MTU 10V1600C Series Operating Instructions Manual
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MTU 10V1600C Series Operating Instructions Manual

MTU 10V1600C Series Operating Instructions Manual

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Operating Instructions
Diesel Engine
10V1600Cx0
12V1600Cx0
MS150100/06E

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Summary of Contents for MTU 10V1600C Series

  • Page 1 Operating Instructions Diesel Engine 10V1600Cx0 12V1600Cx0 MS150100/06E...
  • 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: Table Of Contents

    Table of Contents 1 Safety 5.5 Emission label – Check 5.6 Engine shutdown 1.1 Important provisions for all products 5.7 After stopping the engine 1.2 C&I and O&G, application 1600 – Intended 5.8 Plant – Cleaning 1.3 Personnel and organizational requirements 6 Maintenance 1.4 Safety regulations for initial start-up and operation...
  • Page 4 8.11.5 Charge-air coolant pump – Relief bore check 9 Appendix A 8.12 Belt Drive 9.1 Abbreviations 8.12.1 Drive belt – Condition check 9.2 MTU Contact/Service Partners 8.12.2 Drive belt – Replacement 8.13 Battery-Charging Generator 10 Appendix B 8.13.1 Battery-charging generator – Cleaning 10.1 Special Tools...

  • Page 5: Safety

    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. MS150100/06E 2017-08 | Safety | 5...
  • Page 6 Exception: Engines used exclusively in land-based, military applications other than by US government agen- cies. Please note the following when replacing components with emission labels: • The relevant emission labels must be affixed to the spare part. • Emission labels shall not be transferred from the replaced part to the spare part. •...

  • Page 7: C&I And O&G, Application 1600 - 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 8: Personnel And Organizational Requirements

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

  • Page 9: Safety Regulations For Initial Start-Up And Operation

    1.4 Safety regulations for initial start-up and operation Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 10 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. Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times.

  • Page 11: Safety Regulations For Assembly, Maintenance, And Repair Work

    1.5 Safety regulations for assembly, maintenance, and repair work Safety regulations for work prior to assembly, maintenance, and repair Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 12 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 13 Before starting welding work: • Switch off the power supply master switch. • Disconnect the battery cables or actuate the battery isolating switch. • Separate the electrical ground of electronic equipment from the ground of the unit. No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld- ing is in progress.
  • Page 14 Do not secure cables on lines carrying fluids. Do not use cable ties to secure lines. Always use connector pliers to tighten union nuts on connectors. Subject the device as well as the product to functional testing on completion of all repair work. The emergen- cy stop function must be tested in particular.

  • Page 15: 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 16 Particularly hazardous substances used with our products are named in a list: www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products Compressed air • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion.

  • Page 17: Standards For Warning Notices In The Text And Highlighted Information

    1.7 Standards for warning notices in the text and highlighted information DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...

  • Page 18: Transport

    2 Transport 2.1 Transportation Special tools, Material, Spare parts Designation / Use Part No. Qty. Crossbeam T80092479 DANGER Suspended load. Danger to life! • Use appropriate lifting devices and appliances. • Never stand beneath a suspended load. DANGER Engine tips over if unstable. Risk of crushing body or limbs! •...
  • Page 19 Position of the wooden chocks (view of driving end) Position of the wooden chocks on an engine with 4-point mounting (free end and side view) MS150100/06E 2017-08 | Transport | 19...
  • Page 20 Position of the wooden chocks on an engine with 3-point mounting (free end and side view) 20 | Transport | MS150100/06E 2017-08...

  • Page 21: Lifting Requirements

    2.2 Lifting requirements Lifting requirements DANGER Suspended load. Danger to life! • Use appropriate lifting devices and appliances. • Never stand beneath a suspended load. The illustration applies also to 10V1600Cx0. 1 Max. admissible diagonal 2 Center of gravity pull 10° (*) (*) Observe max.

  • Page 22: 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 23: Engine - Overview

    3.2 Engine – Overview Illustrations apply similarly to 10V1600Cx0. 1 Exhaust elbow 6 Battery-charging generator 11 Exhaust turbocharger (low 2 Intake neck 7 Engine governor pressure) 3 Thermostat housing 8 Electric starter (right side) 12 Exhaust turbocharger (high 4 EGR pipe with insulation 9 Flywheel pressure) 5 Cylinder head...
  • Page 24 1 Exhaust flap 7 Actuator 13 Battery-charging generator 2 Oil filter 8 Engine mounting (option) 3 EGR cooler 9 Electric starter (left side) 14 Belt 4 Charge-air cooler (high 10 Oil pan 15 Engine coolant pump pressure) 11 Oil dipstick 16 Charge-air coolant pump 5 Charge-air cooler (low pres- 12 Fuel filter...

  • Page 25: Sensors And Actuators - Overview

    3.3 Sensors and actuators – Overview Sensor overview – Plan view Item Description Description B44.1 HP exhaust turbocharger speed, right side M52.1 HP turbine bypass flap, left side M8.1 HP fuel pump, left side B5.3 Lube oil pressure before filter B9.2 Charge-air temperature after exhaust gas recirculation B5.1...
  • Page 26 Sensor overview – Right side Item Description Description Humidity, pressure, temperature of intake air XY39B2 Injector connection XY57B Engine brake valve, right side XY39B1 Injector connection M53.2 EGR shut-off flap before cooler, right side B48.2 HP fuel, right side (12V only) Oil level in oil pan Adaption of Engine Control Unit ECU9 Adaption of Engine Control Unit ECU9...
  • Page 27 Sensor overview – Left side Item Description Description B48.1 HP fuel, left side M53.1 EGR shut-off flap before cooler, left side XY39A2 Injector connection XY57A Engine brake valve, left side XY39A1 Injector connection B4.21 Exhaust temperature lambda sensor, left side MS150100/06E 2017-08 | General Information | 27...
  • Page 28 Sensor overview – Driving end (KS) Item Description Description B44.4 Speed of LP turbocharger, right side Crankcase pressure M52.2 HP turbine bypass flap, right side Crankshaft speed 28 | General Information | MS150100/06E 2017-08...
  • Page 29 Sensor overview – Free end Item Description Description Lube oil temperature B34.2 Fuel pressure before filter B34.1 Fuel pressure after filter B6.3 Coolant temperature, cylinder head MS150100/06E 2017-08 | General Information | 29...

  • Page 30: Technical Data

    4 Technical Data 4.1 Engine data 10V1600C60 / 10V1600C70, US EPA Nonroad Tier 4 (40 CFR 1039), emissions-optimized Explanation Abbr. Explanation Reference value: Continuous power Reference value: Fuel stop power Design value Guaranteed value Reference value Limit value, up to which the engine can be operated, without change (e.g. of power setting). Non-defined value Not applicable Applicable...
  • Page 31 Consumption Description 10V1600 10V1600 Lube oil consumption after 100 h runtime (B = hourly fuel con- % of B 0.06 0.06 sumption) Model-related data (basic design) Description 10V1600 10V1600 Number of cylinders Cylinder configuration: V angle Degrees (°) Bore Stroke Displacement of a cylinder Liters 1.75...
  • Page 32 Lube oil system Description 10V1600 10V1600 Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, Limit 1 °C Lube oil temperature before engine, Limit 2 °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure before engine, warning Lube oil operating pressure before engine, shutdown...
  • Page 33 Weights / main dimensions Description 10V1600 10V1600 Engine wet weight (with standard accessories installed, w/o cou- pling) 2200 2200 Engine with standard oil pan Sound Description 10V1600 10V1600 Exhaust noise, unsilenced – BL (free-field sound pressure level Lp, dB(A) 1 m distance, ISO 6798, +3 dB(A) tolerance) Exhaust noise, unsilenced –...

  • Page 34: Engine Data 10V1600C60 / 10V1600C70, Us Epa Nonroad Tier 4 (40 Cfr 1039) Compliant, Emissions-Optimized

    4.2 Engine data 10V1600C60 / 10V1600C70, US EPA Nonroad Tier 4 (40 CFR 1039) compliant, emissions-optimized Explanation Abbr. Explanation Reference value: Continuous power Reference value: Fuel stop power Design value Guaranteed value Reference value Limit value, up to which the engine can be operated, without change (e.g. of power setting). Non-defined value Not applicable Applicable...
  • Page 35 Model-related data (basic design) Description 10V1600 10V1600 Number of cylinders Cylinder configuration: V angle Degrees (°) Bore Stroke Displacement of a cylinder Liters 1.75 1.75 Total displacement Liters 17.5 17.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder Combustion air / exhaust gas Description 10V1600...
  • Page 36 Description 10V1600 10V1600 Lube oil temperature before engine, Limit 1 °C Lube oil temperature before engine, Limit 2 °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure before engine, warning Lube oil operating pressure before engine, shutdown Fuel system Description...
  • Page 37 Sound Description 10V1600 10V1600 Exhaust noise, unsilenced – BL (free-field sound pressure level Lp, dB(A) 1 m distance, ISO 6798, +3 dB(A) tolerance) Exhaust noise, unsilenced – BL (sound power level LW, ISO 6798, dB(A) +3 dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) – BL dB(A) (free-field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance)

  • Page 38: Engine Data 12V1600C50 / 12V1600C60 / 12V1600C70, Us Epa Nonroad Tier

    4.3 Engine data 12V1600C50 / 12V1600C60 / 12V1600C70, US EPA Nonroad Tier 4 (40 CFR 1039), emissions-optimized Explanation Abbr. Explanation Reference value: Continuous power Reference value: Fuel stop power Design value Guaranteed value Reference value Limit value, up to which the engine can be operated, without change (e.g. of power setting). Non-defined value Not applicable Applicable...
  • Page 39 Model-related data (basic design) Description 12V1600 12V1600 12V1600 Number of cylinders Cylinder configuration: V angle Degrees (°) Bore Stroke Displacement of a cylinder Liters 1.75 1.75 1.75 Total displacement Liters Number of inlet valves per cylinder Number of exhaust valves per cylinder Combustion air / exhaust gas Description 12V1600...
  • Page 40 Lube oil system Description 12V1600 12V1600 12V1600 Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, Limit 1 °C Lube oil temperature before engine, Limit 2 °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure before engine, warning Lube oil operating pressure before engine, shutdown...
  • Page 41 Capacities Description 12V1600 12V1600 12V1600 Engine coolant, engine side (without cooling equip- Liters ment) Charge-air coolant, engine side Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating inclinations) Engine with standard oil pan Liters Engine with mid sump oil pan Liters Weights / main dimensions Description...

  • Page 42: Engine Data 12V1600C50 / 12V1600C60 / 12V1600C70, Us Epa Nonroad Tier

    4.4 Engine data 12V1600C50 / 12V1600C60 / 12V1600C70, US EPA Nonroad Tier 4 (40 CFR 1039) compliant, emissions- optimized Explanation Abbr. Explanation Reference value: Continuous power Reference value: Fuel stop power Design value Guaranteed value Reference value Limit value, up to which the engine can be operated, without change (e.g. of power setting). Non-defined value Not applicable Applicable...
  • Page 43 Model-related data (basic design) Description 12V1600 12V1600 12V1600 Number of cylinders Cylinder configuration: V angle Degrees (°) Bore Stroke Displacement of a cylinder Liters 1.75 1.75 1.75 Total displacement Liters Number of inlet valves per cylinder Number of exhaust valves per cylinder Combustion air / exhaust gas Description 12V1600...
  • Page 44 Lube oil system Description 12V1600 12V1600 12V1600 Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, Limit 1 °C Lube oil temperature before engine, Limit 2 °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure before engine, warning Lube oil operating pressure before engine, shutdown...
  • Page 45 Capacities Description 12V1600 12V1600 12V1600 Engine coolant, engine side (without cooling equip- Liters ment) Charge-air coolant, engine side Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating inclinations) Engine with standard oil pan Liters Engine with mid sump oil pan Liters Weights / main dimensions Description...

  • Page 46: Firing Order

    4.5 Firing order Firing order Number of cylin- Firing order ders A1–B4–A4–B3–A3–B2–A2–B5–A5–B1 A1–B2–A5–B4–A3–B1–A6–B5–A2–B3–A4–B6 Direction of rotation Direction of rotation (viewed from driving end): Counterclockwise, non-reversible. 46 | Technical Data | MS150100/06E 2017-08...

  • Page 47: Engine - Main Dimensions

    4.6 Engine – Main dimensions Main dimensions of the engine with standard oil pan Engine model Height (A) Length (B) Width (C) 10V1600Cx0 Approx. 1402 mm Approx. 1693 mm Approx. 1231 mm 12V1600Cx0 Approx. 1402 mm Approx. 1865 mm Approx. 1231 mm MS150100/06E 2017-08 | Technical Data | 47...
  • Page 48 Main dimensions of the engine with mid sump oil pan Engine model Height (A) Length (B) Width (C) 10V1600Cx0 Approx. 1487 mm Approx. 1693 mm Approx. 1231 mm 12V1600Cx0 Approx. 1487 mm Approx. 1865 mm Approx. 1231 mm 48 | Technical Data | MS150100/06E 2017-08...

  • Page 49: Operation

    5 Operation 5.1 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Startup Item Action Lube oil system Check engine oil level (→ Page 132). Coolant circuit Check engine coolant level (→ Page 139); Check charge-air coolant level (→...

  • Page 50: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

    5.2 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. Putting the engine into operation after extended out-of-service periods (>3 months) Item...

  • Page 51: Engine - Starting

    5.3 Engine – Starting Preconditions ☑ Engine is not connected to load. 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 52: Operational Checks

    5.4 Operational checks DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 53: Emission Label - Check

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

  • Page 54: Engine Shutdown

    5.6 Engine shutdown Preconditions ☑ Engine is not connected to load. CAUTION Shutting down from full-load operation may cause hot water to escape from the expansion tank. Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety goggles / safety mask. NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress- Overheating of and, therefore, damage to components is possible!

  • Page 55: After Stopping The Engine

    5.7 After stopping the engine Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. NOTICE Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at temperatures below 0 °C. Risk of sensor damage! • Remove pressure sensors and shake off residual water.

  • Page 56: Plant - Cleaning

    5.8 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 57: Maintenance

    6 Maintenance 6.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte- nance Schedule is a standalone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 58: Troubleshooting

    7 Troubleshooting 7.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery low or faulty u Charge or replace (→ manufacturer's documentation). Battery: Cable connections faulty u Check if cable connections are properly secured (→ manufacturer's documentation).
  • Page 59 Air in fuel system u Contact Service. Engine governor faulty Charge-air temperature too high Cause Corrective action u Check (MTU test kit). Engine coolant mixture incorrect Charge-air cooler dirty u Contact Service. Engine room: Air intake u Check fans and intake/exhaust lines.
  • Page 60 White exhaust gas Cause Corrective action u Run engine up to operating temperature. Engine is not at operating temperature Water in fuel u Check fuel system on fuel prefilter. Drain fuel prefilter (→ Page 115). Charge-air cooler u Contact Service. 60 | Troubleshooting | MS150100/06E 2017-08...

  • Page 61: Engine Control Unit Ecu9 - Fault Messages

    7.2 Engine Control Unit ECU9 – Fault messages Possible engine responses in case of yellow alarm: Warning, power limitation/reduction, speed limitation, engine stop Possible engine responses in case of red alarm: Engine stop, power limitation/reduction, speed limitation, warning 5 – HI T-Charge Air Cause Corrective action The charge-air temperature...
  • Page 62 16 – SS P-Lube Oil Cause Corrective action The lube oil pressure measured at 1. Check engine oil level (→ Page 132). sensor B5.1 has violated limit 2. Contact Service. value 2. The lube oil pressure is too low. 19 – HI T-Exhaust A Cause Corrective action u Run injector test according to DiaSys description.
  • Page 63 25 – HI P-Diff. Lube Oil Cause Corrective action The differential oil pressure 1. Replace engine oil filter (→ Page 137). measured at sensors B5.1 and 2. Contact Service. B5.3 has violated limit value 1. The differential oil pressure is too high.
  • Page 64 33 – HI P-Diff-Fuel Cause Corrective action The differential pressure 1. Replace fuel filter (→ Page 113). measured at sensors B34.1 and 2. Contact Service. B34.2 has violated limit value 1. The differential pressure is too high. 34 – SS P-Diff-Fuel Cause Corrective action The differential pressure...
  • Page 65 59 – SS T-Coolant L3 Cause Corrective action u Contact Service. The coolant temperature measured at sensor B6.1 has violated limit value 3. The coolant temperature is too high. 60 – SS T-Coolant L4 Cause Corrective action u Contact Service. The coolant temperature measured at sensor B6.1 has violated limit value 4.
  • Page 66 67 – HI T-Coolant Cause Corrective action The coolant temperature 1. Reduce power. measured at sensor B6.1 has 2. Check cooler and fan operation (plant). violated limit value 1. The coolant 3. Check engine coolant level (→ Page 139). temperature is too high. 4.
  • Page 67 92 – SS No Starter Speed Cause Corrective action The engine has failed to reach the 1. Check starter pressure supply (plant). set speed threshold within the set 2. Observe any other messages. time. 3. Contact Service. 93 – SS T-Preheat Cause Corrective action The engine coolant temperature...
  • Page 68 188 – AL CAN2 Bus Off Cause Corrective action CAN bus 2 to plant-side 1. Check connection between plant automation system and MTU automation (e.g. Murphy Display) automation system. interrupted or faulty. 2. Contact Service. 189 – AL CAN2 Error Passive...
  • Page 69 201 – SD T-Coolant Cause Corrective action The signal from the coolant 1. Check engine wiring (→ Page 157). temperature sensor (B6.1) on the 2. Contact Service. coolant distribution housing is faulty or missing. 203 – SD T-Charge Air Cause Corrective action The charge-air temperature 1.
  • Page 70 214 – SD P-Crankcase Cause Corrective action The signal from the crankcase 1. Check engine wiring (→ Page 157). pressure sensor (B50) is faulty or 2. Contact Service. missing. 215 – SD P-HD Cause Corrective action The rail pressure sensor (B48.1) A 1.
  • Page 71 229 – AL Stop Camshaft Sensor Defect Cause Corrective action u Contact Service. Emergency engine stop following failure of the crankshaft sensor and camshaft sensor. 230 – SD Crankshaft Speed Cause Corrective action The signal from the crankshaft 1. Check engine wiring (→ Page 157). speed sensor (B13) is faulty or 2.
  • Page 72 266 – SD Speed Demand Cause Corrective action The signal for analog speed 1. Switch on plant automation. demand is missing. 2. Contact Service. 321 – AL Wiring Cylinder A1 Cause Corrective action Short circuit fault in injector 1. Check wiring of injector concerned (→ Page 157). wiring of cylinder A1 or injector 2.
  • Page 73 331 – AL Wiring Cylinder B1 Cause Corrective action Short circuit fault in injector 1. Check wiring of injector concerned (→ Page 157). wiring of cylinder B1 or injector 2. Contact Service. faulty. 332 – AL Wiring Cylinder B2 Cause Corrective action Short circuit fault in injector 1.
  • Page 74 343 – AL Open Load Cylinder A3 Cause Corrective action Disruption fault in injector cabling 1. Check wiring of injector concerned (→ Page 157). to cylinder A3. 2. Contact Service. 344 – AL Open Load Cylinder A4 Cause Corrective action Disruption fault in injector cabling 1.
  • Page 75 355 – AL Open Load Cylinder B5 Cause Corrective action Disruption fault in injector cabling 1. Check wiring of injector concerned (→ Page 157). to cylinder B5. 2. Contact Service. 356 – AL Open Load Cylinder B6 Cause Corrective action Disruption fault in injector cabling 1.
  • Page 76 412 – HI U-PDU Cause Corrective action The ECU voltage to control the 1. Check power supply (plant). injectors has violated limit value 2. Check wiring (→ Page 157). 3. Contact Service. 413 – HIHI U-PDU Cause Corrective action The ECU voltage to control the 1.
  • Page 77 442 – AL L2 P-Aux1 Cause Corrective action u Contact Service. The value measured by the pressure measuring sensor at the pressure measuring channel has violated limit value 2. The pressure value at the pressure measuring channel is too low. 444 –...
  • Page 78 470 – SD T-ECU Cause Corrective action u Contact Service. The signal from the temperature sensor in the ECU is faulty or missing 472 – AL Stop SD Cause Corrective action This fault is signaled in case of a u Contact Service. faulty sensor which is defined for engine stop.
  • Page 79 490 – HI ETC4 Overspeed Cause Corrective action The speed of the LP turbocharger 1. Reduce power. on the B side measured at sensor 2. Contact Service. B44.4 has violated limit value 1. The turbocharger speed is too high. Cause: Fault or malfunction of another turbocharger.
  • Page 80 587 – AL Wiring PWM_CM4 Cause Corrective action u Contact Service. The exhaust brake on the B-side Y57B / MB57B cannot be activated. 597 – AL Wiring PWM_CM5 Cause Corrective action The exhaust brake on the A side u Contact Service. Y57A / MB57A cannot be activated.
  • Page 81 626 – AL Wiring PWM_CM8 Cause Corrective action Disruption or short circuit in 1. Check engine wiring (→ Page 157). wiring to servomotor of bypass 2. Contact Service. flap (A side) M52.1. 627 – AL Wiring PWM_CM9 Cause Corrective action Disruption or short circuit in 1.
  • Page 82 635 – SD Air Humidity (HDT2800) Cause Corrective action u Contact Service. The signal from the humidity sensor (B90) is missing. 636 – SD Level Lube Oil J1939 Cause Corrective action The level signal from the 1. Check engine wiring (→ Page 157). combined oil temperature and 2.
  • Page 83 728 – AL L2 Delta T-LT Intercooler Cause Corrective action The differential temperature 1. Check cooler for dirt (plant). measured at sensors B26 and B90 2. Check fan operation (plant). has violated limit value 2. The LT 3. Contact Service. coolant inlet temperature is too high in relation to the ambient air temperature.
  • Page 84 832 – AL EIL Different Engine Number Cause Corrective action The engine number in the EIL 1. Check engine wiring (→ Page 157). does not match the engine 2. Contact Service. number stored in the ECU 833 – AL Emission Warning Cause Corrective action Combined emission fault alarm...
  • Page 85 846 – AL HI T-Charge Air Diff AB Cause Corrective action u Contact Service. The differential temperature measured at sensors B9.2 and B9.3 has violated limit value 1. The charge-air temperature is too high. 847 – AL HIHI T-Charge Air Diff AB Cause Corrective action The differential temperature...
  • Page 86 870 – AL MB Valve defect 2 Cause Corrective action u Contact Service. The exhaust brake on the B-side Y57B / MB57B cannot be activated. 871 – AL NOx ATO1 Communication Lost Cause Corrective action The ECU can no longer detect 1.
  • Page 87 899 – AL OLT Communication Lost Cause Corrective action The ECU can no longer detect the 1. Check engine wiring (→ Page 157). J1939 combined oil temperature 2. Contact Service. and level sensor B93 on the bus. 902 – HI T-Coolant Cylinder Head Cause Corrective action The coolant temperature...
  • Page 88 970 – SD P-Exhaust Cause Corrective action The signal from the exhaust gas 1. Check engine wiring (→ Page 157). pressure sensor (B91.3) is faulty 2. Contact Service. or missing. 973 – AL Check Sum IIG Cause Corrective action The IIG value entered does not 1.
  • Page 89 984 – AL NOx ATO2 Sensor Defect Cause Corrective action The signal from the NOx sensor 1. Check engine wiring (→ Page 157). B88.2 in the exhaust pipe 2. Check NOx sensor, replace as necessary (→ Page 160). downstream of the turbocharger 3.
  • Page 90 1101 – AL Flap Egr B Temperature too high Cause Corrective action u Contact Service. The internal electronics of the servomotor for the EGR shutoff flap on the B side (M53.2/ MA53.2) signal excessively high temperature. 1102 – AL Flap Egr B Targetposition Cause Corrective action The servomotor of the EGR...
  • Page 91 1108 – AL Flap Bypass B Targetposition Cause Corrective action u Contact Service. The servomotor of the bypass flap on the B side (M52.2/MA52.2) has failed to reach its target position within the set time. 1115 – AL Difference P0 P1 Intake Air L1 Cause Corrective action The differential pressure...
  • Page 92 1122 – AL Flap BypassA Calibr. Drive Err Cause Corrective action u Contact Service. The ECU has detected a calibration movement error at the bypass flap on the A side (M52.1/ MA52.1). Cause: The teach-in range (angle) of the calibration movement is not plausible.
  • Page 93 1168 – AL Implausible NOx Low Limit1 Cause Corrective action u Contact Service. NOx emissions too low. Cumulative NOx emissions from the engine have violated limit value 1. 1172 – AL Implausible NOx High Limit2 Cause Corrective action u Contact Service. NOx emissions too high.
  • Page 94 1186 – AL EGR FlpA Wear Limit2 Cause Corrective action Faulty rapid reference movement 1. Check state of battery charge (plant). of the EGR shutoff flap on the A 2. Contact Service. side (M53.1/MA53.1) (always executed after restarting the ECU). Limit value 2. 1187 –...
  • Page 95 1377 – AL Refdrive Impossibl Eng Op Point Cause Corrective action Homing of one or more flaps 1. Run engine up to idling speed. Result: Homing is executed. before engine start was not 2. Contact Service. completed successfully. Homing the affected flaps is no longer possible.
  • Page 96 1385 – AL Act Egr B Ref-Drv Eng Running Cause Corrective action Homing the EGR shutoff flap B 1. Check state of battery charge (plant). side (M53.2) was not successful. 2. Check plug connections to engine governor (→ Page 159). 3.
  • Page 97 1393 – AL Flap Byp B Wear Limit 1 Cause Corrective action u Replace linkage rod at next scheduled maintenance interval The range of rotation on homing the bypass flap B side (M52.2) (→ Page 121). has violated limit value 1. The flap mechanism is beginning to wear.
  • Page 98 1403 – AL Flap Egr B linkage failure Cause Corrective action The range of rotation on homing 1. Check exhaust flap for damage (→ Page 120). the EGR shutoff flap B side 2. Contact Service on detecting any other damage at the exhaust (M53.2) has violated the limit flap.
  • Page 99 1411 – AL Flap Byp B restricted Limit 1 Cause Corrective action The range of rotation on homing 1. Check smooth operation of the exhaust flap mechanism. the bypass flap B side (M52.2) 2. Contact Service. has violated limit value 1. Flap travel is marginally restricted.
  • Page 100 1422 – AL Flap Bypass A blocked drive Cause Corrective action The mechanism of the bypass flap 1. Check smooth operation of the exhaust flap mechanism. A side (M52.1) is blocked. 2. Contact Service. 1423 – AL Flap Bypass B blocked drive Cause Corrective action The mechanism of the bypass flap...
  • Page 101 1437 – AL Act Agr B Voltage Supply Cause Corrective action The servomotor supply voltage for 1. Check state of battery charge (plant). the EGR shutoff flap B side 2. Check plug connections to engine governor (→ Page 159). (M53.2) is below 9 V or above 3.

  • Page 102: Task Description

    8 Task Description 8.1 Engine 8.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6797674 Adapter F30011619 Ratchet adapter F30027340 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 103: Engine - Test Run

    8.1.2 Engine – Test run 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 104: Valve Drive

    8.2 Valve Drive 8.2.1 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.
  • Page 105 Diagram for 12V (two crank- shaft positions) Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • The piston is at firing TDC when the rocker arms at cylinder A1 are unloaded. • The piston is at overlap TDC when the rocker arms at cylinder A1 are loaded. Check valve clearance with cold engine: •...
  • Page 106 Tighten locknut (1) to specified torque using a torque wrench, holding adjusting screw (2) firm with Allen key (5 mm). Name Size Type Lubricant Value/Standard M10x1 Tightening torque 43+4 Nm Check valve clearance, readjust as necessary. Final steps Remove barring tool (→ Page 102). Install cylinder head cover (→...

  • Page 107: Cylinder Head Cover - Removal And Installation

    8.2.2 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, 8–40 Nm F30043446 Ratchet adapter F30027340 Torque screwdriver, 1.0–5.0 Nm F30452774 Engine oil Gasket (→...
  • Page 108 Unscrew wiring from injectors (1). Remove gasket with wiring. Installing cylinder head cover Clean mating face. Check condition of gasket and replace as necessary. Wet the sealing lip along the trapezoidal edges with engine oil on the side of the gas- ket facing the cylinder head.
  • Page 109 Fit cylinder head cover and tighten screws at positions 1 to 4 to the specified initial tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw with twin col- Preload torque (Engine oil) 10 Nm Note: • Consecutive tightening sequence starting at position 1: 1 to 18 (on 12V engines). •...

  • Page 110: Fuel System

    8.3 Fuel System 8.3.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Ratchet adapter F30027340 WARNING Fuels are combustible and explosive.
  • Page 111 Variant B – Venting fuel system with hand pump at fuel prefilter (optional) Unlock fuel priming pump, screw out han- dle (1). Note: Catch emerging fuel with a suitable rag. Undo threaded vent plug (2) and unscrew by approx. 3 to 4 revolutions. Operate the pump with the handle (1) until bubble-free fuel emerges from the threaded vent plug (2).
  • Page 112 Note: Do not fully unscrew threaded vent plug. Open threaded vent plug (arrowed). Operate the pump with the handle until bub- ble-free fuel emerges from the threaded vent plug (arrowed). Screw in threaded vent plug (arrowed) and tighten to specified torque using a torque wrench. Name Size Type...

  • Page 113: Fuel Filter

    8.4 Fuel Filter 8.4.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 20–100 Nm F30026582 Ratchet bit...
  • Page 114 Screw on the cap (1) with fuel filter element and tighten to the specified torque with a torque wrench. Name Size Type Lubricant Value/Standard Screw cap A/F 32 Tightening torque (Engine oil) 40±5 Nm Screw in drain plug (3) and tighten to specified torque using a torque wrench. Name Size Type...

  • Page 115: Fuel Prefilter - Draining

    8.4.2 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is cooled down to ambient temperature. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 116: Fuel Prefilter - Filter Element Replacement

    8.4.3 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ratchet bit F30027340 Diesel fuel Filter element...

  • Page 117: Air Filter

    8.5 Air Filter 8.5.1 Air filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. DANGER Parts can be drawn in through a missing air inlet system. Risk of serious injury – danger to life! • Never operate engine without air filters. Note: Component is genset manufacturer's or vehicle manufacturer's scope of supply.

  • Page 118: Air Intake

    8.6 Air Intake 8.6.1 Service indicator – Check See manufacturer's documentation. 118 | Air Intake | MS150100/06E 2017-08...

  • Page 119: Exhaust Gas Recirculation

    8.7 Exhaust Gas Recirculation 8.7.1 Exhaust flaps – Overview 1 EGR shutoff flap, right 3 Bypass flap, left 2 Bypass flap, right 4 EGR shutoff flap, left MS150100/06E 2017-08 | Exhaust Gas Recirculation | 119...

  • Page 120: Egr Shutoff Flaps - Coupling Rod Function And Play Check

    8.7.2 EGR shutoff flaps – Coupling rod function and play check Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage is applied. WARNING Actuation mechanism in the exhaust and intake area closes automatically. Risk of crushing hands! •...

  • Page 121: Egr Shutoff Flaps - Coupling Rod Replacement

    8.7.3 EGR shutoff flaps – Coupling rod replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage is applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Torque wrench, 4–20 Nm F30044239 Ratchet bit F30027340...
  • Page 122 Unscrew locknut (1) and remove with wash- er (2). Unscrew locknut (4) and remove with wash- er (5). Remove coupling rod (3) with washer (6). Installing coupling rod Install coupling rod (3) and washer (6). Fit nut (1) with washer (2) and tighten to specified torque using a torque wrench. Name Size Type...
  • Page 123 Tighten countersunk-head screws (3, 4) with torque wrench to specified tightening torque. Name Size Type Lubricant Value/Standard Countersunk-head Tightening torque (Assembly compound 5 Nm ±1 Nm screw (Molykote P 37)) Use DiaSys® to carry out an actuator test (learning run) (→ Dialog system E531920/..). MS150100/06E 2017-08 | Exhaust Gas Recirculation | 123...

  • Page 124: Bypass Flap - Coupling Rod Function And Play Check

    8.7.4 Bypass flap – Coupling rod function and play check Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage is applied. WARNING Actuation mechanism in the exhaust and intake area closes automatically. Risk of crushing hands! • To carry out the teach-in routine, keep clear of the safety zone of the actuation mechanism in the intake and exhaust area.
  • Page 125 Check bearing of coupling rod (1). Result: Replace the coupling rod (1) if it is worn (→ Page 126). Move coupling rod (1) at the marked point (arrow) to check operability, ease of movement and make sure that there is no ex- cessive play.

  • Page 126: Bypass Flaps - Coupling Rod Replacement

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ratchet bit F30027340 Assembly paste (Ultra-Therm MTU) 50547 Articulated rod (→ Spare Parts Catalog) Locknut (→ Spare Parts Catalog) Washer (→ Spare Parts Catalog) Screw (→...
  • Page 127 Remove lockwasher (5). Remove screws (2) and remove with wash- ers (1). Remove actuator (3) with holder (6) and cou- pling rod (4) from turbine housing. Remove lockwasher (2) and coupling rod (1). Installing coupling rod Install coupling rod (1) and lockwasher (2). MS150100/06E 2017-08 | Exhaust Gas Recirculation | 127...
  • Page 128 M8x25 Tightening torque (Assembly paste (Ul- 18 Nm +2 Nm tra-Therm MTU)) Note: The coupling rod (4) must be connected under tensile stress with the lever. Connect coupling rod (4) with lever of flap and install lockwasher (5). Install screw (2) with washer (1) and tighten to specified tightening torque using a torque wrench.

  • Page 129: Egr Cooler - Check

    8.7.6 EGR cooler – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oilstone F30454308/03 Crocus cloth Engine oil Gaskets (→ Spare Parts Catalog) WARNING Hot components/surfaces. Risk of burns! •...

  • Page 130: Egr Cooler - Replacement

    8.7.7 EGR cooler – 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, 20–100 Nm F30026582 Ratchet bit F30027340 Engine oil EGR cooler (→...
  • Page 131 Undo coolant piping (2) from EGR cooler. Undo and remove screws (1) to remove the EGR cooler from the mounting plate. Installing EGR cooler Degrease and dry clean bolt-on surfaces on lines, cooler and flaps of exhaust gas recircu- lation system. Bolt new EGR cooler onto the mounting plate and install coolant piping on EGR cooler.

  • Page 132: Lube Oil System, Lube Oil Circuit

    8.8 Lube Oil System, Lube Oil Circuit 8.8.1 Engine oil level – Check Preconditions ☑ Vehicle/device standing level. ☑ Engine is at operating temperature. DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 133 Oil level must be between “min.” (2) and “max.” (1) marks. If necessary, top up oil to the “max.” mark (1) (→ Page 135). Insert oil dipstick into guide tube up to the stop. Checking oil level with engine shut down (mid sump oil pan) Stop engine and disable engine start.
  • Page 134 Checking oil level with engine idling (mid sump oil pan) Engine is running at constant idling speed. Remove oil dipstick (1) from guide tube and wipe it. Insert oil dipstick (1) into guide tube up to the stop, pull out after approx. 10 seconds. Read off the oil level on the side of the oil dipstick inscribed “ENGINE IDLING”.

  • Page 135: Engine Oil - Change

    8.8.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001063/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20–100 Nm...
  • Page 136 Draining engine oil from mid sump oil pan Note: The engine oil can be drained on the right of left side (→ Page 22) Provide a suitable vessel to collect the oil. Remove drain plug (1) and drain oil. Unscrew the drain plug (2) as well if it is ac- cessible and drain off the remaining oil.

  • Page 137: Oil Filtration / Cooling

    8.9 Oil Filtration / Cooling 8.9.1 Engine oil filter – 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 Socket, 32 mm F30006120 Engine oil Sealing ring...
  • Page 138 Unscrew the oil filter covers (1) approx. 3 to 4 revolutions. Wait 10 minutes until the oil has drained from the filter housings. Remove cover (1) with oil filter element (3) and remove oil filter element (3) by pressing on the bottom edge from the side. Check condition of sealing ring (2) on cover.
  • Page 139 8.10 Coolant Circuit, General, High-Temperature Circuit 8.10.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001063/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 140 8.10.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 141). Fill with engine coolant (→ Page 143). 140 | Coolant Circuit, General, High-Temperature Circuit | MS150100/06E 2017-08...
  • Page 141 8.10.3 Engine 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 142 Open drain plugs and drain coolant at crank- case, right side (1, 2). Open drain plugs and drain coolant at crank- case, left side (1, 2). Final steps Insert drain plug with new sealing ring on engine coolant pump and use torque wrench to tighten to specified tightening torque.
  • Page 143 8.10.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001063/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant DANGER Components are moving or rotating.
  • Page 144 Filling coolant Fill coolant through filler neck on expansion tank or through filling line until coolant level reaches lower edge of cast-in eye or marking plate. Check proper condition of valve cover (1), clean sealing faces if required. Fit valve cover (1) and close it. Final steps Start engine and run at idle speed for some minutes.
  • Page 145 8.10.5 Engine coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
  • Page 146 8.11 Low-Temperature Circuit 8.11.1 Charge-air coolant level – Check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001063/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
  • Page 147 8.11.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 148). Fill with charge-air coolant (→ Page 149). MS150100/06E 2017-08 | Low-Temperature Circuit | 147...
  • Page 148 8.11.3 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 149 8.11.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001063/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Sealing ring (→ Spare Parts Catalog) DANGER Components are moving or rotating.
  • Page 150 Filling coolant Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level reaches marker plate. Install plug screws of filling points with new sealing rings. Check proper condition of valve cover (1), clean sealing faces if required. Fit valve cover (1) and close it.
  • Page 151 8.11.5 Charge-air coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
  • Page 152 8.12 Belt Drive 8.12.1 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 153 8.12.2 Drive belt – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Assembly device F6794712 Drive belt (→ Spare Parts Catalog) Elastic belt (→ Spare Parts Catalog) WARNING Exposed rotating parts can eject drawn-in components or draw in body parts.
  • Page 154 Belt drive (version B) – Drive belt replacement Cut elastic belt (4) with a suitable tool. Apply the square drive of a ½" socket wrench extension to the square hole (1) on the belt tensioner. Turn belt tensioner clockwise against the spring force almost up to the stop.
  • Page 155 8.13 Battery-Charging Generator 8.13.1 Battery-charging generator – Cleaning 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 156 8.14 Drive Systems, Driving End and Free End (Coupling) 8.14.1 Coupling – Checking radial/axial play See manufacturer's documentation. 156 | Drive Systems, Driving End and Free End (Coupling) | MS150100/06E 2017-08...
  • Page 157 8.15 Wiring (General) for Engine/Gearbox/Unit 8.15.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Checking engine cabling 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 158 8.16 Accessories for (Electronic) Engine Governor / Control System 8.16.1 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 159 8.16.2 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Checking plug-in connections on engine governor Check firm seating of all connectors on the engine governor. Ensure that the clips (1) are engaged. Check firm seating of all screws (2) on engine governor cable clamps.
  • Page 160 8.16.3 NOx sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Power supply to engine electronics is switched off. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340...
  • Page 161 Installing NOx sensor Note: Note the following: • If the sensor (3) was subjected to shock or impact load, it is considered to be defec- tive and may not be used. • Always replace NOx sensor (3) together with control unit (1). Screw on control unit (1) at the eyelets and tighten screws.
  • Page 162 8.16.4 Lambda sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Power supply to electronic engine management system is switched off. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340 Assembly compound (Molykote P 37)
  • Page 163 Installing Lambda sensor Note: When the sensor was subjected to shock or impact load, it is deemed to be defective and may not be used. Remove protective cap on thread only just before installation. Note: Do not wipe off the thread lubricant applied by the manufacturer.
  • Page 164 Abgasturbolader Exhaust turbocharger Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, pub- lication No. A001063/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting for calibration drift compensation Check Engine Light Signal lamp requesting elimination of a fault as soon as possible.
  • Page 165 Abbreviation Meaning Explanation Fuel Restriction Sensor Fuel differential pressure sensor Fuel Temperature Sensor FWCP Fire Water Control Panel Control cabinet for fire extinguishing water Ground Hochdruck High pressure High Alarm: Measured value exceeds 1st maximum limit HIHI High High Alarm: Measured value exceeds 2nd maximum limit value Hochtemperatur High temperature...
  • Page 166 Abbreviation Meaning Explanation Turbo Boost Sensor Turbocharger Boost Sensor Turbo Compressor Inlet Turbo Compressor Outlet Transmitter Deviation Alarm: Sensor comparison fault Throttle Position Sensor Timing Reference Sensor T-xyz Temperature-xyz Temperature measuring point xyz Unterer Totpunkt Bottom Dead Center (BDC) Variable Nozzle Turbocharger Variable Speed Governor Vehicle Speed Sensor Werkzeugkatalog...
  • Page 167 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 168 10 Appendix B 10.1 Special Tools Adapter Part No.: F30011619 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 102) Allen keys, 2-10 mm Part No.: F30453050 Qty.: Used in: 8.2.1 Valve clearance – Check and adjustment (→ Page 104) Assembly device Part No.: F6794712...
  • Page 169 Barring tool Part No.: F6797674 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 102) Barring tool Part No.: F6790714 Qty.: Used in: 8.2.1 Valve clearance – Check and adjustment (→ Page 104) Box wrench, 14 mm Part No.: F30028346 Qty.: Used in:...
  • Page 170 Crossbeam Part No.: T80092479 Qty.: Used in: 2.1 Transportation (→ Page 18) Feeler gage Part No.: Y20010128 Qty.: Used in: 8.2.1 Valve clearance – Check and adjustment (→ Page 104) High-pressure cleaner Part No.: Qty.: Used in: 5.8 Plant – Cleaning (→ Page 56) Oilstone Part No.: F30454308/03...
  • Page 171 Ratchet bit Part No.: F30027340 Qty.: Used in: 8.4.1 Fuel filter – Replacement (→ Page 113) Qty.: Used in: 8.4.3 Fuel prefilter – Filter element replacement (→ Page 116) Qty.: Used in: 8.7.3 EGR shutoff flaps – Coupling rod replacement (→...
  • Page 172 Torque wrench, 20–100 Nm Part No.: F30026582 Qty.: Used in: 8.2.1 Valve clearance – Check and adjustment (→ Page 104) Qty.: Used in: 8.7.7 EGR cooler – Replacement (→ Page 130) Qty.: Used in: 8.8.2 Engine oil – Change (→ Page 135) Torque wrench, 4–20 Nm Part No.: F30044239...
  • Page 173 Torque wrench, 20–100 Nm Part No.: F30026582 Qty.: Used in: 8.4.1 Fuel filter – Replacement (→ Page 113) Qty.: Used in: 8.9.1 Engine oil filter – Replacement (→ Page 137) Torque wrench, 4–20 Nm Part No.: F30044239 Qty.: Used in: 8.4.1 Fuel filter –...
  • Page 174 10.2 Index Cylinder head cover  – Installation  107 Abbreviations 164 – Removal  107 Actuators  – Overview  25 After stopping the engine 55 Direction of rotation 46 Air filter  Drive belt  – Replacement  117 – Condition check  152 Axial play  – Replacement  153 – Check   –...
  • Page 175 – US EPA Nonroad Tier 4  30 – Maintenance task reference table [QL1]  57 – US EPA Nonroad Tier 4 compliant  34 MTU contact persons 167 – 12V1600C50   – US EPA Nonroad Tier 4  38 – US EPA Nonroad Tier 4 compliant  42...
  • Page 176 Spare parts service 167 Startup  – After extended out-of-service periods (>3 months)  50 – After scheduled out-of-service-period  49 Transportation  – Description  18 – Lifting requirements  21 Troubleshooting 58 Valve clearance  – Adjustment  104 – Check  104 Warning notices, standards 17 176 | Index | MS150100/06E 2017-08...

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