and vibration level Function The crankcase (1) is the component where the power generated by the combustion process of the fuel/air mixture in the cylinders is transmitted to the crankshaft. The crankcase is cast as a single solid unit to with- stand the forces involved.
Page 48: Gear Train
4.2.3 Gear train 1 Gear train for coolant pump, 5 Drive gear for HP fuel pump 9 Drive gear for engine oil LT circuit and fuel delivery pump pump 2 Gear train for coolant pump, 6 Idler gear 10 Drive gear for oil replenish- HT circuit 7 Drive gear for battery-charg- ment pump...
Page 49: Running Gear
4.2.4 Running gear 1 Flywheel 4 Conrod 7 Crankshaft counterweight 2 Crankshaft 5 Vibration damper 8 Ring gear 3 Piston 6 Crankshaft gear KS = Driving end Running gear The running gear is installed in the crankcase. It is supported in sleeve bearings and locked in axial direction. Engine oil from the crankcase is used to lubricate the bearings, vibration damper, and pistons.
Page 50 Crankshaft • Forged • Bolt-on counterweights • Press-fitted crankshaft gear • Low-wear sleeve bearings, oil supply from lube-oil system • Axial fixing by thrust bearing • Radial-lip shaft seals for sealing against external influences (driving end and free end) Vibration damper (free end) •...
Page 51: Cylinder Head With Injector
4.2.5 Cylinder head with injector 1 Cylinder head 6 Valve guide a Charge-air 2 Hold-down clamp 7 Intake valves b Exhaust gas 3 Injector 8 Sealing ring c Coolant 4 HP fuel line 9 Exhaust valves d Engine oil 5 Fuel return line 10 Plunger Cylinder head with injector The cylinder heads containing the valve gear and fuel injection equipment are mounted on the crankcase.
Page 52 Function Charge air flows into the combustion chamber of the cylinder when the intake valves (7) are open. The injector (3) injects fuel into the combustion chamber creating an air/fuel mixture which ignites sponta- neously under compression. When the exhaust valves (9) open, exhaust gas created by the combustion process flows via the outlet duct to the exhaust manifold leading to the exhaust turbochargers.
Page 53: Valve Gear
4.2.6 Valve gear 1 Camshaft drive gear 6 Pushrod 11 Rocker arm (exhaust) 2 Swing follower shaft 7 Rocker shaft 12 Rocker arm bearing block 3 Swing follower (intake) 8 Rocker arm (intake) 13 Valve bridge 4 Swing follower (exhaust) 9 Locknut 5 Camshaft 10 Adjusting screw...
Page 54 Function The camshaft (5) controls opening and closing of the intake and exhaust valves. The motion applied from the cams of the camshaft to actuate the valves is transferred by swing followers (3, 4), pushrods (6) and rocker arms (8, 11) onto the valve bridges (13) of the intake and exhaust valves. The valves open against spring pressure and close with the pressure exerted by the valve springs.
Page 55: Fuel System With Common Rail Injection
4.2.7 Fuel system with Common Rail injection 1 Injector 7 Additional fuel filter 13 HP fuel pump 2 Connecting line, HP fuel line 8 Connection, fuel return to 14 HP fuel distributor (only 16/20V engines) tank 15 Pressure limiting valve 3 Connecting line, return line 9 Connection, supply line 16 HP fuel line to injector...
Page 56 High pressure The high-pressure fuel system (Common Rail injection system) comprises: • HP fuel pump • HP distributor with pressure limiting valve • HP fuel lines (Common Rails) • Injectors with built-in injector accumulator and flow restrictor valve Return • From the injectors and the HP distributor (in emergency mode) to the tank line Open-loop control •...
Page 57: Charge-Air And Exhaust System
4.2.8 Charge-air and exhaust system 1 Exhaust turbocharger, right 6 Charge-air pipe, right side 11 Air intake, connection for side (free end) 7 Exhaust turbocharger, right air filter 2 Exhaust outlet side (driving end) 12 Air supply pipe 3 Exhaust turbocharger, left 8 Exhaust turbocharger, left 13 Inlet duct side (free end)
Page 58 Benefits • Low exhaust emissions • Low fuel consumption • High degree of engine efficiency • Optimum load application characteristics • Optimized inflow to compressor • Straightforward connection to external exhaust system • Increased thermal and mechanical load capacity of pipework before the intercooler Function Exhaust system After the exhaust valves open, exhaust gases flow out of the cylinder combustion chambers through the ex-...
Page 59: Lube Oil System
4.2.9 Lube oil system 1 Exhaust turbocharger, right 11 Pressure relief valve of lube 21 Crankshaft support bearing, side oil pump driving end 2 Exhaust turbocharger, left 12 Lube oil pump 22 Mechanical coupling, gener- side 13 Oil priming pump outlet al (option) 3 Centrifugal oil filter connection...
Page 60 The oil mainly flows through the five lube oil filters (6) directly to the lubrication points in the engine and to the main oil gallery (27). The following components / assemblies are supplied directly: • HP fuel pump (9) • Vibration damper (16) •...
Page 61: Fuel Cooler
4.2.10 Fuel cooler Extremely high injection pressure increases the temperature of the uncombusted, depressurized fuel when it is returned to the tank. This can create extremely hot return fuel which exceeds the material limitations of the day tank and the injection equipment. A fuel cooler reduces the fuel temperature in the fuel return line and day tank.
Page 62 Function The fuel cooler is installed in the fuel return line between the engine and the fuel tank. Uncombusted, heated fuel (a) flows through the fuel inlet (5) into the heat exchanger (4). Air (b) drawn through an aluminum radiator block by a centrifugal fan (6) withdraws heat from the fuel. After passing through the heat exchanger (4) comprising a pipe bundle, the air-cooled fuel is returned to the fuel tank via the fuel outlet (2).
Page 63: Cooling System
4.2.11 Cooling system 1 Connection, LT circuit vent 10 Charge-air coolant inlet 19 Crankcase line from charge-air coolant 20 Engine coolant preheater in- 2 Connection, HT circuit vent cooler line 11 Charge-air coolant pump 21 Coolant manifold 3 Space heater supply con- 12 Charge-air coolant drain 22 Intercooler nection...
Page 64 Benefits • Engine, oil and charge-air reach optimum operating temperature very quickly • Prevention of white smoke by preheating the charge-air during idling and low-load operation • Charge-air cooling during load-operation Function Illustrations apply similarly to other cylinder configurations. Engine coolant circuit (high temperature HT) After starting the engine, the engine coolant pump (6) pumps part of the coolant through the lube-oil heat exchanger (3) into the cooling chambers of the crankcase (7).
Page 65 Charge-air coolant circuit (LT) The charge-air coolant pump (5) installed on the engine pumps the charge-air coolant to the intercooler (3). The charge-air coolant reaches the thermostat (6) via the intercooler (3). The charge-air coolant flows to the external charge-air coolant cooler via the thermostat (6) when the engine is at operating temperature. Cooled charge-air coolant coming from the charge-air coolant cooler flows to the charge-air coolant pump (5).
Page 66: Engine Management And Monitoring
4.2.12 Engine management and monitoring 1 Customer controller 4 Data and signals 7 Engine sensor connection 2 Power supply 24 V DC 5 EIL P Plant 3 SmartConnect 6 ECU 9 E Electronic engine manage- ment system Engine management and monitoring The Engine Monitoring Unit permanently evaluates the engine operating values.
Page 67 • Flat housing with three self-locking plug connectors • 24 V DC power supply • Communication with other devices and higher-level systems via CAN bus (to MTU devices via PCS-5 re- dundant, to external devices via J1939) • Integrated engine monitoring •...
Page 68 • Software version identification (application, firmware, CCS, ...) • Data logger for remote maintenance Benefits • Simple handling • No MTU Service personnel required EIL (Engine Identification Label) • Identification of engine hardware • Data storage, e.g. aging data 66 | Series 4000 Engines | MS15065/01E 2019-01...
Page 69: Sensors And Actuators - Overview
4.2.13 Sensors and actuators – Overview Plan view B4.21 Exhaust bulk temperature, A B44.1 Turbocharger speed, A side side B44.2 Turbocharger speed, B side B4.22 Exhaust bulk temperature, B side MS15065/01E 2019-01 | Series 4000 Engines | 67...
Page 70 Left engine side A19 EIL - Engine Ident Label B38 Fuel supply temperature B48.1 HP fuel system pressure, A B9 Charge-air temperature B34.1 Fuel pressure after filter side B10.1 Pressure sensor, charge air B34.3 Fuel pressure before sup- M58.1 Connector for throttle flap, A side plementary filter A side...
Page 71 Right engine side B10.2 Pressure sensor, charge air B90 H-T-P moisture sensor, air XB533 H-Coolant HT (ext. expan- B side quality sion tank) B13 Crankshaft speed M58.2 Connector for throttle flap, XB557 H-Coolant LT (ext. expan- B48.2 HP fuel system pressure, B B side sion tank) side...
Page 72 Free end B1 Camshaft speed B6 Coolant temperature B50 Crankcase pressure B5.1 Engine lube oil pressure B7 Lube oil temperature B54 Oil refill pump pressure (op- B5.3 Lube oil pressure before fil- B26 Charge-air coolant tempera- tional) ture XB54 Connector for optional oil refill pump 70 | Series 4000 Engines | MS15065/01E 2019-01...
Page 73: Exhaust Gas Aftertreatment
4.3 Exhaust Gas Aftertreatment 4.3.1 Exhaust gas aftertreatment system – Overview 1 Jacketed DPF system 7 Fixed bearings 13 DCM exhaust gas aftertreat- 2 DOC/DPF element 8 Tank sensors ment system 3 Dosing units 9 Tank 14 Floating bearing 4 Jacketed SCR system 10 DCM tank 15 Differential pressure sensor 5 Exhaust outlet from exhaust...
Page 74: Dpf System
Thermal management to support the regeneration process is generally only necessary in unusual climatic conditions or when operating continuously in the low-load range. The MTU engine management system in the ECU (Engine Control Unit) calculates DPF load and, if necessary, temporarily increases the exhaust tempera- ture, and hence soot burn-off, significantly by means in-engine thermal management.
Page 75 CRT principle (Continuous Regeneration Trap) The CRT effect (Continuous Regeneration Trap) is based on chemical reactions which take place in the ex- haust gas aftertreatment system of the engine. The diesel oxidation catalyst (DOC) first produces nitrogen dioxide (NO ) from the nitrogen monoxide (NO) in the exhaust gas. Sooty deposits in the DPF are steadily burnt off with the aid of the NO thus gained (see figure).
Page 76: Diesel Particulate Filter (Dpf) - Overview
4.3.2.2 Diesel particulate filter (DPF) – Overview 1 Jacketed DPF system 3 Exhaust outlet from DPF 5 Wiring harness 2 DOC/DPF element system 6 Exhaust inlet to DPF system 4 Externally mounted compo- nents The DPF system reduces particulate emissions by 90 % and more. The CRT (Continuous Regeneration Trap) effect facilitates the use of a continuously regenerating particulate filter system consisting of an diesel oxida- tion catalyst (DOC) and a diesel particulate filter (DPF) connected to it.
Page 77 Benefits • Low emission of soot particles • Optimized fuel consumption • Compact design • Highly integratable with “One Box” system (i.e. sensors and electrical wiring harnesses included in the scope of supply) • Inherent exhaust noise attenuation • Plug & play •...
Page 78: Scr System
4.3.3 SCR System 4.3.3.1 SCR catalyst – Operating principle “Selective Catalytic Reduction”, or SCR for short) is a chemical reaction in the course of which harmful ni- trous oxides (NO ) in the exhaust gas are converted largely into water (H O) and nitrogen (N The entire exhaust mass flow is routed through the catalytic converter system, bringing it into contact with the catalytically active surface.
Page 79: Scr Catalytic Converter - Overview
4.3.3.2 SCR catalytic converter – Overview 1 Jacketed SCR system 4 DCM exhaust gas aftertreat- 7 Exhaust inlet to SCR system 2 RA dosing units ment system 3 Exhaust outlet from SCR 5 Externally mounted compo- system nents 6 Wiring harness All the housing components of the SCR system which might come into contact with reducing agent or ammo- nia are made of stainless steel.
Page 80 Benefits • Low emission of nitrous oxides • Optimized fuel consumption • Compact design • Highly integratable with “One Box” system (i.e. sensors and electrical wiring harnesses included in the scope of supply) • Inherent exhaust noise attenuation • Plug & play •...
Page 81: Ra Dosing System
The RA dosing system comprises a pre-feed module (PFM) (4), supply units (SU) (3), dosing units (DU) (2) and a reducing agent loop (1). The RA tank (5) is supplied by the customer or by MTU as an option. Technology •...
Page 82 The DU (2) features a temperature and pressure sensor to control the amount of RA injected at a pressure of 10 bar (abs.). The opening time of a solenoid valve in the DU controls RA injection. Each SCR system comprises two pairs of supply and dosing units (SU/DU) which are interconnected to form a loop pressurized at approx.
Page 83: Reducing Agent - Handling
DIN 70070 / ISO 222 41-1 is mandatory. SCR systems from MTU are designed for a concentration of 32.5% urea. Mis-filling with diesel fuel may damage seals and hoselines resulting in leaking fuel and fire. Never attempt to start-up or operate the machine/system after mis-filling.
Page 84: Pre-Feed Module (Pfm)
4.3.4.3 Pre-feed module (PFM) 1 Supply to SCR system 4 Heating element 7 Filters (pressure line) 5 Supply from RA tank 8 Return to RA tank 2 Return from SCR system 6 Plunger solenoids 9 RA concentration and tem- (suction line) perature sensor 3 Pressure sensor The PFM comprises two reciprocating plungers (6) which are activated with a phase displacement of 180°...
Page 85 Function • Delivering reducing agent from the tank to the dosing systems • Prefiltering RA by means of an integrated filter • Safeguarding the supply of RA • Maintaining minimum system pressure in the loop supplying the dosing systems and avoiding empty lines by means of an integrated pressure-maintaining valve •...
Page 86: Supply Unit (Su)
4.3.4.4 Supply unit (SU) 1 HDSC connector, DU 4 Inlet from PFM 7 Pressure relief valve 2 HDSC connector, DCM 5 Filters 3 Outlet to DU (pressure line) 6 Electrical heating element The SU comprises a diaphragm pump, an RA prefilter, a pressure limiting valve to protect the system, and an integrated electronic control system.
Page 87: Dosing Unit (Du)
4.3.4.5 Dosing unit (DU) 1 Drain 2 Supply The DU contains a nozzle and a solenoid valve as well as a pressure and temperature sensor for closed-loop control. Design criteria Design criteria Value Material Stainless steel Technical data Operating pressure: 10 bar abs. RA dosing volume: Max.
Page 88: Ra Lines
4.3.4.6 RA lines 1 DU 4 RA line between SCR sys- 7 Connection to RA tank 2 RA line between DU and SU tems 8 PFM 3 SU 5 RA line between PFM and 6 RA line between RA tank and PFM The reducing agent lines are flexible hoses equipped with an SAE J2044 quick-disconnect couplings (QC) and corrugated tubing for protection.
Page 89: Ra Tank (Optional)
4 Level transmitter assembly The RA tank, RA lines between RA tank and PFM and the tank sensors are available from MTU. MTU specifies tank size, sensor types/positions and the RA lines for customers designing or using their own tanks. In either case, the DCM required to connect the tank sensors to the ECU is supplied by MTU.
Page 90: Ra Heating System
4.3.4.8 RA heating system A Heating zone, SCR system 1 3 RA suction filter 9 RA quality sensor B Heating zone, SCR system 2 4 RA main filter 10 Heating element (24 V) C Heating zone, PFM 5 Temperature sensor 11 Main heater for RA tank (not D Heating zone, RA tank 6 Pressure sensor...
Page 91 The RA system heating components are controlled by the ECU. This does not apply to the main RA tank heat- er. MTU recommends permanently heating the RA tank if temperatures below -5 °C can be expected. The component parts of the heating system, including the temperature sensors, are tested for open load and short circuit when activated as soon as the ECU is powered-up and is ready for operation prior to engine start-up.
Page 92: Monitoring, Control And Regulation Equipment
4.3.5 Monitoring, Control and Regulation Equipment 4.3.5.1 EGAT sensors – Overview The following overview drawings also apply to 16V engines. B4.33 Exhaust temperature, ex- B88.8 NOx after SCR XWA1 Connection plug SCR haust gas aftertreatment B82 Ambient temperature XWA2 Connection plug DPF before DPF B85.6 Exhaust temperature, EGAT B91.2 Exhaust gas pressure, DPF...
Page 93 1 Current distributor for elec- 6 PFM DCM B102 PFM pressure to filter tronics 7 DCM tank B103 PFM RA quality 2 Connector cable for DCM E3.1 Heater supply line M81.1 PFM pump 1 SCR 1 E3.2 Heater return line M81.2 PFM pump 2 3 Connector cable for DCM B106_E7 PFM RA temperature...
Page 94: Exhaust Gas Aftertreatment Management And Monitoring
4.3.5.2 Exhaust gas aftertreatment management and monitoring Distributed Control Module (DCM) 1 X41 – CAN connection to 3 X43 – Component wiring ECU on engine (SCR system, pre-feed mod- 2 X42 – 24 V DC power sup- ule, RA tank) 4 Grounding The DCM is an input/output channel extension of the Engine Control Unit (ECU) to monitor and control the RA dosing electronic system components.
Page 95 Monitoring • RA level (tank) • RA quality • RA temperature in the tank • RA temperature in the pre-feed module • RA pressure after pre-feed module • Exhaust gas temperatures before and after SCR system • Exhaust gas temperature before diesel particulate filter •...
Page 96: Dcm Can Connections
4.3.5.3 DCM CAN connections a Series 12V4000 (4x DPF) A Connecting cable DPF – D Connecting cable PFM – b Series 16V4000 (6x DPF) Tank 1 CAN termination resistor, B Connecting cable flow A removed when connected, C Connecting cable flow B R=121 ohm Designation Length [mm]...
Page 97: Technical Data
5 Technical Data 5.1 Product data 12V4000G75S 12V4000G85S Legend DL Reference value: Continuous power. Continuous drivable power under standard conditions BL Reference value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applications (adjustment reserve) A Design value. Value required to design an external system (plant) R Guideline value.
Page 98 General conditions (for maximum power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust back-pressure (total pressure) after engine with EGAT mbar (DPF unloaded) BL/DL, max., (incl. value from module no. 2151) Exhaust back-pressure (total pressure) after engine with EGAT mbar (DPF loaded) BL/DL, max., (incl.
Page 99 Exhaust gas temperature after engine, max. (exhaust turbocharg- °C Exhaust gas temperature after EGAT 1 °C Exhaust gas temperature after EGAT at BL °C Coolant system (HT circuit) Coolant temperature (at engine connection: outlet to cooling °C equipment) Coolant temperature after engine, limit 1 °C Coolant temperature after engine, limit 2 °C...
Page 100 Oil change quantity, max. (standard oil system) (option: max. op- Liters erating inclinations) Oil pan capacity at dipstick mark “min.” (standard oil system) (op- Liters tion: max. operating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil system) Liters (option: max.
Page 101: Product Data 12V4000G15S 12V4000G25S
5.2 Product data 12V4000G15S 12V4000G25S Legend DL Reference value: Continuous power. Continuous drivable power under standard conditions BL Reference value: Fuel stop power. Maximum engine power. Can not be driven continuously in some applications (adjustment reserve) A Design value. Value required to design an external system (plant) R Guideline value.
Page 102 Exhaust back-pressure (total pressure) after engine with EGAT mbar (DPF unloaded) BL/DL, max., (incl. value from module no. 2151) Exhaust back-pressure (total pressure) after engine with EGAT mbar (DPF loaded) BL/DL, max., (incl. value from module no. 2151) Pressure loss in plant-side exhaust system (without supplied ex- mbar haust gas aftertreatment) Pressure loss in plant-side exhaust system, max.
Page 103 Coolant system (HT circuit) Coolant temperature (at engine connection: outlet to cooling °C equipment) Coolant temperature after engine, limit 1 °C Coolant temperature after engine, limit 2 °C Coolant antifreeze content, max. Coolant system (LT circuit) Coolant temperature (at engine connection: outlet to cooling °C equipment) Coolant temperature before intercooler, limit 1...
Page 104 Weights / main dimensions Engine mass, dry (standard scope of supply) 6710 6710 Dry engine mass (with standard accessories installed, incl. cou- 6742 6742 pling) Noise Exhaust noise, attenuated (EGAT 1) – BL (free-field sound pres- dB(A) sure level Lp, 1 m distance, ISO 6798, 3dB(A) tolerance) Exhaust noise, attenuated (EGAT 1) –...
Page 105: Product - Main Dimensions
5.3 Product – Main dimensions Main dimensions, 12V engine Engine model Length (A) Width (B) Height (C) 12V4000Gx5S with 2-cylinder HP pump 2433 mm 1660.5 mm 2176.5 mm 12V4000Gx5S with 4-cylinder HP pump 2495 mm 1660.5 mm 2176.5 mm MS15065/01E 2019-01 | Technical Data | 103...
Page 106 Main dimensions, DPF module Engine model Length (A) Length (B) Height (C) Width (D) Height (E) Height (F) 12V4000Gx5S 1414.7 mm 1375 mm 206 mm 1246 mm 706 mm 982.75 mm 104 | Technical Data | MS15065/01E 2019-01...
Page 107 Main dimensions, SCR module Width (A) Height (B) Length (C) Height (D) Height (E) 1124.1 mm 771 mm 1774.5 mm 1626.1 mm 1161 mm MS15065/01E 2019-01 | Technical Data | 105...
Page 108 Main dimensions, exhaust gas aftertreatment system 12V Engine model Length (A) Height (B) Width (C) Height (D) 12V4000Gx5S 3436.6 mm 992.8 mm 2656 mm 1636.1 mm 106 | Technical Data | MS15065/01E 2019-01...
Page 109: Exhaust Gas Aftertreatment System - Main Dimensions
5.4 Exhaust gas aftertreatment system – Main dimensions Item Dimensions Length (A) Approx. 3437 mm Width (B) Approx. 1246 mm Height of SCR system (C) Approx. 1636 mm Height of DPF system (D) Approx. 993 mm Table 2: DPF system with SCR system – Main dimensions MS15065/01E 2019-01 | Technical Data | 107...
Page 110 Item Dimensions Length (A) Approx. 3680 mm Width (B) Approx. 1360 mm Height (C) Approx. 1761 mm Table 3: DPF system with SCR system on module frame – Main dimensions 108 | Technical Data | MS15065/01E 2019-01...
Page 111 Item Dimensions Length (A) Approx. 2043 mm Width (B) Approx. 1000 mm Height (C) Approx. 1335 mm Table 4: RA tank – Main dimensions MS15065/01E 2019-01 | Technical Data | 109...
Page 112: Firing Order
5.5 Firing order Firing order Number of cylinders Firing order 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 110 | Technical Data | MS15065/01E 2019-01...
Page 113: Operation
6.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications (A001070/..) available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item Action Engine Depreserve (→...
Page 114: Putting Into Operation After Scheduled Out-Of-Service-Period
6.2 Putting into operation after scheduled out-of-service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation/Commissioning Item Action Lube oil system Check engine oil level (→ Page 271). Coolant circuit Check engine coolant level (→ Page 280). Check intercooler coolant level (→ Page 304). Coolant circuit Heat engine coolant with coolant preheater.
Page 115: Emission Label - Check
6.3 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 116: Engine - Starting In Manual Mode (Test Run)
6.4 Engine – Starting in manual mode (test run) Preconditions ☑ Generator (if applicable) 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 117 Starting the engine Item Action Switch cabinet, operator If coolant temperature is panel, etc. (depending on • > 40 °C (with preheating system), or manufacturer) • > 5 °C (without preheating system): Press start button. • Automatic starting sequence is performed; •...
Page 118: Re-Starting The Engine Following An Automatic Safety Shutdown
6.5 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 119: Safety System - Override
6.6 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 120: Operational Monitoring
6.7 Operational monitoring DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Exhaust gases are harmful to health and may cause cancer.
Page 121: Emergency Engine Start (Override Mode)
6.8 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 122: Engine Shutdown In Manual Mode (Test Run)
6.9 Engine shutdown 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 123: Emergency Engine Stop
6.10 Emergency engine stop DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING A high level of noise is produced when the engine is running.
Page 124: After Stopping The Engine - Engine Remains Ready For Operation
6.11 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. control 122 | Operation | MS15065/01E 2019-01...
Page 125: After Stopping The Engine - Putting The Engine Out Of Operation
6.12 After stopping the engine – Putting the engine out of operation Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. After stopping the engine Item Action Coolant circuit Drain engine coolant (→ Page 283); Drain charge-air coolant (→ Page 307) if: •...
Page 126: Plant - Cleaning
6.13 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaner (→ Tools Catalog) Cleaner (Hakupur 50/136) X00056700 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...
Page 127: Exhaust Gas Aftertreatment System - Regeneration Procedure
6.14 Exhaust gas aftertreatment system – Regeneration procedure 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 128: Fault Messages
7 Troubleshooting 7.1 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 Procedure following an automatic safety shutdown (→ Page 116) 3 –...
Page 129 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. The 3. Check cooler (plant side) for contamination. coolant temperature in intercooler 4.
Page 130 25 – HI P-Diff-Lube Oil Cause Corrective action The differential oil pressure at 1. Replace engine oil filter (→ Page 275). sensors B5.1 and B5.3 has 2. Contact Service. violated limit value 1. The differential oil pressure is too high. 26 –...
Page 131 33 – HI P-Diff-Fuel Cause Corrective action The differential pressure at 1. Replace fuel filter (→ Page 230). sensors B34.1 and B34.3 2. Contact Service. exceeded limit value 1. The differential pressure is too high. 34 – SS P-Diff-Fuel Cause Corrective action The differential pressure at 1.
Page 132 52 – SS T-Lube Oil Cause Corrective action The lube oil temperature at sensor 1. Check operation of cooler and fan (plant side). B7 has violated limit value 2. Lube 2. Check engine coolant level (→ Page 280). oil temperature is too high. 3.
Page 133 67 – HI T-Coolant Cause Corrective action The coolant temperature at 1. Reduce power. sensor B6 has violated limit value 2. Check operation of cooler and fan (plant side). 1. Coolant temperature is too 3. Check engine coolant level (→ Page 280). high.
Page 134 92 – SS Starter Speed Not Reached Cause Corrective action Engine speed has not reached the 1. Check pressure supply (plant) of starter. specified speed threshold within 2. Check for additional messages. the specified time. 3. Contact Service. 93 – SS T-Preheat Cause Corrective action Engine coolant temperature has...
Page 135 120 – HI ECU Power Supply Voltage Cause Corrective action The supply voltage of the ECU has 1. Check state of charge of batteries (plant side). violated limit value 1. 2. Check plug connections to Engine Control Unit (→ Page 323). 3.
Page 136 207 – SD T-Exhaust B Cause Corrective action The signal from the exhaust gas 1. Check engine cabling (→ Page 321). temperature sensor (B4.2) in the 2. Contact Service. B side exhaust pipe is faulty or missing. 208 – SD P-Charge Air Cause Corrective action The signal from the charge-air...
Page 137 221 – SD P-Diff Lube Oil Cause Corrective action The signals from lube oil pressure 1. Check engine cabling (→ Page 321). sensors B5.3 and/or B5.1 are 2. Contact Service. faulty or missing. 222 – SD Level Leakage Fuel Cause Corrective action The signal from the fuel leak 1.
Page 138 232 – SD Charger 1 Speed Cause Corrective action The signal from the speed sensor 1. Check engine cabling (→ Page 321). (B44.1), ETC A side, is faulty or 2. Contact Service. missing. 233 – SD Charger 2 Speed Cause Corrective action The signal from the speed sensor 1.
Page 139 322 – AL Wiring Cylinder A2 Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 321). wiring for cylinder A2 or injector 2. Replace injector (→ Page 212). faulty. 3. Contact Service. 323 –...
Page 140 329 – AL Wiring Cylinder A9 Cause Corrective action Short circuit fault in injector 1. Check wiring of affected injector (→ Page 321). wiring cylinder A9 or injector 2. Replace injector (→ Page 212). faulty. 3. Contact Service. 330 – AL Wiring Cylinder A10 Cause Corrective action Short circuit fault in injector...
Page 141 336 – AL Wiring Cylinder B6 Cause Corrective action Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 321). wiring for cylinder B6 or injector 2. Replace injector (→ Page 212). faulty. 3. Contact Service. 337 –...
Page 142 344 – AL Open Load Cylinder A4 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 321). to cylinder A4. 2. Contact Service. 345 – AL Open Load Cylinder A5 Cause Corrective action Disruption fault in injector wiring 1.
Page 143 352 – AL Open Load Cylinder B2 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 321). to cylinder B2. 2. Contact Service. 353 – AL Open Load Cylinder B3 Cause Corrective action Disruption fault in injector wiring 1.
Page 144 360 – AL Open Load Cylinder B10 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of affected injector (→ Page 321). to cylinder B10. 2. Contact Service. 365 – AL Stop MV-Wiring Ground Cause Corrective action Short circuit of injector positive 1.
Page 145 536 – AL Wiring PWM_CM1 Cause Corrective action The M8 HP fuel control block of 1. Check engine cabling (→ Page 321). the HP fuel pump can not be 2. Contact Service. activated. 586 – LO P-Oil Refill Pump Cause Corrective action Oil level in oil refill tank too low.
Page 146 634 – SD T0-Ambient Air (HDT2800) Cause Corrective action u Contact Service. The signal from the temperature sensor (B90) is missing. 635 – SD Air Humidity (HDT2800) Cause Corrective action The signal from the humidity u Contact Service. sensor (B90) is missing. 648 –...
Page 147 727 – AL L1 Delta T-NT Intercooler Cause Corrective action The differential temperature at 1. Check cooler (plant side) for contamination. sensors B26 and B90 has violated 2. Check operation of fan (plant side). limit value 1. The LT coolant inlet 3.
Page 148 735 – AL_HI1_dp_Exh_DPFsys_F1 Cause Corrective action u Contact Service. The differential pressure through the DPF measured at sensor B91.2 has violated limit value 1. The differential pressure is too high. 736 – AL_HI2_dp_Exh_DPFsys_F1 Cause Corrective action The differential pressure through u Contact Service.
Page 149 741 – AL DPF Rigorous TM Aborted Cause Corrective action u If possible, run the engine under higher load (>30% load) for a Rigorous thermomanagement has been terminated too many times longer period (approx. 30 min.) or operate the locomotive in Self- due to adverse operating Load mode.
Page 150 752 – AL_SD_Level_RA_RA_tank_1 Cause Corrective action The signal from the level sensor in 1. Check engine cabling (→ Page 321). the RA tank (B590) is faulty or 2. Contact Service. missing. 753 – AL_SD_T_RA_RA_tank Cause Corrective action The signal from the temperature 1.
Page 151 793 – AL L2 P-Charge Air B Cause Corrective action The charge-air pressure at sensor 1. Reduce power. B10.2 has violated limit value 2. 2. Check sensor B10.11, replace as necessary. The charge-air pressure is too 3. Contact Service. high. 800 –...
Page 152 845 – AL HIHI T-Charge Air before EGR Cause Corrective action u Check sensor. The charge-air temperature at sensor B9 has violated limit value 2. The charge-air temperature is too high. 852 – AL Max. Blank Shot time expired Cause Corrective action u Contact Service.
Page 153 923 – AL_HI2_T_Exh_SCRsys_outl_F1 Cause Corrective action The exhaust gas temperature after 1. Reduce power. SCR outlet 1 / flow 1 at sensor 2. Contact Service. B85.6 has violated limit value 2. The exhaust gas temperature is too high. 924 – AL_HI1_T_Exh_SCRsys_inl_F2 Cause Corrective action The exhaust gas temperature...
Page 154 943 – AL_LO1_NOx_conversion_SCRsys_F2 Cause Corrective action u Contact Service. The aging compensator for the NOx setpoint value integrated in the ECU logic has reached its limit value. Satisfactory operation of the B side catalytic converter is no longer possible. 954 – AL NOx value invalid Cause Corrective action Status information of NOx sensor...
Page 155 1015 – AL Total breakdown NOx sensors Cause Corrective action Both NOx sensors (B88.1 and 1. Replace NOx sensors (→ Page 265). B88.2) indicate sensor defect or 2. Contact Service. an invalid value. 1019 – AL_RA_balance_plausibility_F1 Cause Corrective action The ratio between NOx reduction u Contact Service.
Page 156 1075 – AL_HI1_T_RA_SUDU_F1 Cause Corrective action u Contact Service. The temperature of the reducing agent measured at one of the dosing units flow 1 has violated the limit value. The temperature of the reducing agent is too high. 1078 – AL_RA_consumption_plausibility_F2 Cause Corrective action The consumption of reducing...
Page 157 1113 – AL Act Intake Temperature Warning Cause Corrective action u Contact Service. Internal electronics of the servomotor of thermomanagement flap 1 (M58.1) signal excessively high temperature. 1114 – AL Act Intake Air Targetposition Cause Corrective action The servomotor of u Contact Service.
Page 158 1134 – AL_SD_T_RA_prefeed_module Cause Corrective action The signal from the temperature 1. Check engine cabling (→ Page 321). sensor for reducing agent at the 2. Contact Service. pre-feed module (B103) is faulty or missing. Substitute value is used. 1136 – AL_SD_p_RA_prefeed_module Cause Corrective action The signal from the pressure...
Page 159 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 160 1214 – AL_CommLost_DCM_ID4 Cause Corrective action The ECU can no longer detect the 1. Check engine cabling (→ Page 321). DCM with ID4 on the CAN bus. 2. Check DCM, replace as necessary. 3. Contact Service. 1215 – AL_CommLost_DCM_ID5 Cause Corrective action The ECU can no longer detect the 1.
Page 161 1223 – AL_LO1_U_DCM_ID2 Cause Corrective action The operating voltage for the DCM 1. Check engine cabling (→ Page 321). designated ID2 is too low. 2. Check (plant) supply voltage. 3. Check DCM, replace as necessary. 4. Contact Service. 1224 – AL_LO1_U_DCM_ID3 Cause Corrective action The operating voltage for the DCM...
Page 162 1231 – AL_DCM_ID2_Ignition_Lost Cause Corrective action The ECU transmits an ignition 1. Check engine cabling (→ Page 321). signal to all DCMs in the system 2. Check (plant) supply voltage. via a PWM output. The DCM 3. Check DCM, replace as necessary. designated ID2 signals a voltage 4.
Page 163 1240 – AL_DCM_ID4_Internal_Error Cause Corrective action The DCM designated ID4 signals 1. Check DCM, replace as necessary. an internal sensor error. 2. Contact Service. 1241 – AL_HI1_T_DCM_ID5 Cause Corrective action The component temperature of 1. Check ambient temperature at DCM. the DCM designated ID5 has 2.
Page 164 1306 – AL_PFM_solenoid_coils_defect Cause Corrective action One of the two DCM control 1. Check component(s) and wiring, replace as necessary. channels (PO1 and/or PO2) of the 2. Contact Service. pre-feed module has detected an electrical fault (overcurrent monitoring). 1308 – AL_PFM_heater_cartridge_defect Cause Corrective action The DCM control channel (PO3) of...
Page 165 1315 – AL_RA_line_feed_DU1_defect Cause Corrective action Heating of RA line “Flow 1 supply 1. Check component(s) and wiring, replace as necessary. unit / dosing unit 1 supply” is 2. Contact Service. faulty. 1316 – AL_RA_line_feed_DU2_defect Cause Corrective action Heating of RA line “Flow 1 supply 1.
Page 166 1332 – AL_SD_T_Exh_DPFsys_inl_F2 Cause Corrective action The signal from the exhaust gas 1. Check engine cabling (→ Page 321). temperature sensor before the 2. Contact Service. DOC in flow 2 (B4.33) is faulty or missing. 1333 – AL_SD_T_Exh_DPFsys_inl_F3 Cause Corrective action The signal from the exhaust gas 1.
Page 167 1349 – AL_RA_line_feed_RA_tank_1_1_defect Cause Corrective action Heating of supply line from 1. Check engine cabling (→ Page 321). reducing agent tank to pre-feed 2. Check component, replace as necessary. module is faulty. 3. Contact Service. 1350 – AL_RA_line_return_RA_tank_1_2_defec Cause Corrective action Heating of return line from pre- 1.
Page 168 1383 – AL Act Intake Air 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 of thermal 2. Check plug connections to Engine Control Unit (→ Page 323). management flap 1 (M58.1) was 3.
Page 169 1419 – AL Flap Intake restricted Limit 2 Cause Corrective action u Contact Service. The turning range on homing thermal management flap 1 (M58.1) has violated limit value 2. Flap travel is restricted. 1425 – AL Flap Intakeair blocked drive Cause Corrective action The mechanism of thermal...
Page 170 1459 – AL Act Intakeair Comm Lost to ECU Cause Corrective action The servomotor of thermal 1. Check engine cabling (→ Page 321). management flap 1 (M58.1) does 2. Contact Service. not receive any ECU data via the CAN bus. 1461 –...
Page 171 1468 – AL_SD_p_Exh_DPFsys_outl_F2 Cause Corrective action The signal from the pressure 1. Check pressure sensor / differential pressure sensor B91.2 and sensor / differential pressure replace as necessary. sensor at the pre-feed module of 2. Check engine cabling (→ Page 321). the DOC/DPF (B91.2) is faulty or 3.
Page 172 1474 – AL_HI2_T_Exh_DPFsys_inl_F2 Cause Corrective action The exhaust gas temperature 1. Check sensor B4.33 and replace as necessary. before the DOC measured at 2. Contact Service. sensor B4.33 has violated limit 2 for the set time. The exhaust gas temperature before the DOC was/is too high.
Page 173 1480 – AL_CommLost_NOx_EGAT_inl_F2 Cause Corrective action The ECU can no longer detect the 1. Check component(s) and wiring, replace as necessary. NOx sensor before SCR inlet 2 / 2. Contact Service. flow 2 (B88.7) on the CAN bus. 1483 – AL_SD_NOx_EGAT_outl_F1 Cause Corrective action The signal from the NOx sensor...
Page 174 1491 – AL_heater_cartridge_defect_SU1 Cause Corrective action The heating cartridge power 1. Check component(s) and wiring, replace as necessary. supply or the heating cartridge in 2. Contact Service. supply unit M80.1X3 is faulty. 1492 – AL_CommLost_SUDU2 Cause Corrective action The ECU can no longer detect 1.
Page 175 1498 – AL_CommLost_SUDU4 Cause Corrective action The ECU can no longer detect 1. Check component(s) and wiring, replace as necessary. supply unit / dosing unit 4 2. Contact Service. (M80.2X1, flow 2) of the SCR system on the CAN bus. 1499 –...
Page 176 1505 – AL_dosing_unit_defect_DU6 Cause Corrective action u Contact Service. Supply unit / dosing unit 6 (M80.2X1, flow 3) of the SCR system has signaled an internal fault via component CAN bus 5. 1506 – AL_heater_cartridge_defect_SU6 Cause Corrective action The heating cartridge power 1.
Page 177 1511 – AL Flap Intakeair B Wear Limit 2 Cause Corrective action u Contact Service. The turning range on homing thermal management flap 2 (M58.2) has violated limit value 2. The flap mechanism is significantly worn. 1512 – AL Flap Intakeair B linkage failure Cause Corrective action The turning range on homing...
Page 178 1517 – AL Act Intake Air B Voltage Supply Cause Corrective action The supply voltage of the 1. Check state of charge of batteries (plant side). servomotor for the thermal 2. Check plug connections to Engine Control Unit (→ Page 323). management flap 2 (M58.2) is 3.
Page 179 1522 – AL Act Intake Air B Targetposition Cause Corrective action u Contact Service. The servomotor of thermomanagement flap 2 (M58.2) was unable to reach its target position. The difference between target position and actual position exceeds limit value 1528 – AL_heatsocket_feed_RA_tank_defect Cause Corrective action A wire break or short circuit has...
Page 180 1549 – AL_Empty_Level_RA_RA_tank Cause Corrective action u Fill up the reducing agent tank. The reducing agent level in the tank measured at sensor B590.3 has violated the lower limit value. The reducing agent tank is empty. 1558 – AL Act Intake A Targetpos Blocked Cause Corrective action u Contact Service.
Page 181 1572 – AL_HI1_dp_Exh_DPFsys_F2 Cause Corrective action u Contact Service. The differential pressure through the DPF measured at sensor B91.2 has violated limit value 1. The differential pressure is too high. 1573 – AL_HI2_dp_Exh_DPFsys_F2 Cause Corrective action The differential pressure through 1.
Page 182 1584 – AL_DCM_ID5_Role_Conflict Cause Corrective action u Contact Service. There is a conflict in roles between a number of DCMs. A role conflict is indicated when at least 2 DCMs transmit messages with the same CAN address. The DCM role is configured with the role resistor in connector XRD1.
Page 183 1700 – AL_supply_unit_defect_SU1 Cause Corrective action u Contact Service. The OBD system of RA dosing system 1 has signaled one or more fault states in the supply unit. The fault may lead to dosing / circulation cooling failure. 1703 – AL_hydraulics_fault_SUDU1 Cause Corrective action The OBD system of RA dosing...
Page 184 1707 – AL_hydraulics_fault_SUDU3 Cause Corrective action u Contact Service. The OBD system of RA dosing system 3 has signaled one or more hydraulic fault states. The fault may lead to dosing / circulation cooling failure. 1708 – AL_supply_unit_defect_SU4 Cause Corrective action The OBD system of RA dosing u Contact Service.
Page 185 1712 – AL_supply_unit_defect_SU6 Cause Corrective action u Contact Service. The OBD system of RA dosing system 6 has signaled one or more fault states in the supply unit. The fault may lead to dosing / circulation cooling failure. 1713 – AL_hydraulics_fault_SUDU6 Cause Corrective action The OBD system of RA dosing...
Page 186: Troubleshooting
7.2 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery low or defective u Charge or replace (→ manufacturer's documentation). u Check cable connections for secure seating (→ manufacturer's Cable connections defective documentation). Starter (electric): Engine cabling u Check that cable connections are properly secured.
Page 187 Engine Control Unit faulty u Contact Service. Charge-air temperature too high Cause Corrective action Engine coolant mixture incorrect u Check (→ MTU test kit). Intercooler contaminated u Contact Service. Engine room: Air intake u Check fans and intake/exhaust lines. temperature too high...
Page 188 Black/gray exhaust gas Cause Corrective action u Check signal ring position of service indicator (→ Page 254). Air filter clogged u Replace (→ Page 212). Injector faulty u Contact Service. Engine: Excessive load u Contact Service. DPF element faulty or leaking Blue exhaust gas Cause Corrective action...
Page 189: Maintenance
8 Maintenance 8.1 Maintenance task reference table [QL1] The required maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
Page 190 Task Item Maintenance tasks WM00189 ENGINE MOUNTING Check general condition of resilient generator mounts (visual inspection) (→ Page 319) WM00188 ENGINE MOUNTING Check generator mount securing screws for firm seating (→ Page 320) WM00216 FUEL SUPPLY SYSTEM Check reading on vacuum gauge (→...
Page 191: Task Description
9 Task Description 9.1 Engine 9.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 192 Engage barring tool (2) in ring gear of fly- wheel and mount on flywheel housing. Fit ratchet (1) on barring tool. Note: No resistance other than compression resist- ance must be encountered. Rotate crankshaft in engine direction of rota- tion. Result: If the resistance exceeds the normal com- pression resistance, contact Service.
Page 193: Engine - Cranking On Starting System
9.1.2 Engine – Cranking on starting system DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before barring the engine, make sure that there are no persons in the engine's danger zone. •...
Page 194: Engine - Test Run
9.1.3 Engine – Test run DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Exhaust gases are harmful to health and may cause cancer.
Page 195: Cylinder Liner
9.2 Cylinder Liner 9.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 208). Remove injector (→...
Page 196 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 195). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...
Page 197: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination
9.2.2 Cylinder liner – Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina- tion report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
Page 198 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and burn marks are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.
Page 199: Crankcase Breather
9.3 Crankcase Breather 9.3.1 Crankcase breather – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Engine oil Filter insert (→ Spare Parts Catalog) Sealing ring (→...
Page 200 Unscrew nut (2) remove together with wash- ers. Remove cover (1) and sealing ring. Replace filter element (3). Replace sealing ring as necessary. Install sealing ring and cover (1). Screw on new nut (2) with new washers and tighten nut (2) to specified torque using a torque wrench. Name Size Type...
Page 201: Valve Drive
9.4 Valve Drive 9.4.1 Valve protrusion – Measurement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Measuring jig 1 Y4350009 Depth gauge, 200 mm Y20000918 Measuring jig 2, optional Y4350010 Preparatory steps Remove cylinder head covers (→...
Page 202 Turn measuring unit screws (1) into the threads and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque 20 Nm Set all dial gages to 0. Unscrew measuring unit (2) from calibration plate (3). Step 1: Measure valve protrusion at the valve head with measuring jig 1 Check TDC position of piston in cylinder A1: •...
Page 203 Loosen adjusting screw (1) and remove valve bridge. Do not remove rocker arm (2). Measure distance (A) between valve stem end and cylinder head top at the injector bore with depth gauge. • The specified value for a new cylinder head: 93.8 mm.
Page 204 Note: Do not remove rocker arm (2). Loosen adjusting screw (1) and remove valve bridge. Place measuring unit 2 (2) on the cylinder head (3). Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specified torque using a torque wrench.
Page 205: Valve Gear - Lubrication
9.4.2 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication Remove cylinder head covers (→ Page 208). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjusting screws with oil.
Page 206: Valve Clearance - Check And Adjustment
9.4.3 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20098771 Valve setting gauge Y4349603...
Page 207 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 208 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 209 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 210: Cylinder Head Cover - Removal And Installation
9.4.4 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30510423 Ratchet bit F30027341 Assembly compound (Kluthe Hakuform 30-15) X00067260 Engine oil O-ring...
Page 211: Injection Pump / Hp Pump
9.5 Injection Pump / HP Pump 9.5.1 HP fuel pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Fuel suction pipe F30378207 Engine oil WARNING...
Page 212 WARNING Oils/oil vapors are combustible/explosive. Risk of fire and explosion! • Avoid open flames, electric sparks and ignition sources. • Do not smoke. NOTICE HP fuel pump not filled with engine oil. Damage to components, major material damage! • Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation. NOTICE Contamination of components.
Page 213 Screw in union (1) and use a torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Neck M16x1.5 Tightening torque 40 Nm Final steps Install oil line. MS15065/01E 2019-01 | Injection Pump / HP Pump | 211...
Page 214: Injector
9.6 Injector 9.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 213). 212 | Injector | MS15065/01E 2019-01...
Page 215: Injector - Removal And Installation
9.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6789889 Milling cutter F30452739 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340...
Page 216 Nameplate The nameplate contains the following infor- mation: 1. DMC - Data Matrix Code 2. L'Orange part number 3. MTU part number 4. IIG code (Initial Injector Equalization) 5. EMI-ID code 6. Serial number 7. Date of manufacture Preparatory steps Allow HP system to cool down.
Page 217 Note: Be very cautious of system pressure. Residu- al pressure in the HP system is still 25 bar even 10 minutes after stopping the engine. Slowly undo unions on HP line (4, 6). Remove HP fuel line (5). Note: When the adapter is unscrewed, the stored volume of the injector is emptied.
Page 218 Installing new injector Note: • The new sealing ring is included in the scope of supply of the injector. • Use a multi-purpose grease without solids content. Install new sealing ring (1) abutted to (Multi- purpose grease)so that it makes contact and check that the installation position is correct.
Page 219 Coat screw head mating face and thread of hold-down clamp (2) with engine oil. Position hold-down clamp (1) correctly and use a torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 100 Nm+10 Nm Undo hold-down clamp screw again.
Page 220 Fit cable connector on injector. Resetting CDC parameters after installing new injectors Note: If the drift correction (CDC) is not reset, the emission certification becomes invalid. Reset drift compensation (CDC) using DiaSys® and enter injector code (IIG) (→ Dialog system DiaSys® E531920/..).
Page 221: Injector Rings - Replacement
9.6.3 Injector rings – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6789889 Milling cutter F30452739 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Torque wrench, 60–320 Nm...
Page 222 Nameplate The nameplate contains the following infor- mation: 1. DMC - Data Matrix Code 2. L'Orange part number 3. MTU part number 4. IIG code (Initial Injector Equalization) 5. EMI-ID code 6. Serial number 7. Date of manufacture Preparatory steps Allow HP system to cool down.
Page 223 Note: Be very cautious of system pressure. Residu- al pressure in the HP system is still 25 bar even 10 minutes after stopping the engine. Slowly loosen nuts (4, 6) and remove HP fuel line (5). Note: The fuel stored in the injector drains out when the adapter (3) is unscrewed.
Page 224 Installing injector, replacing rings Note: • Replace sealing ring (1) between injector and water sleeve whenever the injector is disassembled. • Make sure that the sealing ring (consisting of CE-ring and support ring) is correctly seated: The closed CE-ring side must be abut on the injector, and the protruding (open) CE-ring side must face towards the combustion chamber.
Page 225 Coat screw head mating face and thread of hold-down clamp (2) with engine oil. Position hold-down clamp (1) correctly and use a torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 100 Nm+10 Nm Undo hold-down clamp screw again.
Page 226 Fit cable connector on injector. Note: Do not reset drift correction (CDC) after re-in- stalling a used injector. After fitting new injectors (→ Page 213). Final steps Install cylinder head cover (→ Page 208). Open fuel supply to engine. 224 | Injector | MS15065/01E 2019-01...
Page 227: Fuel System
9.7 Fuel System 9.7.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 228 Note: See figure (a). Unlock hand pump: Hold sleeve (2). Turn han- dle (1) counterclockwise until sleeve can be moved back (arrow). 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 229: Fuel Cooler - External Contamination And Leak-Tightness Check
9.7.2 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 230: Fuel Cooler - Cleaning
9.7.3 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 231 Cleaning with compressed-air pistol Blow out cooler elements with a jet of compressed air working against the direction of the cooling air parallel to the cooling fins. Remove and dispose of dirt before putting engine into operation. Use industrial high-pressure cleaner to clean fuel cooler in case of stubborn contamination. Cleaning with industrial high-pressure cleaner Note: •...
Page 232: Fuel Filter
9.8 Fuel Filter 9.8.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 233: Additional Fuel Filter - Replacement
9.8.2 Additional fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 234: Fuel Prefilter - Pressure Ratios
9.8.3 Fuel prefilter – Pressure ratios WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Liquid or gaseous media, e.g.
Page 235: Fuel Prefilter (Non-Switchable) - Draining
9.8.4 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 236 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 237: Fuel Prefilter (Switchable) - Draining
9.8.5 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 238 During engine operation, turn the switchover level as far as the stop (arrowed) to cut out the filter module to be serviced. Result: • Filter module (1) is cut in • Filter module (2) is cut out Open threaded vent plug (1) of filter to be serviced.
Page 239 Draining fuel prefilter in case of high pressure, version B Note: The filter modules can be drained without switchover during engine operation and at engine stand- still! Provide a suitable container to collect the water. Take care when opening drain plug (1) be- cause fuel or water can spurt out.
Page 240: Fuel Prefilter (Switchable) - Low Pressure Indicator Check
9.8.6 Fuel prefilter (switchable) – Low pressure indicator check Low pressure indicator on switchable fuel prefilter Check low pressure indicator reading at low pressure gauge (3): • Red zone (1): -1.0 bar to -0.4 bar (low pressure) • Green zone (2): -0.4 bar to +0.5 bar (nor- mal operation) Switch over the fuel prefilter or replace a fil- ter element (→...
Page 241: Fuel Prefilter (Non-Switchable) - Filter Element Replacement
9.8.7 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 242 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 243: Fuel Prefilter (Switchable) - Filter Element Replacement
9.8.8 Fuel prefilter (switchable) – Filter element replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 Ratchet bit F30027340 Diesel fuel Filter parts kit (→ Spare Parts Catalog) DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 244 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 245 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 246: Fuel Prefilter - Venting
9.8.9 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 247 Undo threaded vent plugs (2, 3) unscrewing at least one rotation. Note: • Only operate the fuel priming pump man- ually! • Move the pump plunger only vertically to avoid damaging the pump! Unlock fuel priming pump, screw out han- dle (1).
Page 248: Charge-Air Cooling
9.9 Charge-Air Cooling 9.9.1 Charge-air cooler – Leak check Preconditions ☑ Engine is stopped and starting disabled. WARNING Condensation contains acid. Risk of chemical burns! • Wear protective goggles. • Wear protective gloves. Checking charge-air cooler for leaks With the engine cooled down and stationary, unscrew screws (2) with washers (3) and take off holder (4).
Page 249: Throttle Flap After Intercooler - Lever Position Check
9.9.2 Throttle flap after intercooler – Lever position check Preconditions ☑ Engine is stopped and starting disabled. DANGER Rotating, moving engine parts. Danger of crushing, danger of body parts being drawn in or caught! • Ensure that the engine can not be started. •...
Page 250: Throttle Flap After Intercooler - Teach-In Routine Initiation
9.9.3 Throttle flap after intercooler – Teach-in routine initiation DANGER Rotating, moving engine parts. Danger of crushing, danger of body parts being drawn in or caught! • Ensure that the engine can not be started. • After completion of work, make sure that all protective devices are installed. Throttle flap after intercooler –...
Page 251: Air Filter
9.10 Air Filter 9.10.1 Air filter ‒ Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Air filter ‒ Replacement Remove air filter and install new one (→ Page 251). Reset signal ring of service indicator (→ Page 254). MS15065/01E 2019-01 | Air Filter | 249...
Page 252: Air Filter - Check
9.10.2 Air filter – Check Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Checking air filter Check entire circumference of air filter for damage. Fit new air filter if damaged (→ Page 249). 250 | Air Filter | MS15065/01E 2019-01...
Page 253: Air Filter - Removal And Installation
9.10.3 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. DANGER Falling from great heights. Risk of serious injury – danger to life! • When working high on the equipment, always use suitable ladders or work platforms. •...
Page 254: Heavy Duty Air Filter - Filter Insert And Filter Element Removal And Installation
9.10.4 Heavy duty air filter – Filter insert and filter element removal and installation Preconditions ☑ Engine-generator set is stopped and starting disabled. ☑ Stepladder, platform, or similar equipment is provided. Special tools, Material, Spare parts Designation / Use Part No. Qty.
Page 255 Heavy duty air filter – Version B Release closures (1). Remove cover (2). Remove filter insert (3) and filter element (4). Wipe out filter housing (5) and cover (2) with a damp cloth. Insert new filter element (4) and filter in- sert (3).
Page 256: Air Intake
9.11 Air Intake 9.11.1 Service indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position When the yellow piston (2) has reached the red-shaded Service lettering (3), replace air filter (→ Page 249). After installation of new filter, press reset button (1).
Page 257: Exhaust Gas Aftertreatment
9.12 Exhaust Gas Aftertreatment 9.12.1 Reducing agent lines – Replacement Preconditions ☑ Work on the exhaust gas aftertreatment system shall be performed by trained and qualified personnel on- ☑ Engine shut down with master switch and circulation cooling completed. Circulation cooling may run-on for up to 7 hours after engine stop.
Page 258 NOTICE Deformation of housing. Damage to component! • Do not step on the housing. Removing reducing agent lines Shut off supply and return line from pre-feed module to RA tank. Take photos or use the Spare Parts Catalog to identify and arrange the RA lines. Provide suitable containers to collect escaping reducing agent.
Page 259 Remove reducing agent lines (blue) from RA tank. Installing reducing agent lines Ensure that all mating connectors are clean and free of deposits (e.g. urea crystals). Install new reducing agent lines in reverse order. Open supply and return line from pre-feed module to RA tank before starting engine. MS15065/01E 2019-01 | Exhaust Gas Aftertreatment | 257...
Page 260: Supply Unit - Filter Element Replacement
9.12.2 Supply unit – Filter element replacement Preconditions ☑ Work on the exhaust gas aftertreatment system shall be performed by trained and qualified personnel on- ☑ Engine shut down with master switch and circulation cooling completed. Circulation cooling may run-on for up to 7 hours after engine stop.
Page 261 WARNING High-pressure water jet. Risk of injury! • Do not direct water jet at persons, electric or electronic equipment. • Wear protective clothing, gloves, and goggles / safety mask. NOTICE Contamination of components. Damage to component! • Observe manufacturer's instructions. •...
Page 262 Installing filter Note: Only use new parts. Check parts of spare parts kit for: • Completeness • Presence of housing vent in filter housing bottom (5) • Presence of frost compensating diaphragm (3) and gasket (4) in filter housing (5) •...
Page 263: Dosing Unit - Replacement
9.12.3 Dosing unit – Replacement Preconditions ☑ Work on the exhaust gas aftertreatment system shall be performed by trained and qualified personnel on- ☑ Engine shut down with master switch and circulation cooling completed. Circulation cooling may run-on for up to 7 hours after engine stop. ☑...
Page 264 NOTICE Contamination of components. Damage to component! • Observe manufacturer's instructions. • Check components for special cleanliness. Removing dosing unit Note: Shutoff devices for the urea solution lines must be available on the plant side. Shut off supply and return line from pre-feed module to tank.
Page 265: Pre-Feed Module - Filter Element Replacement
9.12.4 Pre-feed module – Filter element replacement Preconditions ☑ Work on the exhaust gas aftertreatment system shall be performed by trained and qualified personnel on- ☑ Engine shut down with master switch and circulation cooling completed. Circulation cooling may run-on for up to 7 hours after engine stop.
Page 266 Pre-feed module – Filter ele- ment replacement Note: Shutoff devices for RA lines must be provided on the plant. Shut off supply and return line from pre-feed module to RA tank. Provide a suitable container to collect the re- ducing agent. Clean pre-feed module (1) externally before opening it.
Page 267: Nox Sensor - Replacement
9.12.5 NOx sensor – Replacement Preconditions ☑ Work on the exhaust gas aftertreatment system shall be performed by trained and qualified personnel on- ☑ Engine shut down with master switch and circulation cooling completed. Circulation cooling may run-on for up to 7 hours after engine stop. ☑...
Page 268 NOTICE High voltage. Risk of damage to components! • Switch off ignition before replacing components. NOTICE Ceramic cell breakage due to shock or impact. Risk of damage to components! • Avoid shocks and impacts. • Exercise extreme care when handling sensors. NOTICE Deformation of housing.
Page 269 Installing NOx sensors – new sensors Note: Do not wipe off thread grease of manufactur- er. Do not apply any more lubricant. Only remove protective cap from thread im- mediately before assembly. Screw in sensors by hand. Use a torque wrench to tighten hexagon (2) to specified tightening torque. Name Size Type...
Page 270: Lube Oil System, Lube Oil Circuit
9.13 Lube Oil System, Lube Oil Circuit 9.13.1 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty.
Page 271 Unscrew one of the drain screws (1 to 8) and drain engine oil. Fit drain screw (1 to 8) with new sealing ring. Engine oil filtration Check layer thickness of oil residues in the centrifugal oil filter, clean centrifugal oil filter and replace filter sleeve (→...
Page 272 Filling 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 271). 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 273: Engine Oil Level - Check
9.13.2 Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Oil is hot. Oil can contain residue/substances which are harmful to health. Risk of injury and poisoning! • Allow the product to cool to below 50 °C before beginning work. •...
Page 274: Engine Oil - Sample Extraction And Analysis
9.13.3 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit F6798833 Engine oil DANGER Components are moving or rotating.
Page 275 Screw Tightening torque (Engine oil) 20 Nm +2 Nm Using the equipment and chemicals of the MTU test kit, analyze oil for: • Dispersancy (spot test) • Water content • Fuel dilution MS15065/01E 2019-01 | Lube Oil System, Lube Oil Circuit | 273...
Page 276: Oil Priming Pump - Visual Inspection
9.13.4 Oil priming pump – Visual inspection Preconditions ☑ Engine is stopped and starting disabled. Visually inspecting oil priming pump Inspect oil priming pump and connections for firm seating and leaks. Retighten loose threaded connections as necessary. Check leak telltale bore (2) for oil discharge. Result: If oil emerges, the gear pump (1) usually has to be replaced (→...
Page 277: Oil Filtration / Cooling
9.14 Oil Filtration / Cooling 9.14.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Oil is hot.
Page 278 Replacing engine oil filter Use filter wrench to remove engine oil filter. Clean sealing surface on connecting piece. Check sealing ring (1) of new engine oil filter and apply a thin coat of engine oil. Check inscription on filter: must be “Oil Fil- ter”.
Page 279: Centrifugal Oil Filter - Cleaning And Filter Sleeve Replacement
9.14.2 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 280 Disassembling centrifugal oil fil- Remove V-band clamp (17). Undo cover nut (2) and take off cover (1). Carefully lift rotor unit (14), allow oil to drain and remove from housing. Note: Do not clamp rotor unit in a bench vise. Holding the rotor unit (14) firmly with an oil filter wrench, unscrew rotor cover (3) by turn- ing at hexagon.
Page 281 Install V-band clamp (17) and use a torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Clamp Tightening torque 20 Nm ±3 Nm Use a torque wrench to tighten cover nut (2) to specified tightening torque. Name Size Type...
Page 282: Coolant System, General, High-Temperature Circuit
9.15 Coolant System, General, High-Temperature Circuit 9.15.1 Engine coolant level – Check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. DANGER Falling from great heights. Risk of serious injury – danger to life! •...
Page 283 Checking coolant level by means of level sensor Switch on engine control system and check readings on the display. Top up coolant if necessary (→ Page 285). MS15065/01E 2019-01 | Coolant System, General, High-Temperature Circuit | 281...
Page 284: Engine Coolant Change
9.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 283). Fill with engine coolant (→ Page 285). 282 | Coolant System, General, High-Temperature Circuit | MS15065/01E 2019-01...
Page 285: Engine Coolant - Draining
9.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. DANGER Falling from great heights. Risk of serious injury – danger to life! • When working high on the equipment, always use suitable ladders or work platforms. •...
Page 286 Close all other open drain points. Position valve cover on filler neck and close. 284 | Coolant System, General, High-Temperature Circuit | MS15065/01E 2019-01...
Page 287: Engine Coolant - Filling
9.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Ratchet bit...
Page 288 Preparatory steps Turn valve cover on coolant expansion tank (1) counterclockwise until the first stop and release pressure. Continue to turn valve cover (1) counter- clockwise and remove. Filling with coolant from below using a pump Open venting point on distributor (arrowed). Note: Important: Fill engine only from below! Connect appropriate pump with hose to drain...
Page 289 Use a torque wrench to tighten shutoff cock at elbow of engine coolant pump (2) to specified tightening tor- que. Name Size Type Lubricant Value/Standard Spindle 11 A/F Tightening torque 12 Nm Check proper condition of valve cover on coolant expansion tank, clean sealing faces if required. Fit valve cover and close it.
Page 290 Top up coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. When coolant emerges from the venting point, close the venting point. Check proper condition of valve cover (1) on coolant expansion tank and clean sealing faces if required.
Page 291: Engine Coolant Pump - Relief Bore Check
9.15.5 Engine coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Hot components/surfaces.
Page 292: Engine Coolant - Sample Extraction And Analysis
9.15.6 Engine coolant – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit F6798833 DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 293 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/..)). MS15065/01E 2019-01 | Coolant System, General, High-Temperature Circuit | 291...
Page 294: Preheater - Overview
9.15.7 Preheater – Overview 1 Outlet 5 Control thermostat 9 Pump 2 24 VDC input 6 Intake Arrow Flow direction 3 Main power supply input 7 Safety thermostat 4 Control box 8 Housing cover Variant Heating output Rated voltage Frequency Phases 9 kW 400 V...
Page 295: Preheater - Function And Leak Check
9.15.8 Preheater – Function and leak check Preconditions ☑ Preheater is switched on. WARNING Coolant is hot and highly pressurized. Risk of injury! Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Coolant contains antifreeze and is toxic.
Page 296: Preheater - Overhaul
9.15.9 Preheater – Overhaul Preconditions ☑ Engine is stopped and starting disabled. ☑ All preheater power sources are disconnected. Replacing solenoid switch Replace solenoid switch (→ Page 295). Cleaning heating element and replacing gasket Clean heating element and housing and check (→ Page 297). Replacing thermostat Replace thermostat (→...
Page 297: Preheater - Solenoid Switch Replacement
9.15.10 Preheater – Solenoid switch replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solenoid switch (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 298 Replacing solenoid switch Undo screws on control box (1) and open control box. 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.
Page 299: Preheater - Heating Element And Housing Check
9.15.11 Preheater – Heating element and housing check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Screw locking compound (Loctite 586) 40033 O-ring (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 300 Open drain plug at coolant inlet (arrow) and drain coolant. Undo clamps on both lines on preheater side. Checking heating element and housing for contamination Undo screws (1) between electrical part (2) and housing. Pull electrical part (2) with heating element out of housing.
Page 301 Final steps Connect preheater power sources. Switch on preheater. MS15065/01E 2019-01 | Coolant System, General, High-Temperature Circuit | 299...
Page 302: Preheater Thermostats - Replacement
9.15.12 Preheater thermostats – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Thermostat (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 303 Replacing safety thermostat Undo screws (1) on cover of electrical part (2) and remove cover. 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.
Page 304 Mark cables prior to disconnection. Disconnect wires. Remove screws (2) and control thermo- stat (1). Install new control thermostat (1) with screws (2). Connect cable. Fit housing cover and tighten screws. Final steps Connect preheater to power supply. Switch on preheater. 302 | Coolant System, General, High-Temperature Circuit | MS15065/01E 2019-01...
Page 305: Coolant Expansion Tank Valve Cover - Replacement
9.15.13 Coolant expansion tank valve cover – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Valve cover (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
Page 306: Low-Temperature Circuit
9.16 Low-Temperature Circuit 9.16.1 Charge-air coolant level – Check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. DANGER Falling from great heights. Risk of serious injury – danger to life! • When working high on the equipment, always use suitable ladders or work platforms.
Page 307 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 309). MS15065/01E 2019-01 | Low-Temperature Circuit | 305...
Page 308: Charge-Air Coolant - Change
9.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 307). Fill with charge-air coolant (→ Page 309). 306 | Low-Temperature Circuit | MS15065/01E 2019-01...
Page 309: Charge-Air Coolant - Draining
9.16.3 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Ratchet bit F30027340 Sealing ring (→ Spare Parts Catalog) DANGER Falling from great heights. Risk of serious injury –...
Page 310 Unscrew drain screw (1) and drain charge-air coolant at thermostat housing. Open drain valve (2) and drain charge-air coolant at charge-air coolant pump. 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...
Page 311: Charge-Air Coolant - Filling
9.16.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Ratchet bit...
Page 312 Preparatory steps Turn valve cover on coolant expansion tank (1) counterclockwise until the first stop and release pressure. Continue to turn valve cover (1) counter- clockwise and remove. Filling coolant with pump Connect appropriate pump with hose to drain valve (1). Release the vent line union at the distributor piece (1).
Page 313 Close drain valve and use a torque wrench to tighten to specified tightening torque . Name Size Type Lubricant Value/Standard Spindle 11 A/F Tightening torque 12 Nm Check proper condition of valve cover and clean sealing faces if required. Position valve cover on filler neck and close. Start engine (→...
Page 314: Charge-Air Coolant Pump - Relief Bore Check
9.16.5 Charge-air coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Hot components/surfaces.
Page 315: Belt Drive
9.17 Belt Drive 9.17.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. WARNING Exposed rotating parts can eject drawn-in components or draw in body parts. Risk of crushing, limbs or extremities may be pinched, trapped or entangled! Risk of injury due to flying parts! •...
Page 316: Battery-Charging Generator
9.18 Battery-Charging Generator 9.18.1 Battery-charging generator – Drive belt tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm F30452768 Ratchet bit F30027341 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340...
Page 317: Battery-Charging Generator Drive - Drive Belt Replacement
9.18.2 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm F30452768 Ratchet bit F30027341 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Drive belt...
Page 318: Engine Mounting / Support
9.19 Engine Mounting / Support 9.19.1 Engine mounting – Checking resilient element NOTICE Contamination of engine mounts made of natural rubber with fuel or oil. Engine mounts swell. Risk of shorter service life or destruction of the mounts! • Cover engine mounts when working with fuel or oil. •...
Page 319: Engine Mounting - Checking Securing Screws For Firm Seating
9.19.2 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 320 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 321: Generator Mounting - Check
9.19.3 Generator mounting – Check Special tools, Material, Spare parts Designation / Use Part No. Qty. Resilient element (→ Spare Parts Catalog) NOTICE Contamination of engine mounts made of natural rubber with fuel or oil. Engine mounts swell. Risk of shorter service life or destruction of the mounts! •...
Page 322: Generator Mounting - Securing Screw Firm Seating Check
9.19.4 Generator mounting – Securing screw firm seating check Preconditions ☑ Engine is stopped and starting disabled. Generator mounting, securing screw firm seating check Check securing screws for firm seating. Tighten loose screws. 320 | Engine Mounting / Support | MS15065/01E 2019-01...
Page 323: Wiring (General) For Engine/Gearbox/Unit
9.20 Wiring (General) for Engine/Gearbox/Unit 9.20.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.
Page 324: Accessories For (Electronic) Engine Governor / Control System
9.21 Accessories for (Electronic) Engine Governor / Control System 9.21.1 Engine governor and connector – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g.
Page 325: Engine Control Unit Plug Connections - Check
9.21.2 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 326: Engine Governor Ecu 9 - Removal And Installation
9.21.3 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 327: Abbreviations
— Baureihe Series British Thermal Unit British unit for heat energy Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publica- tion No. A0106x Cranking Amperes Starting current supplied by a battery at 0 °C (32 °F) Computer-Aided Design — Controller Area Network...
Page 328 Abbre- Meaning Explanation viation Cubic Feet per Minute Unit of flow rate Communication equipment Hardware interface (serial connection) Carbon Dioxide Carbon dioxide Cyclic Redundancy Control Checksum procedure to detect data transmission faults Continuous Regeneration Trap — Canadian Standards Association Canadian standardization association Current Transformer —...
Page 329 Abbre- Meaning Explanation viation High Temperature — ICXN ISO Continuous Exceedable Power specification category as per ISO 3046-1. ISO standard power; continuous power value with 10% overload capability Identification (number) — International Electrotechnical Commission International standardization organization for electri- cal, electronic and associated technologies IEEE Institute of Electrical und Electronic Engi- International organization for the promotion of tech-...
Page 330 Abbre- Meaning Explanation viation OSHA Occupational Safety and Health Administra- US American federal authority for health and safety tion at work Oberer Totpunkt Top Dead Center Panel Control panel Power Factor — Pre-Feed Module — Phase — Permanentmagnet Permanent magnet Particulate Matter Particles Permanentmagnetgenerator...
Page 331 Abbre- Meaning Explanation viation Technical Evolution Network Technical sales documentation, engine data, techni- cal data Transfer Switch — T-xyz Temperature-xyz Temperature measuring point xyz Symbol for electric voltage User Datagram Protocol Network protocol for communication via Ethernet Underwriters Laboratories Global non-profit-making organization for product safety testing and certification Ultra- UltraCaps modules...
Page 332: Conversion Tables
10.2 Conversion tables Length Unit A multiplied by factor = Unit B 25.4 = mm 0.3048 0.9144 stat. mile 1.609 = km 1.852 = km = ft = in Unit B multiplied by factor = Unit A 0.03937 = in 3.281 = ft 0.6215...
Page 333 Volumetric flow Unit A multiplied by factor = Unit B gal/min (GPM, U.S.) 3.79 = l/min gal/min (GPM, U.S.) 0.134 = ft /min (cfm) 1.70 /min (cfm) Unit B multiplied by factor = Unit A l/min 0.264 = gal/min (U.S.) 7.48 = gal/min (U.S.) /min (cfm)
Page 334 Density Unit A multiplied by factor = Unit B 515.4 slug/ft = kg/m Unit B multiplied by factor = Unit A 0.00194 kg/m = slug/ft Torque Unit A multiplied by factor = Unit B lbf ft 1.3558 = Nm Unit B multiplied by factor = Unit A 0.7376...
Page 335 Unit B multiplied by factor = Unit A 0.7376 = lbf ft 0.0002388 = kcal 0.0009478 = BTU 0.00052656 = CHU Power Unit A multiplied by factor = Unit B 0.7355 = kW 0.7457 = kW BTU/s 1.054 = kW kcal/h 1.163 = lbf ft/s...
Page 336: 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 337: Special Tools
11 Appendix B 11.1 Special Tools Angular screw driver Part No.: F30002815 Qty.: Used in: 9.4.3 Valve clearance – Check and adjustment (→ Page 204) Barring tool Part No.: F6555766 Qty.: Used in: 9.1.1 Engine – Barring manually (→ Page 189) Qty.: Used in: 9.2.1 Cylinder liner –...
Page 338 Depth gauge, 200 mm Part No.: Y20000918 Qty.: Used in: 9.4.1 Valve protrusion – Measurement (→ Page 199) Endoscope Part No.: Y20097353 Qty.: Used in: 9.2.1 Cylinder liner – Endoscopic examination (→ Page 193) Feeler gauge Part No.: Y20098771 Qty.: Used in: 9.4.3 Valve clearance –...
Page 339 Filter wrench, 27 A/F Part No.: Qty.: Used in: 9.12.4 Pre-feed module – Filter element replacement (→ Page 263) Fuel suction pipe Part No.: F30378207 Qty.: Used in: 9.5.1 HP fuel pump – Filling with engine oil (→ Page 209) High-pressure cleaner Part No.: Qty.:...
Page 340 Qty.: Used in: 9.6.2 Injector – Removal and installation (→ Page 213) Qty.: Used in: 9.6.3 Injector rings – Replacement (→ Page 219) MTU test kit Part No.: F6798833 Qty.: Used in: 9.13.3 Engine oil – Sample extraction and analysis (→...
Page 341 Oil filter wrench Part No.: F30455924 Qty.: Used in: 9.14.2 Centrifugal oil filter – Cleaning and filter sleeve re- placement (→ Page 277) Ratchet bit Part No.: F30027340 Qty.: Used in: 2.4 Crankshaft transport locking device (→ Page 29) Qty.: Used in: 9.6.2 Injector –...
Page 342 Ratchet bit Part No.: F30027341 Qty.: Used in: 9.4.4 Cylinder head cover – Removal and installation (→ Page 208) Qty.: Used in: 9.6.2 Injector – Removal and installation (→ Page 213) Qty.: Used in: 9.6.3 Injector rings – Replacement (→ Page 219) Qty.: Used in: 9.13.1 Engine oil –...
Page 343 Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 9.4.3 Valve clearance – Check and adjustment (→ Page 204) Socket, A/F 46 Part No.: F30006128 Qty.: Used in: 9.12.2 Supply unit – Filter element replacement (→ Page 258) Torque screwdriver, 1–5 Nm Part No.: F30452774 Qty.:...
Page 344 Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 2.4 Crankshaft transport locking device (→ Page 29) Qty.: Used in: 9.3.1 Crankcase breather – Filter element replacement (→ Page 197) Qty.: Used in: 9.5.1 HP fuel pump – Filling with engine oil (→ Page 209) Qty.: Used in: 9.6.2 Injector –...
Page 345 Torque wrench, 4–20 Nm Part No.: F30044239 Qty.: Used in: 9.14.2 Centrifugal oil filter – Cleaning and filter sleeve re- placement (→ Page 277) Qty.: Used in: 9.15.4 Engine coolant – Filling (→ Page 285) Qty.: Used in: 9.16.3 Charge-air coolant – Draining (→ Page 307) Qty.: Used in: 9.16.4 Charge-air coolant –...
Page 346 Torque wrench, 6–50 Nm Part No.: F30027336 Qty.: Used in: 9.8.7 Fuel prefilter (non-switchable) – Filter element re- placement (→ Page 239) Qty.: Used in: 9.8.8 Fuel prefilter (switchable) – Filter element replace- ment (→ Page 241) Torque wrench, 8–40 Nm Part No.: F30043446 Qty.:...
Page 347: Index
11.2 Index Crankcase breather – Filter element replacement 197 Abbreviations 325 Crankshaft transport locking device Actuators – Installation 29 – Overview 67 – Removal 29 Additional fuel filter Cylinder – Replacement 231 – Designation 33 After stopping the engine Cylinder head cover –...
Page 348 Engine Exhaust gas aftertreatment system – Barring – Main dimensions 107 – Manually 189 – Overview 71 – Cranking – Regeneration procedure 125 – On starting system 191 – Emergency start (Override mode) 119 Fault messages – Emergency stop 121 –...
Page 349 312 Maintenance schedule Putting the engine-generator set into operation after ex- – Maintenance task reference table [QL1] 187 tended out-of-service-periods (>3 months) 111 MTU contact persons 334 Putting the engine-generator set into operation after scheduled out-of-service-period 112 Nameplate 39 NOx sensor RA dosing system ...
Page 350 Valve gear 51 – Lubrication 203 Safety regulations Valve protrusion – Assembly work 14 – Measurement 199 – Auxiliary materials 18 – Environmental protection 18 – Fire prevention 18 Warning notices, standards 20 – Fluids and lubricants 18 – Important provisions 6, 10 –...

This manual is also suitable for:

12v4000g25s 12v4000g75s 12v4000g85s 12v4000g15s

MTU 12V4000Gx5S Series Operating Instructions Manual

1 Safety

2 Transport

3 General Information

4 Functional Description

5 Technical Data

6 Operation

7 Troubleshooting

8 Maintenance

9 Task Description

10 Appendix A

11 Appendix B

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Summary of Contents for MTU 12V4000Gx5S Series