MTU 12 V 4000 G73 Operating Instructions Manual
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MTU 12 V 4000 G73 Operating Instructions Manual

MTU 12 V 4000 G73 Operating Instructions Manual

Diesel engine
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Operating Instructions
Diesel engine
12 V 4000 G73
16 V 4000 G73
Application group 3B
MS150054/02E

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Summary of Contents for MTU 12 V 4000 G73

  • Page 1 Operating Instructions Diesel engine 12 V 4000 G73 16 V 4000 G73 Application group 3B MS150054/02E...
  • Page 2 This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐ filming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 4.9 After stopping the engine – putting the engine out of service 1.1 General conditions 1.2 Personnel and organizational requirements 1.3 Transport 5 Maintenance 1.4 Crankshaft transport locking device 1.5 Safety regulations for startup and operation 5.1 Maintenance task reference table [QL1] 1.6 Explosion hazard when removing inspection port cover on engine...
  • Page 4 8 Appendix A Temperature Circuit 8.1 Abbreviations 7.15.1 Engine coolant – Level check 8.2 MTU contacts/service partners 7.15.2 Engine coolant – Change 7.15.3 Engine coolant – Draining 7.15.4 Engine coolant – Filling 7.15.5 Engine coolant pump – Relief bore check 9 Appendix B 7.15.6 Engine coolant –...

  • Page 5: Safety

    Modifications or conversions Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided in such case.

  • Page 6: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Personnel requirements Work on the engine must only be carried out by appropriately qualified and instructed personnel. Observe the minimum legal age. Responsibilities of the operating, maintenance and repair personnel must be specified by the operating company.

  • Page 7: Transport

    Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.

  • Page 8: Crankshaft Transport Locking Device

    1.4 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Torque wrench, 60-320 Nm F30047446 Engine oil Transport locking device Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine transport.
  • Page 9 Fitting the transport locking device on driving end (KS) Note: Always use the screws supplied with or installed in the transport locking device to secure it on the en‐ gine. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel housing and tighten to the specified tightening torque.
  • Page 10 Installing guard plates and engine mounting brackets (if applicable) on driving end (KS) Note: Always use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure them on the engine. Install engine mounting brackets (2) on both sides with guard plates (1) washers (3), and screws (4).

  • Page 11: Safety Regulations For Startup And Operation

    Safety requirements for initial operation Prior to initial operation of the unit, install the assembly or unit according to the specifications and check the installation according to the MTU specifications. Before putting the device or plant into operation, always ensure: •...

  • Page 12: Explosion Hazard When Removing Inspection Port Cover On Engine

    1.6 Explosion hazard when removing inspection port cover on engine DANGER Explosion hazard due to oil vapors. Risk of serious injury – danger to life! • Allow the engine to cool down before opening the crankcase! • Avoid open flames, electrical sparks and ignition sources. Safety instructions Before starting maintenance work, allow the engine to cool down for at least 10 min.

  • Page 13: Safety Regulations For Maintenance And Repair Work

    1.7 Safety regulations for maintenance and repair work Safety regulations for maintenance and repair work Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
  • Page 14 Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
  • Page 15 For conducting light-beam procedures and measurement work, only the following laser devices must be used: • Laser devices of classes 1, 2 or 3A. • Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.

  • Page 16: Fluids And Lubricants, Fire Prevention And Environmental Protection

    Use only fuel of prescribed quality to comply with emission limit values. Dispose of used fluids, lubricants and filters in accordance with local regulations. Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are subjected to proper recycling procedures.
  • Page 17 Lead • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 18: Conventions For Safety Instructions In The Text

    1.9 Conventions for safety instructions in the text DANGER In the event of immediate danger. Consequences: Death or serious injury • Remedial action WARNING In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action CAUTION In the event of dangerous situations.

  • Page 19: General Information

    2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).

  • Page 20: Engine Layout

    2.2 Engine layout Illustration also applicable to 16 V 1 Oil cooler 8 Intercooler 18 Fuel filter 2 Crankcase breather 9 Flywheel 19 HP fuel pump 3 Exhaust pipe 10 Lifting eye 20 Engine oil filter, (automat‐ 4 Combustion-air inlet con‐ 11 Starter ic oil filter is optional) nection (elbows are op‐...

  • Page 21: Sensors, Actuators And Injectors - Overview

    2.3 Sensors, actuators and injectors – Overview Illustration also applicable to 16 V a Version with easy-change 3 F46 Leak fuel level moni‐ 7 B07 Engine oil tempera‐ filter toring ture b Version with automatic fil‐ 4 M8 Suction restrictor (HP 8 XY44 Solenoid valve of pump) fan clutch...
  • Page 22 1 B50 Crankcase pressure 5 B01 Camshaft speed 8 B06 Engine coolant tem‐ 2 B05 Engine oil pressure 6 B43 Charge-air coolant perature 3 B33 Fuel temperature in pressure Common Rail 7 B26 Charge-air coolant 4 B48 Fuel pressure in temperature Common Rail 22 | General Information | MS150054/02E 2012-02...
  • Page 23 1 Injectors Y39.11 to Y39.n 3 B10 Charge-air pressure 6 Engine governor (B-side) 4 XM2 Oil priming pump 2 B16 Engine coolant pres‐ 5 B09 Charge-air tempera‐ sure ture The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and necessa‐ ry activities (→...
  • Page 24 1 B13 Crankshaft speed 24 | General Information | MS150054/02E 2012-02...

  • Page 25: Technical Data

    3 Technical Data 3.1 12, 16V 4000 G73 engine data, emissions-optimized (EPA - Tier 2) Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated without changes (e.g. of power set‐ ting) Not yet defined value Not applicable...
  • Page 26 MODEL-RELATED DATA (basic design) Number of cylinders Engine with turbochargers (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Working method: four-stroke diesel engine, single-acting Combustion method: direct injection Cooling method: treated water Direction of rotation: c.c.w. (viewed on driving end) Number of cylinders Cylinder configuration: V angle Degrees...
  • Page 27 LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from °C Lube-oil operating temperature before engine, to °C Lube-oil temperature before engine, warning °C Lube-oil temperature before engine, shutdown °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to FUEL SYSTEM Number of cylinders...

  • Page 28: Firing Order

    3.2 Firing order Number of cyl‐ Firing order inders 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 28 | Technical Data | MS150054/02E 2012-02...

  • Page 29: Engine - Main Dimensions

    3.3 Engine – Main dimensions Engine – Main dimensions Length approx. 2550 mm approx. 3020 mm Width (B) 12V approx. 1590 mm approx. 1590 mm Height (C) 12V approx. 1870 mm approx. 1870 mm MS150054/02E 2012-02 | Technical Data | 29...

  • Page 30: Operation

    4.1 Putting the engine into operation after extended out-of- service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting into operation after long out-of-service periods (>3 months) Item Action Engine Depreserve (→...

  • Page 31: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 102). Coolant circuit Check engine coolant level (→ Page 116), check charge-air coolant level (→...

  • Page 32: Start Engine In Manual Mode (Testing Mode)

    4.3 Start engine in manual mode (testing mode) Preconditions ☑ Generator (if provided) not connected to network. ☑ External start interlock is not activated. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A).

  • Page 33: Starting The Engine In Emergency Situations (Override Mode)

    4.4 Starting the engine in emergency situations (override mode) CAUTION Safety functions and engine shutdown alarms will be disregarded. Serious damage to plant! • Initiate emergency start only in emergency situations. Preparation Item Task Operating mode switch Set to emergency mode. Starting the engine in emergency situations Item Task...

  • Page 34: Operational Checks

    4.5 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 35: Stop Engine In Manual Mode (Testing Mode)

    4.6 Stop engine in manual mode (testing mode) Preconditions ☑ Generator (if provided) not connected to network. ☑ Engine is running in manual mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! •...

  • Page 36: Emergency Stop

    4.7 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop Item Action Emergency stop pushbut‐ Press EMERGENCY STOP button. • Engine is stopped by disconnecting the power supply to the ECU; •...

  • Page 37: After Stopping The Engine - Engine Remains Ready For Operation

    4.8 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 MS150054/02E 2012-02 | Operation | 37...

  • Page 38: After Stopping The Engine - Putting The Engine Out Of Service

    If the engine is to remain out of service for more than 1 week, seal the engine's air and exhaust sides. If the engine is to remain out of service for more than 1 month, preserve engine (→ MTU Fluids and Lubricants Speci‐ fications A001061/.. ).

  • Page 39: Maintenance

    5 Maintenance 5.1 Maintenance task reference table [QL1] The 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 40: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Cause Action Battery Low or faulty Charge or replace (see manufacturer's documentation). Cable connections defective Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter Engine wiring or starter defective Check if cable connections are proper‐...
  • Page 41 Faulty Contact Service. Charge air temperature too high Component Cause Action Engine coolant Incorrect engine coolant concentration. Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air inlet temperature too high. Check fans and intake/exhaust lines. Charge-air pressure too low...
  • Page 42 Blue exhaust gas Component Cause Action Engine oil Too much oil in engine. Drain engine oil (→ Page 103). Oil separator of crankcase breather Replace (→ Page 70). contaminated Exhaust turbocharg‐ Faulty Contact Service. er, cylinder head, pis‐ ton rings, cylinder lin‐ White exhaust gas Component Cause...

  • Page 43: Engine Governor Adec (Ecu 7) For Series 4000 Oil &Gas Engines - Fault Messages

    6.2 Engine governor ADEC (ECU 7) for Series 4000 Oil &Gas engines – Fault messages The fault code numbers are generated by the engine governor and transmitted to the display below. The fault code (1) comprises three digits. Fault messages may also be caused by faulty sensors/actuators. Contact Service to have sensors/actua‐ tors tested and replaced as necessary if troubleshooting as described in the table below proves unsuc‐...
  • Page 44 Related Fault code parameter Designation Meaning Task Check oil level, top Oil pressure too low up as necessary 2.0100.92 LO P-Lube Oil (1st limit value). (→ Page 102). 1. Check oil level, top up as necessa‐ ry (→ Page 102). Oil pressure too low 2.
  • Page 45 Related Fault code parameter Designation Meaning Task Alarm configuration limit value 1; preliminary warn‐ ing: speed of primary turbo‐ 2.3011.93 HI ETC1 Overspeed charger too high. Contact Service. Automatic power reduction by en‐ gine control sys‐ ETC 1 – overspeed (2nd tem.
  • Page 46 Related Fault code parameter Designation Meaning Task Check fuel lines for leaks. Clean fuel prefilter. Flush fuel prefilter. Replace filter ele‐ ment of fuel prefil‐ ter. Fuel supply pressure too Replace fuel filter 2.0102.92 LO P-Fuel low (1st limit). (→ Page 85). Check fuel lines for leaks.
  • Page 47 Related Fault code parameter Designation Meaning Task Preliminary warning: Recir‐ culation temperature too 2.0128.93 HI T-Recirculation high. Reduce power. Main warning: Recirculation 2.0128.93 SS T-Recirculation temperature too high. Reduce power. Engine speed did not attain SS Engine Speed too 200 rpm. A stop is activat‐ Check for addition‐...
  • Page 48 Related Fault code parameter Designation Meaning Task Supply voltage too high Check ECU supply (2nd limit value); automatic voltage. HIHI ECU Power Sup‐ engine shutdown (configu‐ 2.0140.93 ply Voltage rable). Contact Service. 1. Improve engine room ventilation. Temperature in ECU hous‐ 2.0132.92 HI T-ECU ing too high (1st limit value).
  • Page 49 Related Fault code parameter Designation Meaning Task Alarm configuration; This error message is generated if a CRC is faulty during a data upload to ADEC (indi‐ AL LifeData restore in‐ cated for each indiv. mod‐ 2.4000.00 complete ule). Contact Service. Alarm configuration;...
  • Page 50 Related Fault code parameter Designation Meaning Task Contact Service. Check that at least one CAN station is available. Check cabling as re‐ CAN 2 in Error-Passive quired. Check state, minor bus disruption shielding, improve 2.0500.68 AL CAN2 Error Passive or CAN station missing. as necessary.
  • Page 51 Related Fault code parameter Designation Meaning Task 1. Check cabling. Sensor B50 faulty (crank‐ 2. Replace if nec‐ 1.8004.56 SD P-CrankCase case pressure). essary. 1. Check cabling. Sensor B48 faulty (rail pres‐ sure, HP regulator); emer‐ 2. Replace if nec‐ 1.8004.56 SD P-HD gency mode active.
  • Page 52 Related Fault code parameter Designation Meaning Task 1. Check sensor and wiring. Sensor B13 faulty (crank‐ 1.8004.49 SD crankshaft Speed shaft speed). 2. Contact Service. 1. Check sensor and wiring. Sensor B1 faulty (camshaft 1.8004.49 SD Camshaft Speed speed). 2. Contact Service. 1.
  • Page 53 Related Fault code parameter Designation Meaning Task Replace injector concerned if the Timing Bank 1 (solenoid fault message ap‐ AL Timing Cylinder valve 1) ... Timing Bank 1 pears frequently 1.8004.50 (A1-A10) (solenoid valve 10) (→ Page 78). 1.8004.50 1.8004.50 1.8004.50 1.8004.50 1.8004.50...
  • Page 54 Related Fault code parameter Designation Meaning Task 1. Check solenoid Wiring Bank 1 (solenoid valve. AL Wiring Cylinder (A1- valve 1) ... Wiring Bank 1 1.8004.52 A10) (solenoid valve 10) 2. Contact Service. 1.8004.52 1.8004.52 1.8004.52 1.8004.52 1.8004.52 1.8004.52 1.8004.52 1.8004.52 1.8004.52 1.
  • Page 55 Related Fault code parameter Designation Meaning Task 1.8004.54 1.8004.54 1.8004.54 1.8004.54 1.8004.54 1.8004.54 1.8004.54 1.8004.54 1.8004.54 1. Check solenoid Open Load Bank 2 (sole‐ valve. AL Open Load Cylinder noid valve 1) ... Open Load 1.8004.55 (B1- B10) Bank 2 (solenoid valve 10) 2.
  • Page 56 Related Fault code parameter Designation Meaning Task Alarm configuration; Internal electronic fault (electronics possibly faulty: Start ITS). If 1. Check solenoid the ITS diagnosis result is valve cabling. "electronics OK", note fur‐ ther fault messages (e.g. 2. Replace engine 1.8004.49 AL Power Stage High cabling faults).
  • Page 57 Related Fault code parameter Designation Meaning Task Alarm configuration; Short circuit or wire break on tran‐ sistor output, plant-side 3 Check cabling to 2.8006.64 AL Wiring TOP 3 (TOP 3). plant. Alarm configuration; Short circuit or wire break on tran‐ sistor output, plant-side 4 Check cabling to 2.8006.64...
  • Page 58 Related Fault code parameter Designation Meaning Task 1. Check cabling. Alarm configuration; Line disruption on digital input 3; 2. Contact Serv‐ AL Open Load Digital Cabling faulty or no resist‐ ice.; Check input of 2.8006.62 Input 3 ance over switch. target device.
  • Page 59 Related Fault code parameter Designation Meaning Task 1. Check cabling. 2. Check power Alarm configuration limit supply. value; Main warning: Injec‐ 2.0141.93 HIHI U-PDU tor voltage too high. 3. Contact Service. Alarm configuration limit HI Level Water Fuel value 1; Warning: water lev‐ 2.0156.93 Prefilter el in fuel prefilter too high.
  • Page 60 Related Fault code parameter Designation Meaning Task SD alarm configuration; In‐ jector power stage sensor defect; Internal fault in Replace ADEC 1.8004.57 SD U-PDU ECU7. (ECU 7). SD alarm configuration; Ambient air pressure sensor Replace engine 1.8004.58 SD P-Ambient Air faulty.
  • Page 61 Related Fault code parameter Designation Meaning Task Check signal sen‐ sor and cabling, replace as neces‐ sary. SD alarm configuration; An‐ alog input signal for Aux 2 Error cleared after faulty; Short circuit or wire restarting the en‐ 1.8004.59 SD AUX 2 break.
  • Page 62 Related Fault code parameter Designation Meaning Task Alarm configuration; Engine stop, since all shutdown 1. Check cabling. channels have "sensor faul‐ 2.8006.59 AL Stop SD ty". 2. Contact Service. Alarm configuration; Cable 1. Check cabling. break or short circuit on 1.8004.59 AL Wiring PWM_CM2 channel PWM_CM2.

  • Page 63: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 64: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • before barring or starting the engine, ensure that nobody is in the danger zone. • After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.

  • Page 65: Engine - Test Run

    7.1.3 Engine – Test run DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 66: Cylinder Liner

    7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 76). Remove injector (→...
  • Page 67 Final steps Install injector (→ Page 79). Install cylinder head cover (→ Page 76). MS150054/02E 2012-02 | Task Description | 67...

  • Page 68: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    7.2.2 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 exami‐ nation report. Findings Measure Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
  • Page 69 Findings Measure Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring 2 onwards and less pro‐ nounced from TDC-ring 1.

  • Page 70: Crankcase Breather

    7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027340 Engine oil Filter element...
  • Page 71 Checking diaphragm Remove cover (4). Remove spring (5), gasket (2) and dia‐ phragm (3). Check diaphragm (3) for damage, fit new diaphragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).

  • Page 72: Valve Drive

    7.4 Valve Drive 7.4.1 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication Remove cylinder head covers (→ Page 76). Fill oil chambers of valve bridges with oil.

  • Page 73: Valve Clearance - Check And Adjustment

    7.4.2 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 Y20010128 Torque wrench, 60-320 Nm F30047446...
  • Page 74 Diagram for 12V engines (two crankshaft positions) Diagram for 16V 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 75 Adjusting valve clearance Release locknut (1). Insert feeler gauge between valve bridge and rocker arm. Using Allen key, set adjusting screw (2) so that the specified valve clearance is provid‐ Feeler gauge must just pass through the gap. Tighten locknut (1) to 90 +9 Nm, holding adjusting screw (2) firmly.

  • Page 76: Cylinder Head Cover - Removal And Installation

    7.4.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/Emulgier) X00058061 O-ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (3) prior to removal.

  • Page 77: Injection Pump / Hp Pump

    7.5 Injection Pump / HP Pump 7.5.1 HP pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 78: Injection Valve / Injector

    7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 79). 78 | Task Description | MS150054/02E 2012-02...

  • Page 79: Injector - Removal And Installation

    7.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal tool F6789889 Milling cutter F30452739 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30452769 Torque wrench, 60-320 Nm F30452768...
  • Page 80 Remove HP fuel line (4). Remove return line (5). Note: The injector accumulator will be emptied when removing the adapter. Remove adapter (3). Remove screw (2) and take off hold-down clamp (1). Install installation/removal tool on cylinder head. Remove injector with installation/removal tool.
  • Page 81 Installing injector Remove plug before installing the injec‐ tor. (Do not remove the plug from the HP line before installing the adapter.) Coat injector with assembly paste at the seat of the nozzle clamping nut. Fit new sealing ring (4) (included in the scope of supply of the injector) with grease on injector, observe installation position of sealing ring (4).
  • Page 82 Coat screw head mating face (2) and thread with engine oil. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the specified initial tightening torque. Name Size Type Lubricant Value/Standard Screw Preload torque (Engine oil) 5 Nm to 10 Nm Note:...
  • Page 83 Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening sequence: 1 Adapter (4) 2 Rail (6) Name Size Type Lubricant Value/Standard Union nut / thrust Tightening torque 40 Nm + 5 Nm screw Fit cable connector onto injector.

  • Page 84: Fuel System

    7.7 Fuel System 7.7.1 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. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 85: Fuel Filter

    7.8 Fuel Filter 7.8.1 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. Risk of fire and explosion! •...

  • Page 86: Fuel Prefilter Cleaning

    7.8.2 Fuel prefilter cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Sealing ring (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 87: Fuel Prefilter - Differential Pressure Gauge Check And Adjustment

    7.8.3 Fuel prefilter – Differential pressure gauge check and adjustment DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 88: Fuel Prefilter - Draining

    7.8.4 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 89 7.8.5 Fuel prefilter ‒ Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Gasket (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Fuels are combustible.
  • Page 90 Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the un‐ filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6).
  • Page 91 7.8.6 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible.
  • Page 92 Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐ ment (3).
  • Page 93 7.9 Charge-Air Cooling 7.9.1 Intercooler – Check drain for coolant leakage and obstruction DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...
  • Page 94 7.10 Air Filter 7.10.1 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 95). Reset signal ring of service indicator (→ Page 97). 94 | Task Description | MS150054/02E 2012-02...
  • Page 95 7.10.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installation Release clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it.
  • Page 96 7.10.3 Rubber sleeves between air intake elbow and turbocharger – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Rubber sleeve (→ Spare Parts Catalog) Also applicable to 12 V Preparatory steps Remove air filter (→...
  • Page 97 7.11 Air Intake 7.11.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 94). After installation of new filter, press reset button (1).
  • Page 98 7.11.2 Emergency air-shutoff flaps – Functional check with electric actuation DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Air flaps close abruptly.
  • Page 99 7.11.3 Rubber sleeves in air pipework before intercooler – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Rubber sleeve (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) Also applicable to 12 V Preparatory steps Remove air filter (→...
  • Page 100 Replacing rubber sleeves on left engine side Release clamps (3). Remove retainer (5) on charge-air pipe. Remove screws from elbow (7) and remove elbow. Pull off charge-air pipe (6). Clean charge-air pipe and elbow and check for obstructions. Slide new rubber sleeves (4) onto exhaust turbocharger and charge-air pipe (6). Slide clamps onto all rubber sleeves.
  • Page 101 7.12 Starting Equipment 7.12.1 Air starter – Manual operation DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A).
  • Page 102 7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Engine oil level – Check Preconditions ☑ Engine shut down and starting disabled. Checking oil level prior to engine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to stop, withdraw after approx.
  • Page 103 7.13.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 40-200 Nm...
  • Page 104 Tighten drain plugs (2) and (3) with torque wrench to the specified torque. Name Size Type Lubricant Value/Standard Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm Filling with new oil Open cover on filler neck. Fill oil through filler neck up to "max." mark at oil dipstick.
  • Page 105 7.13.3 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 5605892099/00 DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! •...
  • Page 106 Drain approx. 1 liter engine oil into a clean container. Close screw. Using the equipment and chemicals of the MTU test kit, examine oil for: • Dispersion capability (spot test); • Water content; • Dilution by fuel. 106 | Task Description | MS150054/02E 2012-02...
  • Page 107 7.14 Oil Filtration / Cooling 7.14.1 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 Hot oil.
  • Page 108 7.14.2 Automatic oil filter – Oil filter candles replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 Engine oil O-ring (→ Spare Parts Catalog) Oil filter candles (→...
  • Page 109 Withdraw filter insert (1). Remove O-ring. Remove screw (2). Withdraw spinner (1) with spring. Remove nut (3). Take off spring washer and washer. Remove screw (4). Remove flushing arm (5) from screen plate (6). Turn filter insert upside down and use ap‐ propriate tool to push out filter candles (1).
  • Page 110 Oil filter candles – Installation For installation follow reverse sequence of working steps. In addition, the following work must be performed: • Replace all sealing elements with new parts. • Coat O-rings with grease. • Insert O-rings in grooves. • Pay attention to installation position of fillister-head screw to slot in shaft. 110 | Task Description | MS150054/02E 2012-02...
  • Page 111 7.14.3 Oil indicator filter – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Strainer (→ Spare Parts Catalog) Square-section ring (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) WARNING Hot oil.
  • Page 112 Checking strainer Item Findings Task Strainer Metallic residues • Clean • Monitor engine operation • Check strainer daily • Contact Service. Strainer Damaged Replace Square-section ring Damaged Replace O-ring Damaged Replace Cleaning strainer Wash strainer (5) with cleaner. Remove stubborn deposits with soft brush. Blow out strainer (5) with compressed air from inside.
  • Page 113 7.14.4 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 6-50 Nm F30027336 Filter wrench F30379104 Cold cleaner (Hakutex 60) 50602 Grease (Kluthe Hakuform 30-10/Emulgier) X00029933...
  • Page 114 Cleaning centrifugal oil filter and replacing filter sleeve, variant A Remove clamp (3). Release screw of cover (1) and take off cover (2). Carefully lift rotor (6), allow oil to drain and remove from housing. Holding the rotor (6) firmly, release rotor cover nut (7).
  • Page 115 Cleaning centrifugal oil filter and replacing filter sleeve, variant B Release screw (1) and remove. Remove clamp (3) and take off cover (2). Carefully remove rotor (5) from housing. Holding the rotor (5) firmly with the filter wrench, release knurled nut (7). Take off rotor cap (8).
  • Page 116 7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 117 7.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Changing engine coolant Drain engine coolant (→ Page 118). Fill with engine coolant (→ Page 120). MS150054/02E 2012-02 | Task Description | 117...
  • Page 118 7.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing rings (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 119 Drain pint on driving end, left and right side. Final steps Close all drain valves and install drain plugs with new sealing rings. Set breather valve onto filler neck and close it. MS150054/02E 2012-02 | Task Description | 119...
  • Page 120 7.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
  • Page 121 Filling coolant with pump Connect a suitable pump with a hose to the drain valve of the engine coolant pump (ar‐ row). Release union at distributor (arrow). Open drain valve and pump coolant into en‐ gine at 0.5 bar minimum. Close venting point when coolant emerges from the released union.
  • Page 122 Alternatively: Filling coolant through filler neck Release union at distributor (arrow). Fill in coolant via filler neck on expansion tank until the coolant emerges from the re‐ leased union. Tighten union (arrow). Fill expansion tank until overflow edge is reached. Check proper condition of breather valve, clean sealing faces if required.
  • Page 123 7.15.5 Engine coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...
  • Page 124 7.15.6 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 5605892099/00 DANGER Unguarded rotating and moving engine components.
  • Page 125 7.15.7 Coolant filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Coolant filter (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 126 7.16 Low-Temperature Circuit 7.16.1 Charge-air coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
  • Page 127 7.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Charge-air coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 128). Fill with charge-air coolant (→ Page 129). MS150054/02E 2012-02 | Task Description | 127...
  • Page 128 7.16.3 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 129 7.16.4 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. Charge-air coolant WARNING Coolant is hot and under pressure.
  • Page 130 Filling with charge-air coolant using pump Connect a suitable pump with a hose to the drain valve (arrow). Release union at distributor (arrow). Open drain valve and pump coolant into en‐ gine at 0.5 bar minimum. Close venting point when coolant emerges from the released union.
  • Page 131 Alternatively: Filling coolant through filler neck Open venting point at distributor (arrow). Fill in coolant in expansion tank until the coolant level at top edge of filler neck re‐ mains constant. Close venting point when coolant emerges. Check proper condition of breather valve, clean sealing faces if required.
  • Page 132 7.16.5 Charge-air coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...
  • Page 133 7.17 Belt Drive 7.17.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt Belt is oily, shows signs of over‐ Replace(→...
  • Page 134 7.18 Battery-Charging Generator 7.18.1 Battery-charging generator – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Checking battery-charging generator Item Findings...
  • Page 135 7.18.2 Battery-charging generator drive – Drive belt tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Ratchet adapter F30027340 WARNING Spring/circlip/tensioning roller preload. Risk of injury! •...
  • Page 136 7.18.3 Battery-charging generator drive – Drive belt and belt tensioner replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Ratchet adapter F30027340 WARNING Heavy object. Risk of crushing! •...
  • Page 137 7.19 Fan Drive 7.19.1 Fan drive – Drive belt check / adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Optibell 2 belt tension tester Y4345711 Preparatory steps Remove protective cover. Check belt condition visually (→...
  • Page 138 Adjusting drive belt tension Release screws (2) until fan coupling can be moved. Tighten stud (1) until the required frequency is achieved. Tighten screws (2) to 100 Nm ± 10 Nm. 138 | Task Description | MS150054/02E 2012-02...
  • Page 139 7.19.2 Fan drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Preparatory steps Remove protective cover. Remove fan. Replacing drive belt Release screws (2).
  • Page 140 7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.
  • Page 141 7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent.
  • Page 142 7.21.2 EMU and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol EMU and connectors – Cleaning Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. Remove dirt from connector and cable surfaces with isopropyl alcohol.
  • Page 143 7.21.3 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Checking plug-in connections on engine governor Check all plug-in connections for secure seating.
  • Page 144 7.21.4 EMU – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. EMU – checking plug-in connections Verify that all plug-in connections are securely seated. Secure loose connectors and latch. 144 | Task Description | MS150054/02E 2012-02...
  • Page 145 7.21.5 ECU 7 engine governor – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. CAUTION 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 146 7.21.6 EMU 7 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. CAUTION 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. Removing ECU with EMU from engine Note or mark assignment of cables and...
  • Page 147 Abgasturbolader Exhaust turbocharger (ETC) Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publication No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting of drift compensation in engine gov‐ ernor with DiaSys...
  • Page 148 Abbreviation Meaning Explanation Exhaust Gas Recirculation Engine Monitoring Unit Ersatzteilkatalog Spare Parts Catalog (SPC) Electronic Unit Injector Fuel Pressure Sensor Monitors fuel pressure Fuel - Differential Pressure Sensor Fuel Temperature Sensor Monitors fuel temperature FWCP Fire Water Control Panel Control cabinet Ground Hochdruck High Pressure (HP)
  • Page 149 Abbreviation Meaning Explanation Society of Automotive Engineers U.S. standardization organization Sensor Defect Alarm: Sensor failure Stop Engine Light 1st function: Warning lamp (stop engine and rectify fault) 2nd function: Read out fault codes System Identifier Synchronous Reference Sensor TDC cylinder 1 Safety System Safety system alarm Turbocharger Boost Sensor...
  • Page 150 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 the outstanding flexibility of our service staff, we are always ready to assist you - either during operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply.
  • Page 151 7.6.2 Injector – Removal and installation (→ Page 79) Milling cutter Part No.: F30452739 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 79) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.13.3 Engine-oil – Sample extraction and analysis (→ Page 105) Qty.: Used in: 7.15.6 Engine coolant –...
  • Page 152 Ratchet adapter Part No.: F30027340 Qty.: Used in: 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement (→ Page 70) Qty.: Used in: 7.18.2 Battery-charging generator drive – Drive belt tension adjustment (→ Page 135) Qty.: Used in: 7.18.3 Battery-charging generator drive –...
  • Page 153 Torque wrench, 10-60 Nm Part No.: F30452769 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 79) Torque wrench, 20-100 Nm Part No.: F30026582 Qty.: Used in: 7.18.2 Battery-charging generator drive – Drive belt tension adjustment (→ Page 135) Qty.: Used in: 7.18.3 Battery-charging generator drive –...
  • Page 154 9.2 Index 12, 16V 4000 G73 engine data, emissions-optimized Cylinder head cover (EPA - Tier 2) 25 – Removal and installation  76 Cylinder liner – Endoscopic examination  66 Abbreviations 147 – Instructions and comments on endoscopic and visual Actuators examination  68 – Overview  21 After stopping the engine –...
  • Page 155 Inspection port cover – Explosion hazard  12 Intercooler – Drain, coolant leakage  93 Maintenance and repair work – Safety regulations  13 MTU contact persons 150 Oil indicator filter – Check 111 Operational checks 34 Personnel and organizational requirements 6 Putting engine into operation – Preparation after extended out-of-service periods (>3 months)  30...

This manual is also suitable for:

16 v 4000 g73

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