MTU 12 V 4000 T94 Operating Instructions Manual
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MTU 12 V 4000 T94 Operating Instructions Manual

MTU 12 V 4000 T94 Operating Instructions Manual

Diesel
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Operating Instructions

Diesel engine
12 V 4000 T94, T94L
MS150096/01E

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Summary of Contents for MTU 12 V 4000 T94

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 4000 T94, T94L MS150096/01E...
  • Page 2 This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐ filming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 6 Troubleshooting 1.1 General conditions 6.1 Troubleshooting 1.2 Personnel and organizational requirements 6.2 Fault messages on the SAM display 1.3 Transport (optional) 1.4 Crankshaft transport locking device 6.3 Fault messages of Engine Control Unit 1.5 Safety regulations for startup and operation ECU 9 for Series 4000 1.6 Explosion hazard when removing inspection port cover on engine...
  • Page 4 8 Appendix A 7.16 Low-Temperature Circuit 8.1 Abbreviations 7.16.1 Charge-air coolant – Level check 8.2 MTU contact persons/service partners 7.16.2 Charge-air coolant – Change 7.16.3 Charge-air coolant – Draining 7.16.4 Charge-air coolant – Filling 7.16.5 Charge-air coolant pump – Relief bore check 9 Appendix B 7.17 Belt Drive...

  • Page 5: Safety

    Correct use also includes observation of and compliance with the maintenance specifications. Modifications or conversions Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies.

  • Page 6: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Personnel requirements All work on the engine shall be carried out by trained and qualified personnel only. The specified legal minimum age must be observed. The operator must specify the responsibilities of the operating, maintenance and repair personnel. Organizational measures This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐...

  • Page 7: Transport

    Place the engine/genset 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 an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to- case basis.

  • Page 8: Crankshaft Transport Locking Device

    1.4 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Torque wrench, 60-320 Nm F30047446 Engine oil Transport locking device Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine transport.
  • Page 9 Installing the transport locking device from driving end (KS), version A Screw holder (4) with spacer sleeves (5) and screws (6) onto crankshaft. Spacer sleeves (5) are optional. Tighten screws (6) with torque wrench to specified tightening torque. Name Size Type Lubricant Value/Standard...
  • Page 10 Note: Always use the screws supplied with or installed in the transport locking device to secure it on the en‐ gine. Fitting the transport locking device on driving end (KS), version B Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel housing and tighten to the specified tightening torque.
  • Page 11 Note: Always use the screws supplied with the or removed from the guard plates and engine mounting brack‐ ets to secure them on the engine. Installing guard plates and engine mounting brackets (if applicable) on driving end (KS) Install engine mounting brackets (2) on both sides with guard plates (1) washers (3), and screws (4).

  • Page 12: Safety Regulations For Startup And Operation

    Safety precautions when putting the equipment into operation Prior to initial operation of the assembly or plant, install the assembly or unit according to the specifica‐ tions and check the installation according to the MTU specifications. Before putting the device or plant into operation, always ensure: •...

  • Page 13: Explosion Hazard When Removing Inspection Port Cover On Engine

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

  • Page 14: Safety Regulations For Maintenance And Repair Work

    1.7 Safety regulations for maintenance and repair work Safety regulations for maintenance and repair work Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
  • Page 15 Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
  • Page 16 For conducting light-beam procedures and measurement work, only the following laser devices must be used: • Laser devices of classes 1, 2 or 3A. • Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.

  • Page 17: Auxiliary Materials, Fluids And Lubricants, Fire Prevention And Environmental Protection

    Use only fuel of prescribed quality to comply with emission limit values. Dispose of used fluids, lubricants and filters in accordance with local regulations. Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are subjected to proper recycling procedures.
  • Page 18 Lead • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 19: Conventions For Safety Instructions In The Text

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

  • Page 20: General Information

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

  • Page 21: Engine Layout

    29 Crankcase breather 8 EGR cooler KGS Free end 9 Engine coolant line 10 Engine governor Engine model designation Key to the engine model designation 12 V 4000 T94/T94L Number of cylinders Cylinder arrangement: V engine 4000 Series Application Application segment...

  • Page 22: Sensors, Actuators And Injectors - Overview

    2.3 Sensors, actuators and injectors ‒ Overview 1 B13 - Crankshaft speed 3 F57 - Charge-air coolant 2 F70 - Water level in fuel level prefilter (external) 4 F33 - Engine coolant level 22 | General Information | MS150096/01E 2012-08...
  • Page 23 1 M52 - Bypass flap 5 B91.3 - Exhaust pres‐ 9 B13 - Crankshaft speed 2 B44.2 - Turbocharger B sure 10 B10.11 - Charge-air speed 6 B88 - NOx pressure, B-side 3 B90 - Humidity (pres‐ 7 B16 - Engine coolant sure, temperature) of in‐...
  • Page 24 1 M55 - Donor cylinder 6 B9 - Charge-air temper‐ 11 F46 - Leak-off fuel level flap ature 12 B5.3 - Lube-oil pressure 2 B44.3 - Turbocharger C 7 Y39.A1-A6 - Injectors before filter speed A1-A6 13 B7 - Lube-oil tempera‐ 3 B10.1 - Charge-air pres‐...
  • Page 25 1 B50 - Crankcase pres‐ 5 B48 - Fuel pressure 9 B26 - Charge-air cool‐ sure (Rail) ant temperature 2 Y44 - Fan control 6 M8 - HP fuel pump 10 B6 - Engine coolant 3 B5.1 - Lube-oil pressure 7 B1 - Camshaft speed temperature after filter...

  • Page 26: Technical Data

    3 Technical Data 3.1 Engine data 12V 4000 T94, T94L Explanation Abbrev. Meaning Reference value: Continuous power Reference value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power set‐ ting).
  • Page 27 Model related data (basic design) Engine model 12V4000 12V4000 T94L Engine with exhaust turbocharging (ETC) and charge-air cool‐ ing (CAC) Uncooled exhaust lines Number of cylinders Cylinder arrangement: V angle De‐ grees (°) Bore Stroke Displacement of a cylinder Liters 4.77 4.77 Total displacement...
  • Page 28 Engine model 12V4000 12V4000 T94L Coolant temperature before intercooler, shutdown or power re‐ °C duction Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. Thermostat: Starts to open °C Thermostat: Fully open °C Lube oil system Engine model 12V4000 12V4000 T94L...
  • Page 29 Inclinations – standard oil system (reference: waterline) Engine model 12V4000 12V4000 T94L Longitudinal inclination, continuous max. driving end down (op‐ Degrees tion: max. operating inclinations) (°) Longitudinal inclination, continuous max. driving end up (option: Degrees max. operating inclinations) (°) Transverse inclination, continuous max. (option: max. operating Degrees inclinations) (°)

  • Page 30: Firing Order

    3.2 Firing order Firing order Num‐ Firing order ber of cylin‐ ders A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 30 | Technical Data | MS150096/01E 2012-08...

  • Page 31: Main Engine Dimensions

    3.3 Main engine dimensions Main engine dimensions Length (A) approx. 2685 mm Width (B) approx. 1631 mm Height (C) approx. 1921 mm MS150096/01E 2012-08 | Technical Data | 31...

  • Page 32: Operation

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

  • Page 33: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Startup Item Action Lube oil system Check engine oil level (→ Page 146). Coolant circuit Check engine coolant level (→ Page 154); Check charge-air coolant level (→...

  • Page 34: Operational Checks

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

  • Page 35: Starting The Engine In Manual Mode

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

  • Page 36: Stopping The Engine In Manual Mode

    4.5 Stopping the engine in manual mode Preconditions ☑ Engine is not under load. ☑ Engine is running in manual mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! •...

  • Page 37: After Stopping The Engine

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

  • Page 38: Plant Cleaning

    4.7 Plant cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not present. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! •...

  • Page 39: Maintenance

    5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
  • Page 40 Task Measures W1610 Check securing screws of trunnion bearings for tight fit. (→ Page 180) W1636 Reset drift correction parameters (CDC) and enter code of in‐ (→ Page 182) jectors (IIG). Table 1: Maintenance task reference table [QL1] 40 | Maintenance | MS150096/01E 2012-08...

  • Page 41: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Cause Action Battery Low or faulty. Charge or replace (see manufacturer's documentation). Cable connections defective Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter Engine wiring or starter defective.
  • Page 42 Defective Contact Service. Charge-air temperature too high Component Cause Action Coolant Coolant treatment incorrect. Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Inlet air temperature too high. Check fans and air supply / ventilation ducts. Charge-air pressure too low...
  • Page 43 White exhaust gas Component Cause Action Engine Not at operating temperature. Run up to operating temperature. Fuel system Water in fuel. Check fuel system on fuel prefilter. Drain fuel prefilter. Intercooler Leaking Contact Service. MS150096/01E 2012-08 | Troubleshooting | 43...

  • Page 44: Fault Messages On The Sam Display (Optional)

    6.2 Fault messages on the SAM display (optional) The fault code numbers are generated by the engine governor and transmitted to the following display: The fault code (1) comprises three digits. Fault messages can also be caused by faulty sensors/actuators. If the fault cannot be corrected with the troubleshooting information provided in the following table, contact Service.

  • Page 45: Fault Messages Of Engine Control Unit Ecu 9 For Series 4000

    6.3 Fault messages of Engine Control Unit ECU 9 for Series 4000 3 – HI T-Fuel ZKP-Number: 2.0122.931 Fuel temperature too high (limit value 1) Yellow alarm - warning Cause Corrective action Fuel tank may be exposed to 1. Reduce power. heat.
  • Page 46 9 – HI T-Coolant Intercooler ZKP-Number: 2.0124.931 Coolant temperature in intercooler too high (limit value 1) Yellow alarm - warning Cause Corrective action Coolant circuit for charge air 1. Reduce power. faulty. 2. Check intercooler and coolant cooler. 3. Contact Service. 10 –...
  • Page 47 19 – HI T-Exhaust A ZKP-Number: 2.0126.931 Exhaust temperature (A-side) too high (limit value 1) Yellow alarm - warning Cause Corrective action Cable damage. 1. Check air filter and wiring (→ Page 181). 2. Contact Service. 20 – SS T-Exhaust A ZKP-Number: 2.0126.932 Exhaust temperature (A-side) too high (limit value 2) Red alarm - engine shutdown...
  • Page 48 25 – HI P-Diff. Lube Oil ZKP-Number: 2.0154.931 Differential oil pressure at oil filter too high (limit value 1) Yellow alarm - warning Cause Corrective action Oil filter not operating correctly. u Replace oil filter (→ Page 150). 26 – SS P-Diff. Lube Oil ZKP-Number: 2.0154.932 Differential oil pressure at oil filter too high (limit value 2) Red alarm - engine shutdown...
  • Page 49 32 – SS ETC1 Overspeed ZKP-Number: 2.3012.932 Speed of primary turbocharger too high (limit value 2) Red alarm - engine shutdown Cause Corrective action Obstructed charge-air circuit or 1. Check air filter. fault in turbocharger. 2. Contact Service. 33 – HI P-Diff. Fuel ZKP-Number: 2.0114.931 Fuel filter differential pressure too high (limit value 1) Yellow alarm - warning...
  • Page 50 44 – LO Coolant Level Intercooler ZKP-Number: 2.0153.921 Coolant level of intercooler too low (limit value 1) Yellow alarm - warning Cause Corrective action Insufficient charge-air coolant, 1. Check coolant level (→ Page 165). e.g. due to leaks in charge-air 2.
  • Page 51 59 – SS T-Coolant L3 ZKP-Number: 2.0120.933 Coolant temperature too high / low (limit value 3) Red alarm - forced idle Cause Corrective action Coolant circuit not operating 1. Activate fan emergency operating mode if required. correctly (e.g. damage, leaks, 2.
  • Page 52 65 – LO P-Fuel ZKP-Number: 2.0102.921 Fuel supply pressure too low (limit value 1) Yellow alarm - warning Cause Corrective action Leaky or obstructed fuel lines or 1. Check fuel lines for leaks. fuel filter. 2. Check filter, fuel on low-pressure side. 3.
  • Page 53 81 – AL System Leaking ZKP-Number: 1.8004.046 Leakage Yellow alarm - warning Cause Corrective action During start: Pressure gradient in 1. Check engine for leaks. rail too low (HP system leaking, 2. Contact Service. air in system). During stop: Pressure gradient in 1.
  • Page 54 90 – SS Idle Speed Not Reached ZKP-Number: 2.1090.925 Idle speed not reached Red alarm – warning Cause Corrective action Various causes possible. 1. Observe additional messages. 2. Contact Service. 91 – SS Release Speed Not Reached ZKP-Number: 2.1090.924 Runup speed was not attained Red alarm –...
  • Page 55 95 – AL Priming Fault ZKP-Number: 2.1090.920 Oil priming fault. Yellow alarm - warning Cause Corrective action Priming oil pressure not reached. 1. Check priming system. 2. Contact Service. 102 – AL Fuel Cons. Counter Defect ZKP-Number: 1.8004.624 Fault in fuel checksum Yellow alarm - warning Cause Corrective action...
  • Page 56 120 – HI ECU Supply Voltage ZKP-Number: 2.0140.931 Supply voltage too high (limit value 1) Yellow alarm - warning Cause Corrective action Supply voltage at engine 1. Check engine governor supply voltage. governor too high. 2. Contact Service. 121 – HIHI ECU Supply Voltage ZKP-Number: 2.0140.932 Supply voltage too high (limit value 2) Red alarm - start terminated or engine shutdown...
  • Page 57 180 – AL CAN1 Node Failure ZKP-Number: 2.0500.680 Connection to a node on CAN bus 1 failed Yellow alarm - warning Cause Corrective action Connection to or communication 1. Check devices connected to CAN. with a node at CAN bus 1 has 2.
  • Page 58 184 – AL CAN PU Data Flash Error ZKP-Number: 2.0500.684 CAN PU data flash fault Cause Corrective action A programming error occurred u Contact electronic Service. during attempt to copy a received PU data module to the flash module. 186 – AL CAN1 Bus Off ZKP-Number: 2.0500.686 CAN controller 1 is in "Bus-Off"...
  • Page 59 189 – AL CAN2 Error Passive ZKP-Number: 2.0500.689 CAN controller 2 error Yellow alarm - warning Cause Corrective action Missing associated nodes, minor 1. Check CAN bus for short circuit, rectify short circuit as required. disruptions or temporary bus 2. Check shielding, improve shielding if necessary. overload.
  • Page 60 204 – SD Level Lube Oil ZKP-Number: 1.8004.602 Lube oil level sensor signal error Yellow alarm - warning Cause Corrective action Lube oil level sensor faulty. 1. Check sensor and wiring, replace as necessary (→ Page 181). Short circuit or wire break. 2.
  • Page 61 208 – SD P-Charge Air ZKP-Number: 1.8004.566 Charge-air pressure sensor signal error Yellow alarm - warning Cause Corrective action Charge-air pressure sensor 1. Check sensor and wiring (B10), replace as necessary faulty. (→ Page 181). Short circuit or wire break. 2.
  • Page 62 214 – SD P-Crankcase ZKP-Number: 1.8004.568 Crankcase pressure sensor signal error Yellow alarm - warning Cause Corrective action Crankcase pressure sensor 1. Check sensor and wiring (B50), replace as necessary faulty. (→ Page 181). Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 35). 3.
  • Page 63 220 – SD Level Coolant Water ZKP-Number: 1.8004.584 Coolant level sensor signal error Yellow alarm - warning Cause Corrective action Coolant level sensor faulty. 1. Check sensor and wiring (F33), replace as necessary Short circuit or wire break. (→ Page 181). 2.
  • Page 64 227 – SD Oil Pressure Upstream of Filter ZKP-Number: 1.8004.620 Lube oil pressure sensor upstream of filter, signal error Yellow alarm - warning Cause Corrective action Lube oil pressure sensor 1. Check sensor and wiring (B5.3), replace as necessary upstream of filter faulty. (→...
  • Page 65 231 – SD Camshaft Speed ZKP-Number: 1.8004.499 Camshaft sensor signal error Yellow alarm - warning Cause Corrective action Camshaft sensor faulty. 1. Check sensor and wiring (B1), replace as necessary Short circuit or wire break. (→ Page 181). 2. Fault is rectified when engine is restarted (→ Page 35). 3.
  • Page 66 240 – SD P-Fuel ZKP-Number: 1.8004.565 Fuel pressure sensor signal error Yellow alarm - warning Cause Corrective action Fuel pressure sensor faulty. 1. Check sensor and wiring (B34), replace as necessary Short circuit or wire break. (→ Page 181). 2. Fault is rectified when engine is restarted (→ Page 35). 3.
  • Page 67 269 – SD Load P. Analog Filt. ZKP-Number: 2.8006.588 Load pulse analog signal faulty Yellow alarm - warning Cause Corrective action The filtered analog signal of load 1. Check wiring, replace as necessary (→ Page 181). pulse is not present. 2.
  • Page 68 323 – AL Wiring Cylinder A3 ZKP-Number: 1.8004.522 Wiring faulty, cylinder A3 Yellow alarm - misfiring Cause Corrective action Short circuit fault in injector 1. Check injector solenoid valve, replace injector if required wiring, cylinder A3. (→ Page 120). 2. Fault is rectified when engine is restarted (→ Page 35). 3.
  • Page 69 327 – AL Wiring Cylinder A7 ZKP-Number: 1.8004.526 Wiring faulty, cylinder A7 Yellow alarm - misfiring Cause Corrective action Short circuit fault in injector 1. Check injector solenoid valve, replace injector if required wiring, cylinder A7. (→ Page 120). 2. Fault is rectified when engine is restarted (→ Page 35). 3.
  • Page 70 331 – AL Wiring Cylinder B1 ZKP-Number: 1.8004.530 Wiring faulty, cylinder B1 Yellow alarm - misfiring Cause Corrective action Short circuit fault in injector 1. Check injector solenoid valve, replace injector if required wiring, cylinder B1. (→ Page 120). 2. Fault is rectified when engine is restarted (→ Page 35). 3.
  • Page 71 335 – AL Wiring Cylinder B5 ZKP-Number: 1.8004.534 Wiring faulty, cylinder B5 Yellow alarm - misfiring Cause Corrective action Short circuit fault in injector 1. Check injector solenoid valve, replace injector if required wiring, cylinder B5. (→ Page 120). 2. Fault is rectified when engine is restarted (→ Page 35). 3.
  • Page 72 339 – AL Wiring Cylinder B9 ZKP-Number: 1.8004.538 Wiring faulty, cylinder B9 Yellow alarm - misfiring Cause Corrective action Short circuit fault in injector 1. Check injector solenoid valve, replace injector if required wiring, cylinder B9. (→ Page 120). 2. Fault is rectified when engine is restarted (→ Page 35). 3.
  • Page 73 343 – AL Open Load Cylinder A3 ZKP-Number: 1.8004.542 Injector wiring fault, cylinder A3 Yellow alarm - misfiring Cause Corrective action Disruption fault in injector wiring, 1. Check injector wiring for disruption. cylinder A3. 2. Rule out any disruption in injector solenoid valve, replace injector if required (→...
  • Page 74 347 – AL Open Load Cylinder A7 ZKP-Number: 1.8004.546 Injector wiring fault, cylinder A7 Yellow alarm - misfiring Cause Corrective action Disruption fault in injector wiring, 1. Check injector wiring for disruption. cylinder A7. 2. Rule out any disruption in injector solenoid valve, replace injector if required (→...
  • Page 75 351 – AL Open Load Cylinder B1 ZKP-Number: 1.8004.550 Injector wiring fault, cylinder B1 Yellow alarm - misfiring Cause Corrective action Disruption fault in injector wiring, 1. Check injector wiring for disruption. cylinder B1. 2. Rule out any disruption in injector solenoid valve, replace injector if required (→...
  • Page 76 355 – AL Open Load Cylinder B5 ZKP-Number: 1.8004.554 Injector wiring fault, cylinder B5 Yellow alarm - misfiring Cause Corrective action Disruption fault in injector wiring, 1. Check injector wiring for disruption. cylinder B5. 2. Rule out any disruption in injector solenoid valve, replace injector if required (→...
  • Page 77 359 – AL Open Load Cylinder B9 ZKP-Number: 1.8004.558 Injector wiring fault, cylinder B9 Yellow alarm - misfiring Cause Corrective action Disruption fault in injector wiring, 1. Check injector wiring for disruption. cylinder B9. 2. Rule out any disruption in injector solenoid valve, replace injector if required (→...
  • Page 78 363 – AL Stop Injector Output Stage ZKP-Number: 1.8004.560 Internal electronics fault. Red alarm - engine shutdown Cause Corrective action Electronics possibly faulty. 1. Start ITS. 2. Replace engine governor. 3. Check additional fault messages if ITS indicates "Electronics OK" (e.g. wiring faulty). 4.
  • Page 79 383 – AL Wiring TOP 3 ZKP-Number: 2.8006.640 Line disruption on digital input 3 Yellow alarm - warning Cause Corrective action Short circuit or broken wire on u Check wiring to plant. transistor output 3, plant side (TOP 3). 384 – AL Wiring TOP 4 ZKP-Number: 2.8006.641 Line disruption on digital input 4 Yellow alarm - warning...
  • Page 80 401 – AL Open Load Digital Input 2 ZKP-Number: 2.8006.626 Line disruption on digital input 2 Yellow alarm - warning Cause Corrective action Wiring faulty. 1. Check wiring (→ Page 181). No resistance over switch. 2. Check target device input. 3.
  • Page 81 405 – AL Open Load Digital Input 6 ZKP-Number: 2.8006.630 Line disruption on digital input 6 Yellow alarm - warning Cause Corrective action Wiring faulty. 1. Check wiring (→ Page 181). No resistance over switch. 2. Check target device input. 3.
  • Page 82 410 – LO U-PDU ZKP-Number: 2.0141.921 Injector voltage too low (limit value 1) Yellow alarm - warning Cause Corrective action Cable damage or faulty power 1. Check wiring (→ Page 181). supply. 2. Check power supply. 3. Contact Service. 411 – LOLO U-PDU ZKP-Number: 2.0141.922 Injector voltage too low (limit value 2) Red alarm - engine shutdown...
  • Page 83 414 – HI Water Level Fuel Prefilter ZKP-Number: 2.0156.931 Water level in fuel prefilter too high (limit value 1) Yellow alarm - warning Cause Corrective action Water content in fuel too high. u Drain fuel prefilter. Water ingress in fuel tank. 415 –...
  • Page 84 439 – HI P-Fuel 2 (Common Rail) ZKP-Number: 2.0116.931 Rail pressure > set value Red alarm - DBR fuel limitation, start of injection readjusted towards late Cause Corrective action HP fuel block jamming or HP fuel u Contact Service. control block wiring faulty. 441 –...
  • Page 85 448 – HI P-Charge Air ZKP-Number: 2.0103.931 Charge-air pressure too high (limit value 1) Yellow alarm - warning Cause Corrective action Fault at turbine bypass flap. u Contact Service. 449 – SS P-Charge Air ZKP-Number: 2.0103.932 Charge-air pressure too high (limit value 2) Red alarm - engine shutdown Cause Corrective action...
  • Page 86 466 – SD T-AUX 2 ZKP-Number: 1.8004.586 Signal fault, temperature Aux 2 Yellow alarm - warning Cause Corrective action Analog input for Aux 2 1. Check temperature sensor and wiring, replace as necessary temperature faulty. (→ Page 181). Short circuit or wire break. 2.
  • Page 87 472 – AL Stop SD ZKP-Number: 2.8006.593 Engine stops Red alarm - engine shutdown Cause Corrective action Engine stop, since all shutdown 1. Check wiring (→ Page 181). channels detect "sensor defect". 2. Contact Service. 474 – AL Wiring FO ZKP-Number: 2.8006.655 Wiring fault at FO Yellow alarm - warning...
  • Page 88 479 – AL Red Summary Alarm (Plant) ZKP-Number: 2.8006.002 Red summary alarm from system Red alarm Cause Corrective action Various causes possible. u Observe additional messages. 480 – AL Ext. Engine Protection ZKP-Number: 2.0291.921 External engine protection function active Yellow alarm - warning Cause Corrective action The external engine protection...
  • Page 89 491 – SS ETC4 Overspeed ZKP-Number: 2.3015.932 Speed of the 3rd secondary turbocharger too high (limit value 2) Red alarm - engine shutdown Cause Corrective action Obstructed charge-air circuit or u Reduce power. fault in turbocharger. 500 – AL Wiring POM Starter 1 ZKP-Number: 1.4500.900 Wiring faulty, connection of starter 1 at POM Yellow alarm - warning...
  • Page 90 504 – AL CAN POM Node Failure ZKP-Number: 1.4500.904 POM missing on CAN bus Yellow alarm - warning Cause Corrective action If alarm 508 also appears, the u Check connection and POM. resistance in the POM wiring is missing. 506 – AL Starter Voltage Too Low ZKP-Number: 1.4500.906 The battery voltage is too low for the starting process Yellow alarm - warning...
  • Page 91 514 – Flash memory write error ZKP-Number: 1.8004.611 Value was not transferred to flash memory Cause Corrective action Flash memory faulty. u Contact Service. 515 – AL Starter Not Engaged ZKP-Number: 2.1090.926 Yellow alarm – start termination possible Cause Corrective action Starter on POM could not be 1.
  • Page 92 558 – AL Wiring PWM_CM2 ZKP-Number: 1.1041.922 Wiring problem at PWM_CM2 channel Yellow alarm - warning Cause Corrective action Broken cable or short circuit at 1. Check wiring to connected device or check connected device channel PWM_CM2. itself (actuator/sensor) and replace if necessary (→ Page 181). 2.
  • Page 93 582 – AL Emergency Stop Failed ZKP-Number: 1.1005.006 Emergency stop command was not executed Flashing pre-alarm and alarm Cause Corrective action Engine speed does not come to u Contact Service. a stop within a parameterizable time. 586 – LO P-Oil Replenishment Pump ZKP-Number: 2.0159.911 Oil pressure in replenishment pump too low (limit value 1) Yellow alarm - warning...
  • Page 94 594 – AL L1 PRV Faulty ZKP-Number: 1.1301.900 Yellow alarm – warning pressure relief valve, first rail Cause Corrective action HP fuel block jamming or HP fuel u Contact Service. control block wiring faulty. 595 – AL L2 PRV Faulty ZKP-Number: 1.1301.901 Red alarm –...
  • Page 95 599 – AL L2 PRV Faulty ZKP-Number: 1.1302.901 Red alarm breather valve, second rail. Cause Corrective action HP fuel block jamming or HP fuel 1. Check wiring and HP fuel control block (→ Page 181). control block wiring faulty. 2. Contact Service. 600 –...
  • Page 96 608 – AL Wiring PWM_CM6 ZKP-Number: 1.1041.926 Wiring problem at PWM_CM6 channel Yellow alarm - warning Cause Corrective action Cable break or short circuit on 1. Check wiring to connected device or check connected device channel PWM_CM6. itself (actuator/sensor) and replace if necessary (→ Page 181). 2.
  • Page 97 612 – AL Wiring Pressure Regulating Valve 1 ZKP-Number: 1.1301.903 Wiring faulty, pressure regulating valve 1 Yellow alarm - warning Cause Corrective action Cable break or short circuit on 1. Check wiring (→ Page 181). PWM channel, pressure 2. Contact Service. regulating valve 1.
  • Page 98 625 – SD P-Fuel Upstream of Add. Filter ZKP-Number: 1.8004.600 Fuel pressure sensor before additional filter signal error Yellow alarm - warning Cause Corrective action Analog input signal for fuel 1. Check pressure transmitter and wiring, replace as necessary pressure before additional filter (→...
  • Page 99 629 – AL EGR Shutoff Flap A Defect ZKP-Number: 1.0700.011 EGR shutoff flap A faulty Yellow alarm - warning Cause Corrective action Actuator fault at exhaust gas 1. Replace actuator or flap. recirculation shutoff flap A or flap 2. Contact Service. mechanical system is defective.
  • Page 100 633 – SD P-Ambient Air (HDT2800) ZKP-Number: 1.0700.087 Moisture sensor signal error (TRICAN HDT2800) Yellow alarm - warning Cause Corrective action Moisture sensor (TRICAN 1. Check sensor and wiring, replace as necessary (→ Page 181). HDT2800) defective. 2. Contact Service. 634 –...
  • Page 101 640 – SD Smart NOx Oxidation Factor O2 ZKP-Number: 1.0700.145 Signal error, Smart NOx Sensor (Oxidation Factor O2) Yellow alarm - warning Cause Corrective action Smart NOx sensor (oxidation 1. Check sensor and wiring, replace as necessary (→ Page 181). factor O2) faulty.
  • Page 102 647 – SD P-Exhaust Lambda ZKP-Number: 1.0163.900 Exhaust gas sensor near lambda sensor signal error Yellow alarm - warning Cause Corrective action Exhaust gas sensor near lambda 1. Check sensor and wiring (B91), replace as necessary sensor faulty (→ Page 181). Short circuit or wire break.
  • Page 103 727 – AL L1 Delta T-NT Intercooler ZKP-Number: 2.1075.901 T-max. coolant intercooler has exceeded L1 Yellow alarm - warning Cause Corrective action Coolant circuit for charge air 1. Reduce power. faulty. 2. Check intercooler and coolant cooler. 3. Contact Service. 728 –...
  • Page 104 754 – SD Bosch LSU Lambda Sensor ZKP-Number: 1.0800.990 Signal fault, Lambda sensor Yellow alarm - warning Cause Corrective action Bosch Lambda sensor faulty. 1. Check sensors and wiring, replace as necessary (→ Page 181). Short circuit or wire break. 2.
  • Page 105 766 – AL EASF A to B Open ZKP-Number: 1.2510.127 Emergency-air shutoff flap A closed, but emergency-air shutoff flap B remained open Cause Corrective action Flap B stuck. u Check flap B (→ Page 140). Flap B was not energized. Check wiring (→...
  • Page 106 834 – AL Gas Line Warning ZKP-Number: 2.1600.010 Gas line warning Cause Corrective action Lambda sensor faulty. 1. Delete all other fault codes. Lambda regulator at stop. 2. Check sensor and wiring (→ Page 181). 3. Contact Service. 835 – AL Gas Line Fault ZKP-Number: 2.1600.012 Gas line fault Cause...

  • Page 107: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6787910 Ratchet F30006212 DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 108: Engine - Barring With Starting System

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

  • Page 109: Engine - Test Run

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

  • Page 110: Cylinder Liner

    7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 118). Remove injector (→...
  • Page 111 Compile endoscopy report using the table. Use technical terms for description of the liner surface (→ Page 112). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 112: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    7.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐ nation report. Findings Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
  • Page 113 Findings Action Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be‐ coming more visible from the second TDC-ring 2 onwards and less pronounced from TDC-ring 1.

  • Page 114: Valve Drive

    7.3 Valve Drive 7.3.1 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 118). Fill oil chambers of valve bridges with oil.

  • Page 115: Valve Clearance - Check And Adjustment

    7.3.2 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Coolant temperature max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20098771 Allen key F30002815 Torque wrench, 60-320 Nm F30452768...
  • Page 116 Rotate crankshaft with barring device in en‐ gine direction of rotation until "OT-A1" mark and pointer are aligned. Diagram for 12V engines (two crankshaft positions) 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Checking valve clearance at two crankshaft positions Check OT/TDC position of piston in cylinder A1:...

  • Page 117: Adjusting Valve Clearance

    Adjusting valve clearance Release locknut (1). Insert feeler gauge (3) between valve bridge and rocker arm. Using Allen key, set adjusting screw (2) so that the specified valve clearance is provid‐ Feeler gauge (3) must just pass through the gap. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2) to prevent it from turning.

  • Page 118: Cylinder Head Cover - Removal And Installation

    7.3.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/emulsifier) X00058061 O-ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal.

  • Page 119: Injection Pump / Hp Pump

    7.4 Injection Pump / HP Pump 7.4.1 HP pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 120: Injection Valve / Injector

    7.5 Injection Valve / Injector 7.5.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 121). 120 | Task Description | MS150096/01E 2012-08...

  • Page 121: Injector - Removal And Installation

    7.5.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal device F6789889 Milling cutter F30452739 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30452769 Torque wrench, 60-320 Nm F30452768...

  • Page 122: Installing Injector

    Unscrew union nuts (2,5) and remove HP line (3) from rail (4) and cylinder head. Note: The injector accumulator will be emptied when removing the adapter. Remove adapter (1). Remove screw (1). Install installation/removal device on cylin‐ der head. Remove injector (2) and hold-down clamp (6) with installation/removal device.
  • Page 123 Secure new sealing ring (5) on injector (2) with grease. Fit new O-rings (3) (included in the scope of supply of the injector) and damping ring (4) onto the injector (2) and coat with grease. Insert injector (2) together with hold-down clamp (6) into cylinder head, ensuring that the high-pressure fuel line connection is aligned correctly.
  • Page 124 Use torque wrench to tighten union nuts (2,5) on HP line (3) to specified tightening torque. Tightening sequence: 1 Nut on adapter (2) 2 Nut on rail (5) Name Size Type Lubricant Value/Standard Union nut / thrust Tightening torque (Engine oil) 40 Nm + 5 Nm screw Fit cable connector onto injector.

  • Page 125: Fuel System

    7.6 Fuel System 7.6.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 126: Fuel Filter

    7.7 Fuel Filter 7.7.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 127: Auxiliary Fuel Filter - Replacement

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

  • Page 128: Exhaust Turbocharger

    7.8 Exhaust Turbocharger 7.8.1 Exhaust turbocharger – Turbine housing check Special tools, Material, Spare parts Designation / Use Part No. Qty. Turbine housing (→ Spare Parts Catalog) Exhaust turbocharger (low-pressure charger) Check turbine housing (→ Page 129). Exhaust turbocharger (high pressure) Check turbine housing (→...

  • Page 129: Exhaust Turbocharger (Lp) - Turbine Housing Check

    Designation / Use Part No. Qty. Endoscope Y20097353 Engine oil Assembly paste (Ultra-Therm MTU) 50547 Turbine housing (→ Spare Parts Catalog) Note: Procedure is only described for one LP turbocharger; applies inversely to the other side. Checking of the turbine housing of the HP exhaust turbocharger requires separate activities (→ Page 134).
  • Page 130 Removing exhaust pipe insulation Release clamps (1) and remove insula‐ tion (2). Removing exhaust pipe Release clamp (2) and take off with exhaust pipe bellows (1) and sealing ring (1) from turbine housing. Removing exhaust elbow Note: Mark position of clamp. Unscrew screws (5) and remove from con‐...
  • Page 131 Value/Standard Clamp Tightening torque (Assembly paste (Ul‐ 27 Nm + 2 Nm tra-Therm MTU)) Coat screw threads with assembly paste prior to installation. Install screws (5) and spacer sleeves (4) on console and tighten to specified tightening torque. Name Size...
  • Page 132 Installing exhaust pipe Install exhaust pipe bellows (1) with clamp (2) and sealing ring (3) on turbine housing. Installing exhaust pipe insulation Install insulation (2) on exhaust pipe and secure with clamps (1). Installing heat shield 132 | Task Description | MS150096/01E 2012-08...
  • Page 133 Install heat shield (1) with washers (3,5) and screws (2,4) and tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Screws Tightening torque (Engine oil) 42 Nm + 4 Nm Install holder (6) with washers (5) and screws (4) and tighten. Install holder (3) with washers (2) and screws (1) and tighten.

  • Page 134: Exhaust Turbocharger (Hp) - Turbine Housing Check

    Designation / Use Part No. Qty. Endoscope Y20097353 Engine oil Assembly paste (Ultra-Therm MTU) 50547 Turbine housing (→ Spare Parts Catalog) Note: The procedure is only described for the exhaust turbocharger (HP). Checking of the exhaust turbocharg‐ er turbine housing (LP) requires separate activities (→ Page 129).
  • Page 135 Removing exhaust pipe insulation Release clamps (1) and remove insula‐ tion (2). Removing exhaust pipe Release clamp (1) and take off with exhaust pipe (3) and sealing ring (2) from turbine housing. Removing insulation of exhaust pipe bellows Release clamps (1) and remove insula‐ tion (2).
  • Page 136 Removing exhaust pipe bellows Note: Mark position of clamp. Release clamp (2) and take off with sealing ring (1) and exhaust pipe bellows (3) from turbine housing. Checking turbine housing Check turbine housing from the inside for cracks. Note: Cracks are only permissible in the direction of circumference of the spiral.
  • Page 137 Installing insulation of exhaust pipe bellows Install insulation (2) on exhaust pipe bel‐ lows and secure with clamps (1). Installing exhaust pipe Install exhaust pipe (3) with clamp (1) and sealing ring (2) on turbine housing (). Installing exhaust pipe insulation Install insulation (2) on exhaust pipe and secure with clamps (1).
  • Page 138 Installing heat shield Install heat shield (1) with washers (3) and screws (2) and tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Screws Tightening torque (Engine oil) 42 Nm + 4 Nm Install holder (3) with washers (2) and screws (1) and tighten.

  • Page 139: Charge-Air Cooling

    7.9 Charge-Air Cooling 7.9.1 Intercooler – Leak check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 140: Air Intake

    7.10 Air Intake 7.10.1 Emergency air-shutoff flaps – Functional check with electric actuation DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Air flaps close abruptly.

  • Page 141: Exhaust Gas Recirculation

    7.11 Exhaust Gas Recirculation 7.11.1 Exhaust flaps – Overview 1 EGR shutoff flap 2 Donor cylinder flap MS150096/01E 2012-08 | Task Description | 141...
  • Page 142 1 Bypass flap 142 | Task Description | MS150096/01E 2012-08...

  • Page 143: Exhaust Flaps – Checking Operation Of Actuators

    7.11.2 Exhaust flaps – Checking operation of actuators Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied. WARNING Component is hot. Risk of burning! • Wear protective gloves. Checking operation of actuators – mechanically For installation position of exhaust flaps, refer to overview (→ Page 141). Remove guard plates of exhaust flaps.

  • Page 144: Starting Equipment

    7.12 Starting Equipment 7.12.1 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 181). 144 | Task Description | MS150096/01E 2012-08...

  • Page 145: Lube Oil System, Lube Oil Circuit

    7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Engine oil – Level check at sight glass Preconditions ☑ Engine is stopped and starting disabled. Engine oil – Level check at sight glass Engine oil level (2) may be checked in ad‐ vance at sight glass (1).

  • Page 146: Engine Oil – Level Check With Oil Dipstick

    7.13.2 Engine oil – Level check with oil dipstick Checking oil level prior to engine start Pull out dipstick from guide tube and wipe Insert dipstick into guide tube up to the stop, pull out after approx. 10 seconds. Check oil level on oil dipstick side marked "5 Min.

  • Page 147: Engine Oil – Change

    7.13.3 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 148 Note: Install drain plug(s) with new sealing ring. Screw in drain plug (1) and tighten to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw M18 x 1.5 Tightening torque (Engine oil) 50 Nm +10 Nm Screw in drain plugs (2,4) and tighten to specified tightening torque using a torque wrench.

  • Page 149: Engine Oil – Sample Extraction And Analysis

    7.13.4 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 Unguarded rotating and moving engine components.

  • Page 150: Oil Filtration / Cooling

    7.14 Oil Filtration / Cooling 7.14.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) Sealing ring (→...
  • Page 151 Remove oil filter with filter wrench. Clean sealing surface on connecting piece. Note: Use only oil filters with integrated safety valve. Check condition of the new oil filter sealing ring and coat it with engine oil. Screw on and tighten new engine oil filter by hand.

  • Page 152: Centrifugal Oil Filter – Cleaning And Filter Sleeve Replacement

    7.14.2 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 adapter F30027339 Cold cleaner (Hakutex 60) 50602 Grease (Kluthe Hakuform 30-10/Emulgier)
  • Page 153 Centrifugal oil filter – Cleaning and filter sleeve replacement Undo screw (1) and remove. Remove clamp (3) and take off hood (2). Carefully remove rotor (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7). Take off rotor cap (8).

  • Page 154: Coolant Circuit, General, High Temperature Circuit

    7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 155: Engine Coolant – Change

    7.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 156). Fill with engine coolant (→ Page 159). MS150096/01E 2012-08 | Task Description | 155...

  • Page 156: Engine Coolant – Draining

    7.15.3 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 receptacle to catch the coolant.
  • Page 157 Final steps Close all open drain points. Set breather valve onto filler neck and close it. MS150096/01E 2012-08 | Task Description | 157...

  • Page 158: Exhaust Flaps – Draining Coolant

    7.15.4 Exhaust flaps – Draining coolant Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 159: Engine Coolant – Filling

    7.15.5 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
  • Page 160 Filling with engine coolant using a pump Connect appropriate pump with hose to drain valve (arrow). Open vent points on EGR cooler, distribu‐ tors, exhaust turbochargers and oil heat ex‐ changer (arrows). Open drain valve and pump coolant into en‐ gine at 0.5 bar minimum.
  • Page 161 Alternatively: Filling with engine coolant through filler neck Open vent points on EGR cooler, distribu‐ tors, exhaust turbochargers and oil heat ex‐ changer (arrows). Fill in engine coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant.

  • Page 162: Engine Coolant Pump – Relief Bore Check

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

  • Page 163: Engine Coolant – Sample Extraction And Analysis

    7.15.7 Engine coolant – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Unguarded rotating and moving engine components.

  • Page 164: Engine Coolant Filter – Replacement

    7.15.8 Engine coolant filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Coolant filter (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 165: Low-Temperature Circuit

    7.16 Low-Temperature Circuit 7.16.1 Charge-air coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 166: Charge-Air Coolant – Change

    7.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 167). Fill with charge-air coolant (→ Page 169). 166 | Task Description | MS150096/01E 2012-08...

  • Page 167: Charge-Air Coolant – Draining

    7.16.3 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 168 Drain residual coolant at intermediate cool‐ er, A side. Drain residual coolant at intermediate cool‐ er, B side. Drain coolant at bypass flap and EGR shut‐ off flap (→ Page 158). Final steps Close all drain valves and install drain plug with new sealing rings. Set breather valve onto filler neck and close it.

  • Page 169: Charge-Air Coolant – Filling

    7.16.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Charge-air coolant WARNING Coolant is hot and under pressure.
  • Page 170 Filling with charge-air coolant using pump Connect appropriate pump with hose to drain valve (arrow). Open vent points on intercooler, intermedi‐ ate cooler and distributors (arrows). Open drain valve and pump coolant into en‐ gine at 0.5 bar minimum. Fill expansion tank until overflow edge is reached.
  • Page 171 Alternatively: Filling with engine coolant through filler neck Open vent points on intercooler, intermedi‐ ate cooler and distributors (arrows). Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. Check proper condition of breather valve and clean sealing faces if required.

  • Page 172: Charge-Air Coolant Pump – Relief Bore Check

    7.16.5 Charge-air coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 173: Belt Drive

    7.17 Belt Drive 7.17.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt Belt is oily, shows signs of over‐ Replace (→...

  • Page 174: Battery-Charging Generator

    7.18 Battery-Charging Generator 7.18.1 Battery-charging generator – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Checking battery-charging generator Item Findings...

  • Page 175: Battery-Charging Generator Drive – Drive Belt Tension Adjustment

    7.18.2 Battery-charging generator drive – Drive belt tension adjustment Preconditions ☑ Engine is stopped and starting disabled. WARNING Spring/circlip/tensioning roller preload. Risk of injury! • Only use specified tool and equipment. Adjusting belt tension Remove protective cover. Slacken screws (1) and (2) by half a turn. Result: Belt tensioner moves against the drive belt and tensions it.

  • Page 176: Battery-Charging Generator Drive – Drive Belt Replacement

    7.18.3 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. WARNING Spring/circlip/tensioning roller preload. Risk of injury! • Only use specified tool and equipment. Battery-charging generator drive – Drive belt replacement Remove protective cover. Slacken screws (2) and (3) by half a turn.

  • Page 177: Fan Drive

    7.19 Fan Drive 7.19.1 Fan drive (option) – Drive belt check / adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Optibell 2 belt tension tester Y4345711 Preparatory steps Remove protective cover.
  • Page 178 Adjusting drive belt tension Release screws (2) until fan coupling can be moved. Tighten stud (1) until the required frequency is achieved. Using a torque wrench, tighten screws (2) to the specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque 100 Nm ±...

  • Page 179: Fan Drive (Option) – Drive Belt Replacement

    7.19.2 Fan drive (option) – 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 Loosen screws (2).

  • Page 180: Engine Mounting / Support

    7.20 Engine Mounting / Support 7.20.1 Engine mounting – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 80 to 400 Nm F30027338 Ratchet F30027341 Engine oil Checking general condition Item Findings...

  • Page 181: Wiring (General) For Engine/Gearbox/Unit

    7.21 Wiring (General) for Engine/Gearbox/Unit 7.21.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

  • Page 182: Accessories For (Electronic) Engine Governor / Control System

    7.22 Accessories for (Electronic) Engine Governor / Control System 7.22.1 CDC parameters – Reset with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Resetting CDC parameters (DiaSys® is available) Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer appli‐ cable.

  • Page 183: Engine Governor And Connectors – Cleaning

    7.22.2 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent.

  • Page 184: Engine Governor – Checking Plug-In Connections

    7.22.3 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Checking plug-in connections on engine governor Check all plug-in connections for secure seating.

  • Page 185: Abbreviations

    Abgasturbolader Exhaust turbocharger (ETC) Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publication No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting of drift compensation in engine gov‐ ernor with DiaSys...
  • Page 186 Abbreviation Meaning Explanation Exhaust Gas Recirculation Engine Monitoring Unit Ersatzteilkatalog Spare Parts Catalog (SPC) Electronic Unit Injector Fuel Pressure Sensor Monitors fuel pressure Fuel - Differential Pressure Sensor Fuel Temperature Sensor Monitors fuel temperature FWCP Fire Water Control Panel Control cabinet Ground Hochdruck High Pressure (HP)
  • Page 187 Abbreviation Meaning Explanation Society of Automotive Engineers U.S. standardization organization Sensor Defect Alarm: Sensor failure Stop Engine Light 1st function: Warning lamp (stop engine and rectify fault) 2nd function: Read out fault codes System Identifier Synchronous Reference Sensor TDC cylinder 1 Safety System Safety system alarm Turbocharger Boost Sensor...

  • Page 188: Mtu Contact Persons/Service Partners

    Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –...

  • Page 189: Special Tools

    9 Appendix B 9.1 Special Tools Allen key Part No.: F30002815 Qty.: Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page 115) Barring device Part No.: F6787910 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 107) Barring device Part No.: F6555766...
  • Page 190 Feeler gauge Part No.: Y20098771 Qty.: Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page 115) Filter wrench Part No.: F30379104 Qty.: Used in: 7.7.1 Fuel filter – Replacement (→ Page 126) Qty.: Used in: 7.7.2 Auxiliary fuel filter – Replacement (→ Page 127) Qty.: Used in: 7.14.1 Engine oil filter –...
  • Page 191 MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.13.4 Engine oil – Sample extraction and analysis (→ Page 149) Qty.: Used in: 7.15.7 Engine coolant – Sample extraction and analysis (→ Page 163) Optibell 2 belt tension tester Part No.: Y4345711 Qty.:...
  • Page 192 Ratchet adapter Part No.: F30450902 Qty.: Used in: 7.13.3 Engine oil – Change (→ Page 147) Ratchet adapter Part No.: F30027339 Qty.: Used in: 7.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 152) Ratchet with extension Part No.: F30006212 Qty.:...
  • Page 193 Steam jet cleaner Part No.: Qty.: Used in: 4.7 Plant cleaning (→ Page 38) Torque wrench, 0.5-5 Nm Part No.: 0015384230 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 121) Torque wrench, 10-60 Nm Part No.: F30452769 Qty.: Used in: 7.5.2 Injector –...
  • Page 194 Torque wrench, 40-200 Nm Part No.: F30027337 Qty.: Used in: 7.13.3 Engine oil – Change (→ Page 147) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 152) Torque wrench, 60-320 Nm Part No.: F30452768...
  • Page 195 Torque wrench, 80 to 400 Nm Part No.: F30027338 Qty.: Used in: 7.20.1 Engine mounting – Check (→ Page 180) MS150096/01E 2012-08 | Appendix B | 195...

  • Page 196: Index

    9.2 Index Cylinder liner – Endoscopic examination  110 Abbreviations 185 – Instructions and comments on endoscopic and visual Actuators examination  112 – Overview  22 Actuators (exhaust flaps) – Function check  143 Drive belt After stopping the engine 37 – Condition check  173 Auxiliary fuel filter –...
  • Page 197  22 Inspection port cover – Explosion hazard  13 Intercooler – Leak check  139 Maintenance work – Safety regulations  14 MTU contact persons 188 Operation – Safety regulations  12 Operational checks 34 Personnel and organizational requirements 6 MS150096/01E 2012-08 | Appendix B | 197...

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