MTU 12V4000C Series Operating Instructions Manual
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MTU 12V4000C Series Operating Instructions Manual

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Operating Instructions
Diesel Engine
12V4000Cxyz
16V4000Cxyz
MS150049/04E

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Summary of Contents for MTU 12V4000C Series

  • Page 1 Operating Instructions Diesel Engine 12V4000Cxyz 16V4000Cxyz MS150049/04E...
  • 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 6 Maintenance 1.1 Important provisions for all products 6.1 Maintenance task reference table [QL1] 1.2 Correct use of all products 1.3 Personnel and organizational requirements 7 Troubleshooting 1.4 Safety regulations for initial start-up and 7.1 Troubleshooting operation 7.2 Fault messages from DDEC engine governor 1.5 Safety regulations for maintenance and...
  • Page 4 9 Appendix A 8.16.4 Charge-air coolant – Filling 8.16.5 Charge-air coolant pump – Relief bore check 9.1 Abbreviations 9.2 MTU Contact/Service Partners 8.17 Engine Mounting / Support 8.17.1 Engine mounting – Check 10 Appendix B 8.17.2 Securing screws – Check for firm seating 8.18 Belt Drive...

  • Page 5: Safety

    The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product. 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.

  • Page 6: Correct Use Of All Products

    • With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al- so applies to engine control/parameters) •...

  • Page 7: 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 8: 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 9 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. MS150049/04E 2017-04 | Safety | 9...

  • Page 10: Safety Regulations For Maintenance And Repair Work

    1.5 Safety regulations for maintenance and repair work Safety regulations when preparing to perform maintenance and repair work Have 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 11 Take special care when removing ventilation or plug screws from the product. Ensure that O-rings are not installed in a slanted/twisted condition. Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g. components carrying oil, fuel, or air). Note cooling time for components which are heated for installation or removal (risk of burning).
  • Page 12 Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The welding current can induce interfering voltages in the wiring harnesses which may damage the electrical sys- tem. Remove components (e.g. exhaust pipe) from the product before performing necessary welding work. Hydraulic installation and removal Check the function and safe operating condition of tools and fixtures to be used.
  • Page 13 Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package faulty electronic components or assemblies properly before dispatching for repair: • Moisture-proof • Shock-proof • Wrapped in antistatic foil (as necessary) Working with laser equipment Work with laser devices shall be carried out by trained and qualified personnel only.

  • Page 14: Fire Prevention And Environmental Protection, Fluids And Lubricants, Indirect Materials

    The safety data sheet may be obtained from the relevant manufacturer or from MTU. Only use fluids and lubricants which have been approved by the manufacture and are specified in the Fluids and Lubricants Specifications.
  • Page 15 Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • Avoid direct contact with lead or pastes containing lead. • Do not inhale lead vapors. • Wash affected areas after contact with lead or substances containing lead. Compressed air •...

  • Page 16: Standards For Safety Notices In The Text

    1.7 Standards for safety notices in the text 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 17: Transport

    Set the system down on a firm, flat surface only. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set the engine down on its oil pan unless expressly authorized to do so by MTU. MS150049/04E 2017-04 | Transport | 17...

  • Page 18: Lifting Specifications

    2.2 Lifting specifications Lifting specifications DANGER Suspended load. Danger to life! • Use appropriate lifting devices and appliances. • Never stand beneath a suspended load. Applies also to 16V4000Cx0, 16V4000Cx1 1 Max. permissible diagonal 2 Center of gravity pull: 10° Take note of the engine center of gravity Refer to the installation/arrangement drawings for details of the center of gravity of the system or the center of gravity of the engine/generator.

  • Page 19: Crankshaft Transport Locking Device

    2.3 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Engine oil Note: The transport locking device on both sides protects the crankshaft bearings from shocks and possible vibra- tion damage during engine transport.
  • Page 20 Installing the transport locking device on driving end (KS), ver- sion A Screw holder (4) with spacer sleeves (5) and screws (6) onto crankshaft. Spacer sleeves (5), optional. Tighten screws (6) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard...
  • Page 21 Installing the transport locking device on driving end (KS), ver- sion B Secure plate (1) with screws (5) and washers (4) together with cover plate (7) at the bores on both sides of the flywheel housing and tighten to the specified tightening torque. Name Size Type...

  • Page 22: Crankshaft Transport Locking Device - For Transport With Flanged-On Generator

    Tightening torque (Engine oil) 250Nm +25 Nm Installing the transport locking device on driving end (KS) Remove the transport locking device installed by MTU (→ Page 19). Remove protective cover from flywheel housing (1). 22 | Transport | MS150049/04E 2017-04...
  • Page 23 Install the holders (7) on both sides of the crankcase (12) with screw (9) and washer (8). Tighten screw (9). Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 290Nm +20 Nm To allow the holders (3) to be secured on each side of the flywheel (2), the corresponding screws and wash- ers must be removed from the driving end.

  • Page 24: 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 25: Engine - Overview

    3.2 Engine – Overview Image also applies to 16V4000Cxyz 1 Intercooler thermostat 8 Intercooler 15 Cylinder head 2 Fan coupling 9 Crankcase breather 16 Air conditioning compressor 3 Engine oil heat exchanger 10 Charge-air line drive 4 Centrifugal oil filter 11 Electric starter 17 Oil filter 5 Exhaust pipe bellows...
  • Page 26 1 Intercooler 7 Charge-air coolant outlet 13 Oil pan 2 Charge-air line 8 Charge-air coolant inlet 14 Carbon brushes 3 Centrifugal oil filter 9 Battery-charging generator 15 Flywheel 4 Oil cooler 10 Engine coolant pump 16 Flywheel housing 5 Engine coolant inlet 11 Oil dipstick 6 Lifting eyes 12 Oil filler neck...

  • Page 27: Sensors - Overview

    3.3 Sensors – Overview 1 Engine coolant temperature 3 Charge-air temperature 2 Crankshaft speed 4 Charge-air pressure The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and necessary activities (→ Page 96). MS150049/04E 2017-04 | General Information | 27...
  • Page 28 1 Camshaft speed 3 Fuel temperature 5 Intercooler coolant pressure 2 Fuel pressure (LP) 4 HP fuel 6 Engine coolant pressure 1 Intercooler coolant temper- 3 Lube oil temperature ature 4 Lube oil pressure 2 Crankcase pressure 28 | General Information | MS150049/04E 2017-04...

  • Page 29: Technical Data

    4 Technical Data 4.1 Product data 12V4000C11, 12V4000C11R Legend DL Ref. value continuous power (CP): Continuous power under standard conditions BL Ref. value fuel stop power (FSP): Maximum engine power; not available for continuous operation in some applications (control reserve) A Design value: Value required to design an external system (plant) R Reference value: Typical average value for information, only partially suitable for design purposes L Limit: Value which must not be violated (lower limit value, min.
  • Page 30 Performance data Rated engine speed 1900 1900 1900 1900 Continuous power (w/o fan) (fuel stop 1286 1193 1286 1193 power ISO 3046) General conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar Model related data (basic design) Cylinder arrangement: V angle...
  • Page 31 Capacities Engine coolant, engine side (without cool- Liters ing equipment) Charge-air coolant, engine side Liters Engine oil, max. Liters Weights Engine weight, dry (basic engine configu- 6044 6044 6044 6044 ration acc. to scope of delivery specifica- tion) Sound Number of cylinders Unsilenced exhaust noise at 1 m distance dB(A) MS150049/04E 2017-04 | Technical Data | 31...

  • Page 32: Product Data 16V4000C11, 16V4000C11R

    4.2 Product data 16V4000C11, 16V4000C11R Legend DL Ref. value continuous power (CP): Continuous power under standard conditions BL Ref. value fuel stop power (FSP): Maximum engine power; not available for continuous operation in some applications (control reserve) A Design value: Value required to design an external system (plant) R Reference value: Typical average value for information, only partially suitable for design purposes L Limit: Value which must not be violated (lower limit value, min.
  • Page 33 General conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar Model related data (basic design) Cylinder arrangement: V angle Degrees Bore Stroke Displacement of a cylinder Liters Total displacement Liters 65.0 65.0...
  • Page 34 Capacities Engine coolant, engine side (without cooling Liters equipment) Charge-air coolant, engine side Liters Engine oil, max. Liters Weights Engine weight, dry (basic engine configuration 7083 7083 7083 acc. to scope of delivery specification) Sound Unsilenced exhaust noise at 1 m distance dB(A) 34 | Technical Data | MS150049/04E 2017-04...

  • Page 35: Product Data 12V4000C21, 12V4000C21R

    4.3 Product data 12V4000C21, 12V4000C21R Legend DL Ref. value continuous power (CP): Continuous power under standard conditions BL Ref. value fuel stop power (FSP): Maximum engine power; not available for continuous operation in some applications (control reserve) A Design value: Value required to design an external system (plant) R Reference value: Typical average value for information, only partially suitable for design purposes L Limit: Value which must not be violated (lower limit value, min.
  • Page 36 Performance data Rated engine speed 1900 1900 1900 1900 Continuous power (without fan) (fuel stop 1510 1398 1510 1398 power) General conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar Model related data (basic design) Cylinder arrangement: V angle...
  • Page 37 Capacities Engine coolant, engine side (without cool- Liters ing equipment) Charge-air coolant, engine side Liters Engine oil, max. Liters Weights Engine weight, dry (basic engine configu- 6044 6044 6044 6044 ration acc. to scope of delivery specifica- tion) Sound Unsilenced exhaust noise at 1 m distance dB(A) MS150049/04E 2017-04 | Technical Data | 37...

  • Page 38: Product Data 16V4000C21, 16V4000C21R, 16V4000C21L

    4.4 Product data 16V4000C21, 16V4000C21R, 16V4000C21L Legend DL Ref. value continuous power (CP): Continuous power under standard conditions BL Ref. value fuel stop power (FSP): Maximum engine power; not available for continuous operation in some applications (control reserve) A Design value: Value required to design an external system (plant) R Reference value: Typical average value for information, only partially suitable for design purposes L Limit: Value which must not be violated (lower limit value, min.
  • Page 39 Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level Performance data Rated engine speed 1900 1900 1900 1900 1900 Continuous power (without 2013 1864 1864 2013 1491 fan) (fuel stop power) General conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
  • Page 40 Lube oil system Lube oil operating pressure up- stream of engine, from Fuel system Fuel temperature before pump, °C max. Capacities Engine coolant, engine side Liters (without cooling equipment) Charge-air coolant, engine side Liters Engine oil, max. Liters Weights Engine weight, dry (basic engine 7083 7083 7083...

  • Page 41: Product Data 16V4000C31

    4.5 Product data 16V4000C31 Legend DL Ref. value continuous power (CP): Continuous power under standard conditions BL Ref. value fuel stop power (FSP): Maximum engine power; not available for continuous operation in some applications (control reserve) A Design value: Value required to design an external system (plant) R Reference value: Typical average value for information, only partially suitable for design purposes L Limit: Value which must not be violated (lower limit value, min.
  • Page 42 Displacement of a cylinder Liters 4.06 Total displacement Liters 65.0 Number of inlet valves per cylinder Number of exhaust valves per cylinder Combustion air / exhaust gas Charge-air pressure before cylinder Exhaust gas temperature °C Coolant system (HT circuit) Coolant temperature (at engine connection: outlet to cooling °C equipment) Coolant pump: inlet pressure, max.

  • Page 43: Firing Order

    4.6 Firing order Firing order Number of cylin- Firing order ders A1-B4-A4-A2-B3-A3-B2-B1 A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 MS150049/04E 2017-04 | Technical Data | 43...

  • Page 44: Engine - Main Dimensions

    4.7 Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 12V4000Cxyz approx. 2540 mm approx. 1630 mm approx. 2050 mm 16V4000Cxyz approx. 3010 mm approx. 1630 mm approx. 2050 mm 44 | Technical Data | MS150049/04E 2017-04...

  • Page 45: Operation

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

  • Page 46: Putting The Engine Into Operation After Scheduled Out-Of-Service Period

    5.2 Putting the engine into operation after scheduled out-of- service period Preconditions ☑ Engine is stopped and starting disabled. WARNING In case of out-of-service periods of more than one week: Possible corrosion of components carrying air or exhaust gas due to weather conditions, e.g. rain or snow. Risk of injury by flying debris when putting the engine into operation! •...

  • Page 47: Engine - Starting In Manual Mode

    5.3 Engine – Starting in manual mode Preconditions ☑ Engine is not under load. ☑ External start interlock is not activated. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 48: 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 49: Engine - Stopping In Manual Mode

    5.5 Engine – Stopping in manual mode Preconditions ☑ Engine is not under load. ☑ Engine is running in manual mode. NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress- Overheating of and, therefore, damage to components is possible! •...

  • Page 50: After Shutting Down The Engine

    5.6 After shutting down the engine Preconditions ☑ MTU Corrosion-proofing and Reproofing Regulations (A001070/..) are available. After shutting down the engine Item Action Coolant system Drain coolant (→ Page 119), (→ Page 128), if: • freezing temperatures are expected and the engine is to remain out of service for an extended period, but engine coolant has no antifreeze addi- tive;...

  • Page 51: Plant - Cleaning

    5.7 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 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 52: 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 53: 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 that cable connections are properly secured (→ manufacturer's documentation) u Check if cable connections are properly secured, contact Service.
  • Page 54 Air in fuel system u Contact Service. DDEC defective Charge-air temperature too high Cause Corrective action u Check (→ MTU test kit) Engine coolant treatment incorrect Intercooler contaminated u Contact Service. u Check fans and intake/exhaust lines. Engine room: Air-intake...
  • Page 55 Exhaust gas white Cause Corrective action u Warm up Engine is not at operating temperature Fuel system: Water in fuel u Drain fuel prefilter. Check fuel system. Intercooler leaking u Contact Service. MS150049/04E 2017-04 | Troubleshooting | 55...

  • Page 56: Fault Messages From Ddec Engine Governor

    7.2 Fault messages from DDEC engine governor The DDEC engine governor generates alarms which are indicated in different ways depending on the equip- ment configuration: • Two-digit flashing code • Fault code and text on a display or PC screen To facilitate troubleshooting without additional auxiliary equipment, the two-digit flash codes can be read out from the DDEC by means of the vehicle-side alarm lamps CHECK ENGINE LIGHT (yellow) and STOP ENGINE LIGHT (red).
  • Page 57 The following information is available on reading out the fault codes with the DDR. Example: MID:128 Engine TURBO BOOST SENSOR INPUT VOLTAGE HIGH ▴ A1 PID: FMI:3 ▾ Explanation: • 33 → Flashing code • MID: 128 →Information about the source of the fault message •...
  • Page 58 Flash- Description Maintenance tasks code Sensor "Top up coolant", in- 1. Check coolant condition put voltage too low. (→ Page 123). 2. Check coolant level, top up if required (→ Page 116). 3. Check cabling. 4. Contact Service. Temperature sensor/inter- 1.
  • Page 59 Flash- Description Maintenance tasks code Oxygen concentration cir- 1. Check cabling. cuit, input voltage too high. 2. Contact Service. Fuel temperature sensor, in- 1. Check cabling. put voltage too high. 2. Contact Service. Oxygen concentration cir- 1. Check cabling. cuit, input voltage too low. 2.
  • Page 60 Flash- Description Maintenance tasks code CEL, open circuit . 1. Check cabling. 2. Contact Service. Charge pressure sensor, in- 1. Check cabling. put voltage too high. 2. Contact Service. Charge pressure sensor, in- 1. Check cabling. put voltage too low. 2.
  • Page 61 Flash- Description Maintenance tasks code Exhaust gas recirculation Contact Service. flow too low, VNT nozzles do not respond, charge-air pres- sure (version 33.0 or later). VNT vanes do not respond, Contact Service. EGR (version 33.0 or later). No signal from EGR valve 1.
  • Page 62 Flash- Description Maintenance tasks code High range: Oil pressure too 1. Check engine oil level low. (→ Page 108). 2. Contact Service. Oil pressure too low. 1. Check engine oil level (→ Page 108). 2. Contact Service. ECM battery voltage too low. Contact Service. Real-time clock auxiliary bat- Contact Service.
  • Page 63 Flash- Description Maintenance tasks code Temperature at exhaust tur- 1. Check contamination indicator bocharger inlet above range signal ring position (→ Page 107). (version 33.0 or later). 2. Check exhaust system. 3. Contact Service. Temperature at exhaust tur- 1. Check contamination indicator bocharger outlet too high signal ring position (→...
  • Page 64 Flash- Description Maintenance tasks code Auxiliary output 1, mechani- Contact Service. cal system does not respond correctly F3. Auxiliary output 2, short cir- Contact Service. cuit on battery circuit (plus) Auxiliary output 2, open cir- Contact Service. cuit A2. Auxiliary output 2, mechani- Contact Service.
  • Page 65 Flash- Description Maintenance tasks code PWM 1 open circuit. Contact Service. PWM 2 above normal range. Contact Service. PWM 2 below normal range. Contact Service. PWM 2 short circuit on bat- Contact Service. tery circuit (plus). PWM 2 open circuit. Contact Service.
  • Page 66 Flash- Description Maintenance tasks code Coolant pressure sensor, Contact Service. high range (input voltage too high). Coolant pressure sensor, Contact Service. high range (input voltage too low). Air inlet pressure sensor, in- Contact Service. put voltage too high. Air inlet pressure sensor, in- Contact Service.
  • Page 67 Flash- Description Maintenance tasks code Transmission idling switch Contact Service. defective, (ESS transmis- sion). Analog auxiliary input: data Contact Service. failing irregularly or defective (ESS transmission). Analog auxiliary input 1, volt- Contact Service. age too high (ESS transmis- sion). Analog auxiliary input 1, volt- Contact Service.
  • Page 68 Flash- Description Maintenance tasks code Fuel filter differential pres- Contact Service. sure too low. Oil filter differential pressure Contact Service. too low. Engine oil pressure too high. Contact Service. Charge-air pressure too low. Contact Service. Inlet elbow temperature too Contact Service. low.
  • Page 69 Flash- Description Maintenance tasks code Maintenance display lamp, Contact Service. faulty / service interval ex- ceeded (version 32.0 or lat- er). Self-adaptive speed control Contact Service. faulty (version 27.0 or later). Oil level sensor, input volt- Contact Service. age too high. Crankcase pressure sensor, Contact Service.
  • Page 70 Flash- Description Maintenance tasks code Exhaust duct temperature 9, Contact Service. sensor voltage too high (ver- sion 32.0 or later). Exhaust duct temperature Contact Service. 10, sensor voltage too high (version 32.0 or later). Exhaust duct temperature Contact Service. 11, sensor voltage too high (version 32.0 or later).
  • Page 71 Flash- Description Maintenance tasks code EGR OPD, sensor circuit de- Contact Service. fective / low (version 33.0 or later). EGR temperature too low Contact Service. (version 33.0 or later). Exhaust duct temperature 1, Contact Service. sensor voltage too low (ver- sion 32.0 or later).
  • Page 72 Flash- Description Maintenance tasks code Exhaust duct temperature Contact Service. 15, sensor voltage too low (version 32.0 or later). Exhaust duct temperature Contact Service. 16, sensor voltage too low (version 32.0 or later). EGR- temperature, input volt- Contact Service. age too high. EGR differential pressure in- Contact Service.
  • Page 73 Flash- Description Maintenance tasks code Exhaust duct temperature 6, Contact Service. sensor voltage too high (ver- sion 32.0 or later). Exhaust duct temperature 7, Contact Service. sensor voltage too high (ver- sion 32.0 or later). Exhaust duct temperature 8, Contact Service. sensor voltage too high (ver- sion 32.0 or later).
  • Page 74 Flash- Description Maintenance tasks code Pump pressure sensor, input Contact Service. voltage too low. Atmospheric pressure sen- Contact Service. sor, input voltage too low. High range: coolant pressure Contact Service. too low. Coolant pressure too low. Contact Service. Fuel differential pressure too Contact Service.

  • Page 75: Task Description

    8 Task Description 8.1 Engine 8.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Adapter F6558528 Ratchet with extension F30006212 DANGER Rotating/moving engine parts. Risk of crushing, danger of body parts being caught up or drawn in! •...

  • Page 76: Engine - Cranking On Starting System

    8.1.2 Engine – Cranking on starting system DANGER Rotating/moving engine parts. Risk of crushing, danger of body parts being caught up or drawn in! • Ensure that all personnel is clear of the danger zone before cranking the engine on the starter. Cranking engine on starting sys- Remove screws (1, 3) and take off perforated plate (2).

  • Page 77: Cylinder Liner

    8.2 Cylinder Liner 8.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 94). Remove injector (→...
  • Page 78 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 79). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 79: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    8.2.2 Cylinder liner – Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina- tion report. Findings Measure Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod- ucts, particles, broken-off burrs).
  • Page 80 Findings Measure Burn mark Burn marks are caused by a disturbance in the liner / ring tribo system. 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 onwards and less pro- nounced from TDC-ring 1.

  • Page 81: Crankcase Breather

    8.3 Crankcase Breather 8.3.1 Crankcase breather – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Engine oil Filter element (→ Spare Parts Catalog) WARNING Oil is hot.
  • Page 82 Crankcase breather (open-cir- cuit crankcase ventilation) – Fil- ter element cleaning or replace- ment Clean filter externally. Release vent hose on oil separator cover (1) and remove. Remove oil separator cover (1). Loosen clamp (5). Clean or replace filter element (2) (→...

  • Page 83: Crankcase Breather (Open-Circuit Crankcase Ventilation) - Filter Element Cleaning

    8.3.2 Crankcase breather (open-circuit crankcase ventilation) – Filter element cleaning Preconditions ☑ Engine is stopped and starting disabled. WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 84: Running Gear

    8.4 Running Gear 8.4.1 Grounding device – Carbon brush check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Cold cleaner (Hakutex 60) 50602 Carbon brush (→ Spare Parts Catalog) WARNING Compressed air gun ejects a jet of pressurized air.
  • Page 85 Checking grounding equipment Item Findings Measure Carbon brush Damaged Replace (→ Page 86) Wear limit 45 mm (new condition Replace (→ Page 86) 60 mm) Press carbon brush against spring pressure Spring Broken, damaged Replace (→ Page 86) Running surface on adapter Dirty, corroded Clean Cleaning running surface on adapter...

  • Page 86: Grounding Device - Carbon Brush Replacement

    8.4.2 Grounding device – Carbon brush replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Screw locking compound (Loctite 270) 40083 Carbon brush (→ Spare Parts Catalog) Replacing carbon brush Undo screw (1) with washer.

  • Page 87: Valve Drive

    8.5 Valve Drive 8.5.1 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication Remove cylinder head covers (→ Page 94). Fill oil chambers of valve bridges with oil.

  • Page 88: Valve Protrusion - Measurement

    8.5.2 Valve protrusion – Measurement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Depth gage, 200 mm Y20000918 Preparatory steps Remove cylinder-head cover upper section (→ Page 94). Remove injector (→ Page 97). Install barring tool (→...
  • Page 89 Measure distance between valve stem end and cylinder head top at the injector bore with depth gage (see figure). • Specified value for a new cylinder head: 93.8 mm. • Admissible wear: 2 mm. • If the measured value is > 95.8 mm, have the relevant cylinder head replaced by specialist personnel ahead of schedule.

  • Page 90: Valve Clearance - Check And Adjustment

    8.5.3 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y20098771 Torque wrench, 60–320 Nm F30452768...
  • Page 91 Diagram for 8V engines – two crankshaft positions Diagram for 12V engines – two crankshaft positions Diagram for 16V engines – two crankshaft positions MS150049/04E 2017-04 | Valve Drive | 91...
  • Page 92 Diagram for 20V engines – two crankshaft positions Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If rocker arms on cylinder A1 are unloaded, the piston is in firing TDC. • If rocker arms on cylinder A1 are loaded, the piston is in overlap TDC. Check valve clearance adjustment with cold engine: •...
  • Page 93 Tighten locknut (1) to specified torque using a torque wrench, holding the adjusting screw (2) to prevent it from turning. Name Size Type Lubricant Value/Standard M16 x 1.5 Tightening torque (Engine oil) 90 Nm +9 Nm man- ual tightening Replace or rectify adjusting screws and/or locknuts which do not move freely. Check valve clearance.

  • Page 94: Cylinder Head Cover - Removal And Installation

    8.5.4 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Gasket (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (3) prior to removal.

  • Page 95: Injection Pump / Hp Pump

    8.6 Injection Pump / HP Pump 8.6.1 HP fuel 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 96: Injector

    8.7 Injector 8.7.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 97). 96 | Injector | MS150049/04E 2017-04...

  • Page 97: Injector - Removal And Installation

    8.7.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation and removal jig F6794703 Milling cutter F30452739 Slotted screwdriver F30452578 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769...
  • Page 98 Removing injector Note: Always replace the first and last injectors of one engine side first. Replace the inner injec- tors only after the installation of the outer in- jectors on this engine side is completed. Release the cable terminal threaded connec- tion (arrowed) on the injector and remove ca- ble terminals.
  • Page 99 Remove sealing ring (1) from injector or use a self-made hook to take it out of the cylinder head. Remove O-rings (2) from injector. Cover all connections and bores, or seal with suitable plugs. Installing injector Prior to installation, remove all blanking plugs.
  • Page 100 Use slotted screwdriver to check thrust ring at both line ends for secure seating. Tighten loose thrust ring to specified tightening torque. Name Size Type Lubricant Value/Standard Thrust ring Tightening torque 5 Nm to 10 Nm Coat screw head mating face (2) and thread with engine oil.
  • Page 101 Tighten union nut of adapter (limiting valve) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union nut Tightening torque 140 Nm + 10 Nm Tighten union nut of adapter (injector) to specified torque using a torque wrench. Name Size Type...

  • Page 102: Fuel System

    8.8 Fuel System 8.8.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filling device B80144852 Diesel fuel WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 103: Fuel Filter

    8.9 Fuel Filter 8.9.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 104: Charge-Air Cooling

    8.10 Charge-Air Cooling 8.10.1 Charge-air cooler – Check water drain for coolant leakage and obstruction DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 105: Starting Equipment

    8.11 Starting Equipment 8.11.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 145). MS150049/04E 2017-04 | Starting Equipment | 105...

  • Page 106: Cold Start System With Ether Injection - Check

    8.11.2 Cold start system with ether injection – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Ether cartridge (→ Spare Parts Catalog) DANGER Cleaner is an explosive and poisonous substance. Danger to life, major material damage! •...

  • Page 107: Air Intake

    8.12 Air Intake 8.12.1 Service indicator – Check See manufacturer's documentation. MS150049/04E 2017-04 | Air Intake | 107...
  • Page 108 8.13 Lube Oil System, Lube Oil Circuit 8.13.1 Engine oil ‒ Level check Checking oil level before start- ing engine Remove oil dipstick from guide tube and wipe it clean. Insert dipstick into guide tube up to the stop. Pull out after approx. 10 seconds and check oil level.
  • Page 109 8.13.2 Checking engine oil level Preconditions ☑ Engine shut down and secured against being restarted. Checking engine oil level at oil sight glass The oil level (2) can be checked visually in ad- vance at the oil sight glass (1). A correct reading of the engine oil level is on- ly possible with the oil dipstick (→...
  • Page 110 8.13.3 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 40–200 Nm...
  • Page 111 Draining residual oil from equip- ment carrier (only with un- scheduled engine oil change) Provide a suitable container in which to col- lect the engine oil. Remove drain plug (1) and drain oil (approx. 7 liters) from oil heat exchanger and oil filter. Remove drain plugs (2) and (3) and drain en- gine oil: •...
  • Page 112 8.13.4 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 113 8.14 Oil Filtration / Cooling 8.14.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Engine oil filter (→ Spare Parts Catalog) WARNING Oil is hot.
  • Page 114 8.14.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Torque wrench, 6–50 Nm F30027336 Ratchet bit F30027339 Solvent cleaner (Hakutex 60) X00070585 Assembly compound (Kluthe Hakuform 30-11C/Emulgier) X00059351...
  • Page 115 Centrifugal oil filter – Cleaning and filter-sleeve replacement Release screw (1) and remove. Remove clamp (3) and take off cover (2). Carefully remove rotor assembly (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7). Take off rotor cap (8).
  • Page 116 8.15 Coolant Circuit, General, High-Temperature Circuit 8.15.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 117 Checking engine coolant level at sight glass Check coolant level (coolant level must be between “min.” and “max.” mark). Top up coolant if necessary (→ Page 120). MS150049/04E 2017-04 | Coolant Circuit, General, High-Temperature Circuit | 117...
  • Page 118 8.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 119). Fill with engine coolant (→ Page 120). 118 | Coolant Circuit, General, High-Temperature Circuit | MS150049/04E 2017-04...
  • Page 119 8.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps Provide a suitable container in which to collect the coolant.
  • Page 120 8.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING Coolant is hot and under pressure.
  • Page 121 Filling with coolant using a pump Connect appropriate pump with hose to drain valve. Open drain valve and pump coolant into en- gine at 0.5 bar minimum. Fill expansion tank until overflow edge is reached. Close drain valve. Check proper condition of breather valve and clean sealing faces if required.
  • Page 122 8.15.5 Engine coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
  • Page 123 8.15.6 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 Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 124 Using the equipment and chemicals from the MTU test kit, examine coolant for: • antifreeze concentration • Amount of corrosion protection oil • pH value For engine coolant change intervals, refer to (→ MTU Fluids and Lubricants Specifications (A001061/..)). 124 | Coolant Circuit, General, High-Temperature Circuit | MS150049/04E 2017-04...
  • Page 125 8.15.7 Breather valve – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Breather valve (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 126 8.16 Low-Temperature Circuit 8.16.1 Charge-air coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
  • Page 127 8.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 128). Fill with charge-air coolant (→ Page 129). MS150049/04E 2017-04 | Low-Temperature Circuit | 127...
  • Page 128 8.16.3 Charge-air coolant – Drainage 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 8.16.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure.
  • Page 130 Filling with coolant using a pump Connect a suitable pump with a hose to the drain valve (arrowed). Open air bleed on intercooler (arrow). Open drain valve and pump coolant into en- gine at 0.5 bar minimum. When coolant emerges from the bleed valve, close the bleed valve.
  • Page 131 Alternatively: Filling with cool- ant through filler neck Remove plug screws from filling points (ar- rows) on coolant lines from and to the inter- cooler. Open air bleed on the intercooler (arrow). Fill coolant via the filling points on the cool- ant lines to and from the intercooler and via the expansion tank up to the overflow.
  • Page 132 8.16.5 Charge-air coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
  • Page 133 8.17 Engine Mounting / Support 8.17.1 Engine mounting – Check Engine mounting – Check Item Findings Action Visually inspect resilient mounts. • Damage Replace (contact Service). • Brittleness • Deformation • Crack formation • Swelling MS150049/04E 2017-04 | Engine Mounting / Support | 133...
  • Page 134 8.17.2 Securing screws – Check for firm seating Preconditions ☑ Engine is stopped and starting disabled Checking securing screws for firm seating Check securing screws (1) on fan housing (2) for firm seating. Tighten loose threaded connections using a torque wrench. 134 | Engine Mounting / Support | MS150049/04E 2017-04...
  • Page 135 8.18 Belt Drive 8.18.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Protective cover is removed. Drive belt – Condition check Item Findings Measure Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace (→...
  • Page 136 8.19 Battery-Charging Generator 8.19.1 Battery-charging generator – Condition check Preconditions ☑ Engine shut down and starting disabled. Battery-charging generator – Condition check Check if securing screws of battery-charging generator fit firmly. Tighten any loose threaded connections. Check wiring (→ Page 145). 136 | Battery-Charging Generator | MS150049/04E 2017-04...
  • Page 137 8.19.2 Battery-charging generator – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! • Never direct air jet at people. •...
  • Page 138 8.19.3 Battery-charging generator – Removal and installation Preconditions ☑ Engine is stopped and starting disabled WARNING Heavy part, risk of falling or overturning due to lack of stability. Risk of crushing body or limbs! • Use appropriate lifting gear and appliances. •...
  • Page 139 8.19.4 Battery-charging generator – Drive belt and belt tensioner replacement Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Belt tensioner (→ Spare Parts Catalog) WARNING Heavy part, risk of falling or overturning due to lack of stability.
  • Page 140 8.19.5 Battery-charging generator – Drive belt tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm F30452768 Ratchet bit F30027341 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 WARNING...
  • Page 141 Part numbers Frequencies Belt pulleys Fan drive Belt Initial assem- Initial opera- Belt tension bly at MTU tion with fan adjustment UPC.0K601A0515 UPC.06K01 2233 UPC.06K01B0324 47 Hz ±3 Hz 64 Hz ±1 Hz 56 Hz ±1 Hz UPC.0K601A0515 UPC.06K01 2233 X00027176 46 Hz ±3 Hz...
  • Page 142 Part numbers Frequencies Belt pulleys Fan drive Belt Initial assem- Initial opera- Belt tension bly at MTU tion with fan adjustment UPC.0K601A0518 UPC.06K01 2233 X00027176 47 Hz ±3 Hz 62 Hz ±1 Hz 54 Hz ±1 Hz UPC.0K601A0518 UPC.06K01 2264 UPC.06K01B0325 44 Hz ±3 Hz...
  • Page 143 8.20.2 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 144 8.21 Auxiliary PTO 8.21.1 Compressor – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Compressed-air pipes may still be under pressure, although the shut-off valve is closed. Risk of injury! • Before starting work, release pressure from pipework. Checking compressor Check oil supply line (3) and connections for condition and leaks.
  • Page 145 8.22 Wiring (General) for Engine/Gearbox/Unit 8.22.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.
  • Page 146 8.23 Accessories for (Electronic) Engine Governor / Control System 8.23.1 DDEC and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol DANGER Cleaner is an explosive and poisonous substance. Danger to life, major material damage! •...
  • Page 147 Cleaning severely contaminated connectors on DDEC Disconnect connectors on both sides of DDEC. For this purpose, withdraw connec- tors (1). Unscrew connectors (3). Remove covers (2). Clean connector housings, connector socket housings and all contacts with isopropyl alco- hol. When connectors, sockets and all contacts are dry: Install connectors and check plug-in connection on DDEC (→...
  • Page 148 8.23.2 DDEC – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Checking plug-in connections on DDEC Check all plug-in connections on both sides of DDEC for secure seating. Slide connectors (1) on until they latch into position. Screw in connectors (3) securely.
  • Page 149 Abgasturbolader/Abgasturboaufladung Exhaust turbocharger/exhaust turbocharging Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica- tion No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Drift correction setting with DiaSys in engine gover- Check Engine Lamp...
  • Page 150 Abbre- Meaning Explanation viation Engine Control Unit Engine governor Engine Data Module Memory module for engine data Electrically Erasable Programmable Read Electrically Erasable Programmable Read Only Mem- PROM Only Memory EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal Exhaust Gas Recirculation Engine Ident Label EIM-ID Emission Identification Number Engine Monitoring Unit...
  • Page 151 Abbre- Meaning Explanation viation Not Applicable Low Pressure Normal Null Reference surface for heights above sea level Niedertemperatur Low temperature Original Equipment Manufacturer Optimized Idle Oil Level Sensor Monitors oil level Oil Pressure Sensor Monitors oil pressure Oil Temperature Sensor Monitors oil temperature Oberer Totpunkt Top Dead Center...
  • Page 152 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 153 10 Appendix B 10.1 Special Tools Adapter Part No.: F6558528 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 75) Barring tool Part No.: F6555766 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 75) Qty.: Used in: 8.2.1 Cylinder liner –...
  • Page 154 Crossbeam Part No.: T80092210 Qty.: Used in: 2.1 Transportation (→ Page 17) Depth gage, 200 mm Part No.: Y20000918 Qty.: Used in: 8.5.2 Valve protrusion – Measurement (→ Page 88) Endoscope Part No.: Y20097353 Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 77) Feeler gage Part No.: Y20098771...
  • Page 155 Filling device Part No.: B80144852 Qty.: Used in: 8.8.1 Fuel system – Venting (→ Page 102) Filter wrench Part No.: F30379104 Qty.: Used in: 8.9.1 Fuel filter – Replacement (→ Page 103) Qty.: Used in: 8.14.1 Engine oil filter – Replacement (→ Page 113) Qty.: Used in: 8.14.2 Centrifugal oil filter –...
  • Page 156 Milling cutter Part No.: F30452739 Qty.: Used in: 8.7.2 Injector – Removal and installation (→ Page 97) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 8.13.4 Engine oil – Sample extraction and analysis (→ Page 112) Qty.: Used in: 8.15.6 Engine coolant –...
  • Page 157 Ratchet bit Part No.: F30027339 Qty.: Used in: 8.14.2 Centrifugal oil filter – Cleaning and filter-sleeve re- placement (→ Page 114) Ratchet bit Part No.: F30027340 Qty.: Used in: 8.19.5 Battery-charging generator – Drive belt tension ad- justment (→ Page 140) Ratchet with extension Part No.: F30006212...
  • Page 158 Socket box wrench Part No.: F30039526 Qty.: Used in: 8.5.3 Valve clearance – Check and adjustment (→ Page 90) Torque screwdriver, 1–5 Nm Part No.: F30452774 Qty.: Used in: 8.7.2 Injector – Removal and installation (→ Page 97) Torque wrench, 10–60 Nm Part No.: F30452769 Qty.:...
  • Page 159 Torque wrench, 4–20 Nm Part No.: F30044239 Qty.: Used in: 8.4.2 Grounding device – Carbon brush replacement (→ Page 86) Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 2.3 Crankshaft transport locking device (→ Page 19) Qty.: Used in: 2.4 Crankshaft transport locking device –...
  • Page 160 10.2 Index Cylinder liner  – Endoscopic examination  77 Abbreviations 149 Cylinder liner – Instructions and comments on endoscopic After shutting down the engine 50 and visual examination 79 Battery-charging generator  DDEC and connectors – Cleaning 146 – Check  137 DDEC – Checking plug-in connections 148 –...
  • Page 161  87 Valve protrusion  – Measurement  88 Main dimensions  – Engine  44 Maintenance Schedule  – Maintenance task reference table [QL1]  52 MTU contact persons 152 Operational checks  48 Plant  – Cleaning  51 Pump  – Engine coolant   – Relief bore check  122 Putting into operation ...

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