MTU 12 V 4000 G73 Operating Instructions Manual Download Page 4

Page: 4 / 155

7.8.5 Fuel prefilter ‒ Flushing

7.8.6 Fuel prefilter – Filter element replacement

7.9 Charge-Air Cooling

7.9.1 Intercooler – Check drain for coolant leakage

and obstruction

7.10 Air Filter

7.10.1 Air filter – Replacement

7.10.2 Air filter – Removal and installation

7.10.3 Rubber sleeves between air intake elbow and

turbocharger – Replacement

7.11 Air Intake

7.11.1 Contamination indicator – Signal ring position

check

7.11.2 Emergency air-shutoff flaps – Functional

check with electric actuation

7.11.3 Rubber sleeves in air pipework before

intercooler – Replacement

7.12 Starting Equipment

101

7.12.1 Air starter – Manual operation

101

7.13 Lube Oil System, Lube Oil Circuit

102

7.13.1 Engine oil level – Check

102

7.13.2 Engine oil – Change

103

7.13.3 Engine-oil – Sample extraction and analysis

105

7.14 Oil Filtration / Cooling

107

7.14.1 Engine oil filter – Replacement

107

7.14.2 Automatic oil filter – Oil filter candles

replacement

108

7.14.3 Oil indicator filter – Check

111

7.14.4 Centrifugal oil filter – Cleaning and filter-

sleeve replacement

113

7.15 Coolant Circuit, General, High-

Temperature Circuit

116

7.15.1 Engine coolant – Level check

116

7.15.2 Engine coolant – Change

117

7.15.3 Engine coolant – Draining

118

7.15.4 Engine coolant – Filling

120

7.15.5 Engine coolant pump – Relief bore check

123

7.15.6 Engine coolant – Sample extraction and

analysis

124

7.15.7 Coolant filter – Replacement

125

7.16 Low-Temperature Circuit

126

7.16.1 Charge-air coolant – Level check

126

7.16.2 Charge-air coolant – Change

127

7.16.3 Charge-air coolant – Draining

128

7.16.4 Charge-air coolant – Filling

129

7.16.5 Charge-air coolant pump – Relief bore check

132

7.17 Belt Drive

133

7.17.1 Drive belt – Condition check

133

7.18 Battery-Charging Generator

134

7.18.1 Battery-charging generator – Check

134

7.18.2 Battery-charging generator drive – Drive belt

tension adjustment

135

7.18.3 Battery-charging generator drive – Drive belt

and belt tensioner replacement

136

7.19 Fan Drive

137

7.19.1 Fan drive – Drive belt check / adjustment

137

7.19.2 Fan drive – Drive belt replacement

139

7.20 Wiring (General) for Engine/Gearbox/Unit

140

7.20.1 Engine wiring – Check

140

7.21 Accessories for (Electronic) Engine

Governor / Control System

141

7.21.1 Engine governor and connectors – Cleaning

141

7.21.2 EMU and connectors – Cleaning

142

7.21.3 Engine governor – Checking plug-in

connections

143

7.21.4 EMU – Checking plug-in connections

144

7.21.5 ECU 7 engine governor – Removal and

installation

145

7.21.6 EMU 7 – Removal and installation

146

8 Appendix A
8.1 Abbreviations

147

8.2 MTU contacts/service partners

150

9 Appendix B
9.1 Special Tools

151

9.2 Index

154

4 | Table of Contents | MS150054/02E 2012-02

DCL-ID: 0000015772 - 001

Summary of Contents for 12 V 4000 G73

Page 1: ...Operating Instructions Diesel engine 12 V 4000 G73 16 V 4000 G73 Application group 3B MS150054 02E ...

Page 2: ...tten 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 This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation Subject to alterations and amendments ...

Page 3: ...ing the engine Engine remains ready for operation 37 4 9 After stopping the engine putting the engine out of service 38 5 Maintenance 5 1 Maintenance task reference table QL1 39 6 Troubleshooting 6 1 Troubleshooting 40 6 2 Engine governor ADEC ECU 7 for Series 4000 Oil Gas engines Fault messages 43 7 Task Description 7 1 Engine 63 7 1 1 Engine Barring manually 63 7 1 2 Engine Barring with starting...

Page 4: ...e coolant Filling 120 7 15 5 Engine coolant pump Relief bore check 123 7 15 6 Engine coolant Sample extraction and analysis 124 7 15 7 Coolant filter Replacement 125 7 16 Low Temperature Circuit 126 7 16 1 Charge air coolant Level check 126 7 16 2 Charge air coolant Change 127 7 16 3 Charge air coolant Draining 128 7 16 4 Charge air coolant Filling 129 7 16 5 Charge air coolant pump Relief bore ch...

Page 5: ... other use is considered improper use The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case The responsibility is borne by the user alone Correct use also includes observation of and compliance with the operating instructions and mainte nance and repair specifications Modifications or conversions Unauthorized modifications to the engine represent a saf...

Page 6: ...s accessible to operating maintenance repair and transport personnel at all times Use the manual as a basis for instructing personnel on engine operation and repair In particular person nel must have read and understood the safety relevant instructions This is especially important for personnel who work on the engine only on an occasional basis These persons shall receive repeated instruction Use ...

Page 7: ...equipment for heavy loads forklift truck Prior to transporting the engine it is imperative to install transportation locking devices for crankshaft and engine mounts Secure the engine against tilting during transportation The engine must be especially secured against slipping or tilting when going up or down inclines and ramps Setting the engine down after transport Place the engine only on an eve...

Page 8: ...ine is allowed only with the transport locking device removed If the generator is already mounted on the engine ensure that the transport locking device of the generator is also re moved 3 Prior to every engine transport the transport locking device must be reinstalled on both sides according to the instructions 4 If the engine is to be moved together with the generator the transport locking devic...

Page 9: ...s of plates 2 and fasten with the screws 4 4 Tighten screws 4 alternately with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M10 Tightening torque Engine oil 30 Nm 3 Nm 5 Screw on nuts 3 of both screws 4 at plates 2 and secure 6 Fit label 7 to mark the engine as Fitted with transport locking device Removing the transport locking device from driving ...

Page 10: ...ways use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure them on the engine 1 Install engine mounting brackets 2 on both sides with guard plates 1 washers 3 and screws 4 2 Tighten screws 4 10 Safety MS150054 02E 2012 02 TIM ID 0000004010 007 ...

Page 11: ...ring units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages The following steps must be taken if a malfunction of the system is recognized or reported by the system inform supervisor s in charge analyze the message if required carry out emergency operations e g emergency engine stop Engine operation The following conditio...

Page 12: ...ury danger to life Allow the engine to cool down before opening the crankcase Avoid open flames electrical sparks and ignition sources Safety instructions u Before starting maintenance work allow the engine to cool down for at least 10 min danger of explosion due to oil vapors 12 Safety MS150054 02E 2012 02 TIM ID 0000022931 006 ...

Page 13: ...ions clean Always seal connections with caps or covers if a line is removed or opened Take care not to damage lines in particular fuel lines during maintenance and repair work Ensure that all retainers and dampers are installed correctly Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con tact with other components Do not place fuel or oil li...

Page 14: ...haft end until correct sealing is established During hydraulic installation and removal ensure that nobody is standing in the immediate vicinity of the component to be installed removed Working on electrical electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so De...

Page 15: ... 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 MS150054 02E 2012 02 Safety 15 TIM ID 0000000879 022 ...

Page 16: ...ohibited by emission regulations Emission control units systems may only be main tained exchanged or repaired if the components used for this purpose are approved by MTU or equiva lent components Noncompliance with these guidelines might represent a violation of the Clean Air Act and involves the termination of the operating license by the emission authorities MTU does not accept any liability for...

Page 17: ...AII and B out of containers results in a risk of explosion Forcing compressed air into thin walled containers e g containers made of tin plastic and glass for drying purposes or to check for leaks results in a risk of bursting Carry out leak test in accordance with the specifications Painting When carrying out painting work outside the spray stands provided with fume extraction systems en sure tha...

Page 18: ...es Minor injury or material damage Remedial action Note This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which begin with one of the signal words listed above depending on the severity of the hazard Safety instructions 1 Read and familiarize yourself with all safety notices before starting up or repairing the product 2 Pass on all safety instructions to...

Page 19: ...ated A and those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving end of the engine Other components are numbered in the same way i e starting with No 1 on driving end 1 KGS Free end 2 Right engine side 3 KS Driving end 4 Left engine side MS150054 02E 2012 02 General Information 19 TIM ID 0000000863 015 ...

Page 20: ...iller neck 15 Cylinder head 16 Fuel priming pump 17 Oil pan 18 Fuel filter 19 HP fuel pump 20 Engine oil filter automat ic oil filter is optional 21 Coolant filter 22 Centrifugal oil filter 2 centrifugal oil filters are installed if automatic oil filter is fitted Engine model designation Key to the engine model designations 12 16 V 4000 Gxy 12 16 Number of cylinders V Cylinder arrangement V engine...

Page 21: ...r filter 3 F46 Leak fuel level moni toring 4 M8 Suction restrictor HP pump 5 F25 Differential engine oil pressure after filter 6 B05 Engine oil pressure 7 B07 Engine oil tempera ture 8 XY44 Solenoid valve of fan clutch The injectors are underneath the cylinder head covers of the cylinder Injector replacement and necessa ry activities Page 78 MS150054 02E 2012 02 General Information 21 TIM ID 00000...

Page 22: ...Fuel temperature in Common Rail 4 B48 Fuel pressure in Common Rail 5 B01 Camshaft speed 6 B43 Charge air coolant pressure 7 B26 Charge air coolant temperature 8 B06 Engine coolant tem perature 22 General Information MS150054 02E 2012 02 TIM ID 0000012918 002 ...

Page 23: ...ge air pressure 4 XM2 Oil priming pump 5 B09 Charge air tempera ture 6 Engine governor The injectors are underneath the cylinder head covers of the cylinder Injector replacement and necessa ry activities Page 78 MS150054 02E 2012 02 General Information 23 TIM ID 0000012918 002 ...

Page 24: ...1 B13 Crankshaft speed 24 General Information MS150054 02E 2012 02 TIM ID 0000012918 002 ...

Page 25: ...lication group 3B 3B Intake air temperature C 25 25 Charge air coolant temperature C 45 45 Barometric pressure mbar 1000 1000 Site altitude above sea level m 100 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 16 Engine rated speed A rpm 1200 1200 Continuous power as per ISO 3046 10 overload capability rated power DIN 6280 ISO 8528 A kW 1105 1390 GENERAL...

Page 26: ...umber of exhaust valves per cylinder 2 2 Standard flywheel housing flange engine main PTO SAE 00 00 AIR EXHAUST Number of cylinders 12 16 Charge air pressure before cylinder DL R bar abs 3 3 3 0 COOLANT SYSTEM HT circuit Number of cylinders 12 16 Coolant temperature at engine connection outlet to cooling equipment A C 100 94 Coolant temperature after engine warning R C 102 102 Coolant temperature ...

Page 27: ...m R rpm 80 80 Firing speed to R rpm 120 120 CAPACITIES Number of cylinders 12 16 Engine coolant engine side without cooling system R liter 137 175 Charge air coolant engine side R liter 44 42 Engine oil capacity initial filling standard oil system Option max operating inclinations R liter 221 295 Oil pan capacity dipstick mark min standard oil system Op tion max operating inclinations L liter 160 ...

Page 28: ...2 Firing order Number of cyl inders Firing order 12 V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 28 Technical Data MS150054 02E 2012 02 TIM ID 0000023263 001 ...

Page 29: ...ns Engine Main dimensions Length A 12V 16V approx 2550 mm approx 3020 mm Width B 12V 16V approx 1590 mm approx 1590 mm Height C 12V 16V approx 1870 mm approx 1870 mm MS150054 02E 2012 02 Technical Data 29 TIM ID 0000010032 001 ...

Page 30: ...system Check engine oil level Page 102 Bar engine with starting equipment Page 64 Fuel prefilter Fill with fuel if fitted Coolant circuit If engine is out of service for more than one year change engine coolant Page 117 Change charge air coolant Page 127 Coolant circuit Check engine coolant level Page 116 Check charge air coolant level Page 126 Coolant circuit Preheat coolant with coolant preheati...

Page 31: ...em Check engine oil level Page 102 Coolant circuit Check engine coolant level Page 116 check charge air coolant level Page 126 Coolant circuit Preheat engine coolant with coolant preheating unit if fitted Fuel prefilter if fitted Drain water and contaminants see manufacturer s documentation Engine control system Switch on MS150054 02E 2012 02 Operation 31 TIM ID 0000010642 002 ...

Page 32: ...g the engine Item Task Switchgear cabinet control panel etc depending on manufacturer If coolant temperature is 40 C with preheating equipment or 5 C without preheating equipment Press start button Automatic starting sequence is performed Engine speed display instrument indicates increasing crankshaft speed After the starting sequence is completed engine is running at rated speed Connect generator...

Page 33: ...cabinet Actuate switch button for ECU override input Control cabinet Automatic starting procedure is performed any safety functions and alarms leading to engine shutdown are disregarded Tachometer indicates increasing crankshaft speed Engine is running at rated speed when the starting sequence is com pleted Connecting the generator if fitted to mains Item Task Control cabinet If generator is not c...

Page 34: ...eck for abnormal running noise exhaust discoloration and vibrations Page 40 Battery charging generator Check battery charging generator for contamination clean as necessa ry Page 134 Air filter Check differential pressure indication at gauge if fitted Exhaust system Check exhaust color Page 40 Fuel prefilter Drain water and contaminants at the drain cock of fuel prefilter if fitted Page 88 Check r...

Page 35: ... breaker Item Task Engine After opening the generator breaker if provided allow to cool down off load for approx 5 minutes Preparing the pump drive diesel mechanical diesel electric Item Task Engine Allow to cool down for approx 5 minutes at reduced engine speed Ob serve natural resonance of engine installation dependent Stopping the engine Item Task Switchgear cabinet control panel etc depending ...

Page 36: ... stopped by disconnecting the power supply to the ECU Emergency air shutoff flaps close if provided signalization e g by horn beacon is activated After emergency stop Item Action Switchgear cabinet control panel etc depending on manufacturer Press pushbutton for alarm acknowledgment Audible and visual signalization stops Engine Manually open emergency air shutoff flaps if provided Engine is ready ...

Page 37: ...he engine Engine remains ready for operation After stopping the engine Item Action Engine generator pump control Select operating mode e g MANUAL AUTOMATIC OPERATION MS150054 02E 2012 02 Operation 37 TIM ID 0000000983 002 ...

Page 38: ...the engine room is not heated the coolant is not maintained at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Engine generator pump controller Switch OFF Air intake and exhaust sys tem If the engine is to remain out of service for more than 1 week seal the engine s air and...

Page 39: ...nerator for contamination clean if necessary Page 134 W1001 Replace fuel filter or fuel filter element Page 85 W1005 Replace air filter Page 94 W1006 Replace fuel injectors Page 78 W1008 Replace engine oil filter at each oil change or when the time limit years is reached at the latest Page 107 W1009 Check layer thickness of oil residue clean and replace filter sleeve if fitted Page 113 W1011 Perfo...

Page 40: ... engine cannot be barred manually Contact Service Engine turns but does not fire Component Cause Action Starter Poor rotation by starter Battery low or defective Charge or replace battery see manu facturer s documentation Engine cabling Faulty Check Page 140 Fuel system Air in fuel system Vent fuel system Page 84 Engine governor Faulty Contact Service Engine fires unevenly Component Cause Action F...

Page 41: ... Contaminated Contact Service Engine room Air inlet temperature too high Check fans and intake exhaust lines Charge air pressure too low Component Cause Action Air supply Air filter clogged Check signal ring position of service in dicator if fitted Intercooler Contaminated Contact Service Exhaust turbocharger Faulty Contact Service Coolant leaks at intercooler Component Cause Action Intercooler Le...

Page 42: ...t turbocharg er cylinder head pis ton rings cylinder lin er Faulty Contact Service 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 42 Troubleshooting MS150054 02E 2012 02 TIM ID 0000002545 002 ...

Page 43: ... HI T Fuel Preliminary warning Fuel temperature too high Contact Service 2 0122 93 1 004 SS T Fuel Main warning Fuel temper ature too high engine shut down Contact Service 2 0122 93 2 005 HI T Charge Air Preliminary warning Charge air temperature too high 1 Reduce power 2 Check intercool er 2 0121 93 1 006 SS T Charge Air Main warning Charge air temperature too high en gine shutdown 1 Reduce power...

Page 44: ... bank B too high 2nd limit value 1 Check cabling Page 140 2 Contact Service 2 0127 93 2 023 LO Coolant Level Coolant level too low 1st limit value Check coolant lev el in expansion tank Page 116 2 0152 92 1 024 SS Coolant Level Coolant level too low 2nd limit value Check coolant lev el in expansion tank Page 116 2 0152 91 2 025 HI P Diff Lube Oil Oil filter differential pressure too high 1st limit...

Page 45: ... 8004 20 5 039 AL ETC2 Cutin Failure ETC2 failed to cut in 1 Reduce power 2 Contact Service 1 8004 20 4 044 L1 Coolant Level Inter cooler Charge air coolant level too high low 1st limit Check coolant lev el Page 126 2 0153 92 1 051 HI T Lube Oil Lube oil temperature too high 1st limit Reduce power 2 0125 93 1 052 SS T Lube Oil Lube oil temperature too high 2nd limit 1 Reduce power 2 Check engine o...

Page 46: ...erature too high 2nd limit 1 Allow the engine to cool down 2 Contact Service 3 Check coolant cooler clean if necessary 4 Restart engine Page 32 2 0120 93 2 081 AL Rail Leakage Pressure gradient in rail is too low during starting or too high during stopping HP system leaky air in sys tem Contact Service 1 8004 04 6 082 HI P Fuel Common Rail Rail pressure set value DBR fuel limitation start of injec...

Page 47: ...ain warning pre heating temperature too low coolant temperature too low for engine start en gine start interlock active Check preheater 2 1090 92 2 094 LO T Preheat Alarm configuration limit value 1 Preheating temper ature too low coolant tem perature too low for engine start Check preheater 2 1090 92 1 095 AL Prelubrication Fault Alarm configuration Oil pri ming fault Check oil priming system 2 1...

Page 48: ...faulty Engine does not start Replace engine governor 144 BANK2 ECU DEFECT Power output stage for con trol of the solenoid valves on bank 2 is faulty Engine does not start Replace engine governor 145 15V_GOOD ECU DE FECT Power supply faulty auto matic engine shutdown Replace engine governor 146 L1 AD TEST1 SUPPLY Supply voltage A D convert er too low Replace engine governor 147 AD TEST1 ECU DE FECT...

Page 49: ...t Service 2 0500 68 3 184 AL CAN PU Data Flash Error Alarm configuration A pro gramming error occurred when attempting to copy a received PU data module into the Flash module Contact Service 2 0500 68 4 186 AL CAN1 Bus Off CAN 1 in Bus Off state Ei ther short circuit on bus Or massive magnetic fields dis rupting the bus Contact Service Inspect CAN bus for short circuit and rectify short circuit as...

Page 50: ...lant Intercool er Sensor B26 faulty charge air coolant temperature 1 Check cabling 2 Replace if nec essary 1 8004 57 4 205 SD T Exhaust A Sensor B4 21 faulty ex haust temperature engine A side 1 Check cabling 2 Replace if nec essary 1 8004 57 6 206 SD T Exhaust B Sensor B4 22 faulty ex haust temperature engine B side 1 Check cabling 2 Replace if nec essary 1 8004 57 7 208 SD P Charge Air Sensor B1...

Page 51: ...or 1 8004 58 4 221 SD Diff Lube Oil Sensor F25 faulty lube oil differential pressure 1 Check sensor and wiring 2 Replace if nec essary Error cleared after restarting the en gine 1 8004 58 5 222 SD Level Leakage Fuel Sensor F46 faulty leak fuel 1 Check sensor and wiring 2 Replace if nec essary 3 Contact Service 1 8004 58 2 223 SD Level Coolant Inter cooler Sensor F57 faulty charge air coolant level...

Page 52: ... 242 SD T Coolant R Redundant coolant temper ature sensor faulty 1 Check sensor and wiring 2 Contact Service 1 8004 62 2 244 SD P Lube Oil R SD alarm configuration Re dundant lube oil pressure sensor faulty Short circuit or wire break Check sensor and cabling replace as necessary Error cleared after re starting the engine 1 8004 62 1 245 SD ECU Power Supply Voltage Sensor fault ECU operating volta...

Page 53: ...0 3 305 1 8004 50 4 306 1 8004 50 5 307 1 8004 50 6 308 1 8004 50 7 309 1 8004 50 8 310 1 8004 50 9 311 AL Timing Cylinder B1 B10 Timing Bank 2 solenoid valve 1 Timing Bank 2 solenoid valve 10 Replace injector concerned if the fault message ap pears frequently Page 78 1 8004 51 0 312 1 8004 51 1 313 1 8004 51 2 314 1 8004 51 3 315 1 8004 51 4 316 1 8004 51 5 317 1 8004 51 6 318 1 8004 51 7 319 1 8...

Page 54: ... 52 8 330 1 8004 52 9 331 AL Wiring Cylinder B1 B10 Wiring Bank 2 solenoid valve 1 Wiring Bank 2 solenoid valve 10 1 Check solenoid valve 2 Contact Service 1 8004 53 0 332 1 8004 53 1 333 1 8004 53 2 334 1 8004 53 3 335 1 8004 53 4 336 1 8004 53 5 337 1 8004 53 6 338 1 8004 53 7 339 1 8004 53 8 340 1 8004 53 9 341 AL Open Load Cylinder A1 A10 Open Load Bank 1 sole noid valve 1 Open Load Bank 1 sol...

Page 55: ...lenoid valve 2 Contact Service 1 8004 55 0 352 1 8004 55 1 353 1 8004 55 2 354 1 8004 55 3 355 1 8004 55 4 356 1 8004 55 5 357 1 8004 55 6 358 1 8004 55 7 359 1 8004 55 8 360 1 8004 55 9 361 AL Power Stage Low Alarm configuration Internal electronic fault electronics possibly faulty Start ITS If the ITS diagnosis result is electronics OK note fur ther fault messages e g cabling faults 1 Check sole...

Page 56: ... ground 1 Check cabling 2 Attempt to re start engine 1 8004 56 1 371 AL Wiring TO 1 Alarm configuration Short circuit or wire break on tran sistor output 1 TO 1 1 Check turbo charger valve ca bling repair as necessary 2 Replace engine governor 1 8004 63 4 372 AL Wiring TO 2 Alarm configuration Short circuit or wire break on tran sistor output 2 TO 2 1 Check recircula tion valve cabling repair as n...

Page 57: ... Lube Oil Red Alarm configuration limit value 1 Preliminary warn ing Redundant lube oil pressure reading too low 1 Check sensor and wiring 2 Contact Service 2 0112 92 1 395 SS P Lube Oil Red Alarm configuration limit value 2 Main warning Re dundant lube oil pressure reading too low 1 Check sensor and wiring 2 Contact Service 2 0112 92 2 396 AL T Coolant Max De viation Alarm configuration Maxi mum ...

Page 58: ...figuration Line disruption on digital input 7 Cabling faulty or no resist ance over switch 1 Check cabling 2 Contact Serv ice Check input of target device 2 8006 63 1 407 AL Open Load Digital Input 8 Alarm configuration Line disruption on digital input 8 Cabling faulty or no resist ance over switch 1 Check cabling 2 Contact Serv ice Check input of target device 2 8006 63 2 408 AL Open Load Emerg S...

Page 59: ...guration limit value 1 Input signal of Aux 1 has exceeded not at tained limit value 1 depend ing on configuration Determine and rectify reason for limit value viola tion 2 0160 92 1 421 L2 Aux 1 Alarm configuration limit value 1 Input signal of Aux 1 has exceeded not at tained limit value 2 depend ing on configuration Determine and rectify reason for limit value viola tion 2 0160 92 2 428 L1 T Aux...

Page 60: ...er reduction is active 1 Note further fault messages 2 Determine and rectify reason for power reduction 2 7000 01 1 455 AL L1 Aux 1 Plant Alarm configuration limit value 1 Input signal of Aux 1 plant side has exceed ed not attained limit value 1 depending on configuration Determine and rectify reason for limit value viola tion 2 8006 65 0 456 AL L2 Aux 1 Plant Alarm configuration limit value 2 Inp...

Page 61: ... cleared after re starting the engine 1 8004 58 6 467 AL L2 T Aux 1 Alarm configuration limit value 2 Preliminary warn ing Temperature signal of Aux 1 has exceeded not attained limit value 2 de pending on configuration Determine and rectify reason for limit value viola tion 2 0130 92 2 468 SD T AUX 1 SD alarm configuration An alog input for Aux 1 temper ature faulty Replace engine governor 1 80045...

Page 62: ...der is triggered due to engine shutdown Determine and rectify cause of triggering engine shutdown 1 8010 00 9 476 AL Crash Rec Init Er ror Alarm configuration Crash recorder initialization error Check setting with DiaSys 1 8010 00 7 478 AL Comb Alarm Yel Plant Alarm configuration YEL LOW summary alarm from plant Note further fault messages 2 8006 00 1 479 AL Comb Alarm Red Plant Alarm configuratio...

Page 63: ...ry Danger to life Before barring the engine ensure that nobody is in the danger zone Engine Barring manually 1 Remove guard plate 2 Engage barring device 2 with ring gear 3 and install on flywheel housing 3 Place ratchet 1 onto barring device 2 4 Rotate crankshaft in engine direction of ro tation Apart from the normal compression resistance there should be no further re sistance 5 For barring devi...

Page 64: ...emoved from the engine Engine Barring with starting system 1 Release latch of connector X4 2 Remove connector from engine governor 3 Bar engine in unloaded condition Press START button 4 Let the crankshaft rotate until oil pressure is indicated 5 Engine start is automatically interrupted when specified starting period has passed If necessary re start the engine after approx 20 seconds 6 Connect co...

Page 65: ...t nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine Test run 1 Start engine Page 32 2 Perform test run not below 1 3 load and at least until steady state temperature is reached 3 Carry out operational checks Page 34 4 Stop engine Page 35 MS150054 02E 2012 02 Task Description 65 TIM ID 0000000870 007 ...

Page 66: ...ions First signs of marks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined and do not cover the entire stroke area Dark areas in the upper section of the cooling bore remaining cir cumference without objections Piston rings without objections Further en...

Page 67: ...Final steps 1 Install injector Page 79 2 Install cylinder head cover Page 76 MS150054 02E 2012 02 Task Description 67 TIM ID 0000000015 011 ...

Page 68: ...Smoothened areas appear brighter and more brilliant than the surrounding running surface Findings not critical Bright area Bright areas are on the running surface and show local removal of the honing pattern Grooves from honing process are not visible any more Discoloration This is caused by oxidation surface discoloration through oil or fuel and tem perature differences around the liner It appear...

Page 69: ...tion starting in TDC ring 1 have to be replaced Seizure marks scuff ing Irregular circumference lengths and depths Can be caused either by the pis ton skirt or the piston crown Material deposits on the liner smear heavy dis coloration Severe visible scoring Replace liner Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration ar...

Page 70: ...tion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing oil separator element 1 Remove cover 2 with O ring 3 2 Remove filter element 1 from housing 4 3 Insert new filter element in housing 4 4 Install cover 2 with new O ring 5 Use torque wrench to tighten the screws of c...

Page 71: ...aphragm 3 on housing 1 5 Install new seal 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4 to the specified torque Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 10 Nm 2 Nm 7 Check diaphragms in further oil separators in the same way MS150054 02E 2012 02 Task Description 71 TIM ID 0000000017 006 ...

Page 72: ...pare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 76 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjust ing screws with oil 4 Install cylinder head covers Page 76 72 Task Description MS150054 02E 2012 02 TIM ID 0000000921 007 ...

Page 73: ...rts Designation Use Part No Qty Feeler gauge Y20010128 1 Torque wrench 60 320 Nm F30047446 1 Ring socket 24 mm F30039526 1 Preparatory steps 1 Remove cylinder head cover Page 76 2 Install barring device Page 63 3 Rotate crankshaft with barring device in en gine direction of rotation until OT A1 mark and pointer are aligned MS150054 02E 2012 02 Task Description 73 TIM ID 0000012221 003 ...

Page 74: ...C 2 Check valve clearance with cold engine Inlet valves long rocker arm 0 2 mm Exhaust valves short rocker arm 0 5 mm 3 Check all valve clearances in two crankshaft positions firing TDC and overlap TDC of cylinder A1 as per diagram 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve 4 Use feeler gauge to determine the distance between valve bridge and rocke...

Page 75: ...arance is provid ed 4 Feeler gauge must just pass through the gap 5 Tighten locknut 1 to 90 9 Nm holding adjusting screw 2 firmly 6 Replace or rectify adjusting screws and or locknuts which do not move freely 7 Check valve clearance Final steps 1 Remove barring device Page 63 2 Install cylinder head cover Page 76 MS150054 02E 2012 02 Task Description 75 TIM ID 0000012221 003 ...

Page 76: ...linder head covers 3 prior to removal 2 Remove screws 1 and washers 2 3 Take off cylinder head cover 3 with O ring 4 from cylinder head 5 Installing cylinder head cover 1 Clean mounting surface 2 Check O ring 4 for damage replace if necessary 3 Coat O ring 4 with grease 4 Position O ring 4 in groove of cylinder head cover 3 5 Fit cylinder head cover 3 on cylinder head 5 6 Install cylinder head cov...

Page 77: ...not smoke WARNING Oils oil vapors are combustible Risk of fire No open flames no electric sparks Do not smoke Avoid ignition sources CAUTION Fuel system high pressure pump not filled with engine oil Damage to components major material damage Make sure that the high pressure fuel pump is filled with engine oil before installation or initial operation Filling HP pump 1 Fill fresh engine oil into a c...

Page 78: ...ctor Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 79 78 Task Description MS150054 02E 2012 02 TIM ID 0000000022 011 ...

Page 79: ... wrench 60 320 Nm F30452768 1 Assembly paste Optimoly Paste White T 40477 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 1 Engine oil O ring Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Preparatory steps 1 Shut off fuel supply to engine 2 Remove cylinder head cover Page 76 Removing injector 1 D...

Page 80: ... cylinder head 7 Remove injector with installation removal tool 8 Remove installation removal tool 9 Remove sealing ring 4 from injector or use a self made hook to take it out of the cylin der head 10 Remove O rings 3 O ring 2 and damper ring 1 from injector 11 Clean all mating and sealing surfaces 12 Cover all connections and bores or seal with suitable plugs 80 Task Description MS150054 02E 2012...

Page 81: ... observe installation position of sealing ring 4 4 Fit new O rings 3 included in the scope of supply of the injector O ring 2 and damp ing ring 1 onto the injector and coat with grease 5 Clean sealing face on cylinder head and protective sleeve with milling cutter 6 Insert injector into cylinder head ensuring that the HP line adapter is correctly aligned 7 Use installation removal tool to press in...

Page 82: ...h torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque 100 Nm 10 Nm 14 Tighten adapter 3 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Adapter Tightening torque 100 Nm 10 Nm 15 Install return line 7 Note Ensure special cleanness 16 Coat thread and sealing cone of HP line 5 with engine oi...

Page 83: ... sequence 1 Adapter 4 2 Rail 6 Name Size Type Lubricant Value Standard Union nut thrust screw Tightening torque 40 Nm 5 Nm 19 Fit cable connector onto injector Final steps 1 Install cylinder head cover Page 76 2 Open fuel supply to engine MS150054 02E 2012 02 Task Description 83 TIM ID 0000000925 006 ...

Page 84: ...ks and ignition sources Do not smoke Venting LP fuel system 1 Open threaded vent plug 1 2 Unlock fuel priming pump 2 screw out handle by turning it counterclockwise 3 Operate the pump with the handle 2 until bubble free fuel emerges at the threaded vent plug 1 4 Close threaded vent plug 1 5 Screw in handle by turning it clockwise 6 Verify that fuel priming pump 2 is locked Handle must be tightened...

Page 85: ...f fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Replacing fuel filter 1 Remove easy change filter using filter wrench 2 Clean sealing surface on filter head 3 Slightly lubricate seal on the easy change filter 4 Screw on easy change filter by hand until the seal connects and tighten manually 5 Vent fuel system Page 84 6 Replace other easy change filters in...

Page 86: ...off fuel supply 2 Remove nuts from filter head 3 Take off filter housing and drain fuel into appropriate container 4 Remove filter element securing nut and re move filter element by pulling it downwards 5 Wash filter element in clean fuel using a smooth brush 6 Wash filter housing with clean fuel 7 Insert filter element into filter housing and secure with nut 8 Place new sealing ring into groove i...

Page 87: ...en installing the new filter element align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gauge 1 2 Check differential pressure Checking differential pressure of fuel prefilter 1 With the engine running at full load or rated power read off pressure at gauge 1 2 If differential pressure as indicated between position of adjustable pointer 2 and pressure indicating pointer 3 of ...

Page 88: ... drained I Left filter cut in II Right filter cut in 2 Open threaded vent plug 5 of filter to be drained 3 Unlock drain valve 6 by pressing toggle and open it 4 Drain water and contaminants from filter un til pure fuel emerges 5 Close drain valve 6 6 Remove screws for cover and take off cov er 2 7 Fill filter housing with clean fuel 8 Place new gasket in cover 2 9 Fit cover with gasket and secure ...

Page 89: ... life Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Fuel prefilter Flushing 1 Cut out clogged filter I Left filter cut in II Right filter cut in MS150054 02E 2012 02 Task Description 89 T...

Page 90: ...lve 6 Fuel prefilter Topping up with fuel 1 Stop engine Page 35 and disable engine start 2 Remove screws for cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new gasket in cover 2 5 Fit cover with gasket and secure it with screws 6 Check differential pressure Page 87 Result If flushing did not lead to an improvement of the differential pressure replace filter element of fue...

Page 91: ...y Diesel fuel Filter element Spare Parts Catalog Gasket Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Replacing filter element 1 Cut out filter to be drained I Left filter cut in II Right filter cut in MS150054 02E 2012 02 Task Description 91 TIM ID 0000004944 003 ...

Page 92: ... 2 7 Remove spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring housing 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and secure it with screws 12 Cut in the cut out filter again 13 Close threaded vent plug 5 when fuel emerges 14 Adjust the differential pressure gauge Page 87 92 Task Description MS150054 02E 2012 02 TIM ...

Page 93: ...ctors Intercooler Check drain for coolant leakage and obstruction 1 Verify that air emerges from condensate drain bore s on left and right engine sides at driving end when engine is running If no air emerges Clean drain bore s Blow out with compressed air 2 If a large amount of coolant is continuously discharged the intercooler is leaking Con tact Service Emergency measures prior to engine start w...

Page 94: ...Material Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Air filter Replacement 1 Remove air filter and install new one Page 95 2 Reset signal ring of service indicator Page 97 94 Task Description MS150054 02E 2012 02 TIM ID 0000000903 004 ...

Page 95: ...nstallation 1 Release clamp 2 2 Remove air filter 3 and clamp 2 from flange of intake housing 1 3 Verify that there are no objects in the flange of the intake housing 1 and clean it 4 Place new air filter 3 with clamp 2 onto intake housing 1 5 Tighten clamp 2 MS150054 02E 2012 02 Task Description 95 TIM ID 0000005457 004 ...

Page 96: ...ber sleeves 1 Remove screws 3 loosen clamps 1 and take off elbow 4 2 Pull off rubber sleeve 2 from turbocharger intake flange 3 Clean connecting flange of turbocharger and check for obstructions 4 Fit new rubber sleeve 2 on turbocharger intake flange 5 Fit both clamps 1 on rubber sleeve 2 slide on elbow 4 and secure with screws 3 6 Align clamps 1 and tighten 7 Replace further rubber sleeves in the...

Page 97: ...disabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 94 2 After installation of new filter press reset button 1 Result Engaged piston with signal ring moves back to initial position MS150054 02E 2012 02 Task Description 97 TIM ID 0000005484 005 ...

Page 98: ...r ear protectors Emergency air shutoff flaps Functional check with electric actuation 1 Start engine Page 32 2 Activate the appropriate function to trigger emergency air shutoff flaps depending on installation e g by carrying out overspeed test Check the following items The emergency air shutoff flaps must close as soon as the set point is reached The levers must be in position B Emergency engine ...

Page 99: ...ves on right engine side 1 Release clamps 1 2 Remove screws from elbow 8 remove elbow and pull off rubber sleeves 2 3 Remove charge air pipe 9 pull off rubber sleeve 2 4 Clean charge air pipe and elbow and check for obstructions 5 Fit new rubber sleeves on exhaust turbocharger and charge air pipe 6 Slide clamps onto all rubber sleeves 7 Insert elbow 8 and charge air pipe 9 ends into rubber sleeves...

Page 100: ... for obstructions 6 Slide new rubber sleeves 4 onto exhaust turbocharger and charge air pipe 6 7 Slide clamps onto all rubber sleeves 8 Insert elbow 7 and charge air pipe 6 ends into rubber sleeves 9 Secure elbow 7 with new O ring on intercooler 10 Align clamps 3 and secure 11 Install retainer 5 on charge air pipe 6 Final steps u Install air filter Page 94 100 Task Description MS150054 02E 2012 02...

Page 101: ...the engine make sure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Air starter Manual operation 1 Operate pushbutton for manual start ar row and hold 2 Allow compressed air to enter the air start er until the engine fires evenly 3 Release pushbutton MS150054 02E 2012 02 Task Description 101 TIM ID 0000006077 001 ...

Page 102: ...or heat exchanger back to the oil pan 3 The oil level must reach mark 1 or exceed mark 1 by up to 2 cm 4 Top up with oil to mark 1 as necessary Page 103 5 Insert oil dipstick into guide tube up to the stop Checking oil level after the engine is stopped 1 5 minutes after stopping the engine remove oil dipstick from the guide tube and wipe it 2 Insert oil dipstick into guide tube up to stop withdraw...

Page 103: ... inhale oil vapor Procedure without pump Draining oil via drain plug s on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain plug s and drain oil 3 Install drain plug s with new sealing ring Procedure with pump Oil extraction 1 Provide a suitable container to collect the oil 2 Extract all oil from oil pan using the pump Draining residual oil at equipment carrier 1 Provide a s...

Page 104: ... Standard Screw M26 x 1 5 Tightening torque Engine oil 100 Nm 10 Nm Filling with new oil 1 Open cover on filler neck 2 Fill oil through filler neck up to max mark at oil dipstick 3 Close cover on filler neck 4 Check engine oil level Page 102 104 Task Description MS150054 02E 2012 02 TIM ID 0000006152 004 ...

Page 105: ...tective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine oil sample extraction and analysis variant A 1 With the engine running at operating tem perature open screw on flange of centrifu gal oil filter by 1 to 2 rotations 2 Drain approx 2 liters engine oil to flush out the...

Page 106: ...o 2 rotations 2 Drain approx 2 liters engine oil to flush out the oil sludge 3 Drain approx 1 liter engine oil into a clean container 4 Close screw 5 Using the equipment and chemicals of the MTU test kit examine oil for Dispersion capability spot test Water content Dilution by fuel 106 Task Description MS150054 02E 2012 02 TIM ID 0000014111 001 ...

Page 107: ...hing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Remove engine oil filter using filter wrench 2 Clean sealing surface on connecting piece 3 Check condition of new engine oil filter sealing ring and coat it with engine oil 4 Screw on and tighten new engine oil filter by hand 5 Replace further engine oil filters in the same way 6 Che...

Page 108: ...g WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor CAUTION Contamination of components Damage to component Observe manufacturer s instructions Check components for special cleanness Oil filter candles Removal 1 Remove nuts 2 from oil fi...

Page 109: ... washer and washer 9 Remove screw 4 10 Remove flushing arm 5 from screen plate 6 11 Turn filter insert upside down and use ap propriate tool to push out filter candles 1 12 Turn filter insert by 180 and insert new fil ter candles 1 with chamfer facing down wards MS150054 02E 2012 02 Task Description 109 TIM ID 0000006401 003 ...

Page 110: ...s 2 In addition the following work must be performed Replace all sealing elements with new parts Coat O rings with grease Insert O rings in grooves Pay attention to installation position of fillister head screw to slot in shaft 110 Task Description MS150054 02E 2012 02 TIM ID 0000006401 003 ...

Page 111: ...ve clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety mask and ear protectors CAUTION Unsuitable cleaning tool Damage to component Observe manufacturer s instructions Use appropriate cleaning tool Removing strainer 1 Clean oil indicator filter before...

Page 112: ...leaning strainer 1 Wash strainer 5 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 5 with compressed air from inside Installing strainer 1 Coat square section ring 4 on strainer 5 with engine oil and install strainer 5 2 Coat O ring 3 with engine oil and fit in filter housing 3 Fit cover 2 and secure with screws 1 and washers 112 Task Description MS150054 02E 2012 02 TI...

Page 113: ...leeve Spare Parts Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air Risk of injury Do not direct compressed...

Page 114: ...low out with compressed air 12 Check sealing ring 13 fit new one if nec essary 13 Assemble rotor tube 11 conical disk 12 and rotor base 14 with sealing ring 13 14 Insert new filter sleeve 10 in rotor tube 11 with the smooth paper surface facing the wall 15 Check sealing ring 9 fit new one if neces sary 16 Mount rotor cover 8 with sealing ring 9 17 Tighten rotor cover nut 7 with 35 Nm to 45 Nm 18 P...

Page 115: ... nozzles 14 for obstructions 12 Move standpipe 12 over rotor lower sec tion 13 13 Insert new filter sleeve 9 with stiffener plate 10 into rotor cap 8 with the with the smooth paper surface of the filter sleeve 9 facing the rotor cap 8 14 Check sealing ring 11 fit new one if nec essary Coat sealing ring with grease and insert in the groove of the rotor cap 8 15 Place rotor cap 8 onto standpipe 12 1...

Page 116: ...nterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in eye Checking engine coolant level at remote cooler 1 Check coolant level coolant must be visible at marking plate 2 Top up coolant if necessary Page 120 3 Check and clean breather valve 4 Place brea...

Page 117: ...pecial tools Material Spare parts Designation Use Part No Qty Engine coolant Changing engine coolant 1 Drain engine coolant Page 118 2 Fill with engine coolant Page 120 MS150054 02E 2012 02 Task Description 117 TIM ID 0000000036 026 ...

Page 118: ...o 2 Switch off preheating unit if fitted Draining engine coolant 1 Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck 4 Open drain valves and drain plugs and drain coolant at ...

Page 119: ...g end left and right side Final steps 1 Close all drain valves and install drain plugs with new sealing rings 2 Set breather valve onto filler neck and close it MS150054 02E 2012 02 Task Description 119 TIM ID 0000014577 001 ...

Page 120: ...alding Let the engine cool down Wear protective clothing gloves and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counter c...

Page 121: ...at unloaded condi tion for10 seconds stop engine Page 35 11 Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 12 Continue to turn breather valve counter clockwise and remove 13 Check coolant level Page 116 and top up engine coolant as required a Fill in coolant via filler neck on expan sion tank until the coolant level at bot tom edge ...

Page 122: ...pansion tank counterclockwise until the first stop and allow pressure to escape 10 Turn breather valve counterclockwise and remove 11 Check coolant level Page 116 and top up via filler neck if required a Fill in coolant via filler neck on expan sion tank until the coolant level at bot tom edge of filler neck remains con stant b Check proper condition of breather valve clean sealing faces if requir...

Page 123: ...ine coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Shut down engine Page 35 and disable engine start observe general safety instruc tions Maintenance and Repair 3 Clean the relief bore with a wire if it is dirty Permissible coolant discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per hour 4 If discharge exceeds the specified limits Cont...

Page 124: ...r protective clothing gloves and goggles safety mask WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine coolant Sample extraction and analysis 1 With the engine running open drain valve 1 2 Flush sample extraction point by draining approx 1 liter coolant 3 Drain approx 1 liter coolant into a clean container 4 Close drain valve 1 5 Using the equipment and chemic...

Page 125: ...under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Coolant filter Replacement 1 Close shut off cocks 1 2 Remove coolant filter 2 with filter wrench 3 Clean sealing surface on connecting piece 4 Coat seal on new coolant filter with engine oil 5 Screw on coolant filter and tighten hand tight 6 Open shut off cocks 1 MS150054 02E...

Page 126: ...on tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visible at marking plate 4 Top up coolant if necessary Page 129 5 Check proper condition of breather valve clean sealing faces if required 6 Fit breather valve and close it Checking charge air coolant level by means of level se...

Page 127: ...l tools Material Spare parts Designation Use Part No Qty Charge air coolant Charge air coolant Change 1 Drain charge air coolant Page 128 2 Fill with charge air coolant Page 129 MS150054 02E 2012 02 Task Description 127 TIM ID 0000000041 010 ...

Page 128: ... Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 3 Continue to turn breather valve counter clockwise and remove 4 Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck 5 Open drain valves and drain plugs and drain coolant at the following points Charge air coolant pump Thermostat housing 6 ...

Page 129: ... scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valv...

Page 130: ... run at unloaded condi tion for 10 seconds stop engine Page 35 11 Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 12 Continue to turn breather valve counter clockwise and remove 13 Check coolant level Page 126 and top up if required a Fill in coolant via filler neck on expan sion tank until the coolant level at bot tom edge o...

Page 131: ...2 7 After the engine has run at unloaded condi tion for 10 seconds stop engine Page 35 8 Turn breather valve counterclockwise and remove 9 Check coolant level Page 126 and top up if required a Repeat the steps from Start engine Step 6 until coolant is no longer needed to be topped up b Check proper condition of breather valve clean sealing faces if required c Set breather valve onto filler neck an...

Page 132: ...rge air coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Shut down engine Page 35 and disable engine start observe general safety instruc tions Maintenance and Repair 3 Clean the relief bore with a wire if it is dirty Permissible coolant discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per hour 4 If discharge exceeds the specified limits ...

Page 133: ...led 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 heating Replace Page 136 Drive belt B Cracks on entire circumference Drive belt C Chunking MS150054 02E 2012 02 Task Description 133 TIM ID 0000000920 008 ...

Page 134: ...y mask and ear protectors Checking battery charging generator Item Findings Measure Ventilation area arrow Clean None Ventilation area arrow Contaminated Clean Cleaning battery charging generator Note Dry clean battery charging generator only 1 Remove coarse dirt from battery charging generator 2 Blow out ventilation area arrow with compressed air until all dust is cleared 134 Task Description MS1...

Page 135: ... Adjusting belt tension 1 Undo screw arrow and remove protective cover 3 2 Slacken screws 1 and 2 by half a turn Result Belt tensioner moves against the drive belt and tensions it 3 Tighten screw 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M10x1 5 Tightening torque 60 Nm 5 Nm 4 Tighten screw 1 to specified torque using a torque wrench Name Size Type Lu...

Page 136: ...ection indicated by the arrow as far as it will go 5 Tighten screw 4 6 Remove drive belt 7 7 Screw on screw 5 and replace belt ten sioner 8 Fit new drive belt 7 Tensioning drive belt 1 Slacken screw 4 by half a turn Result Belt tensioner moves against the drive belt and tensions it 2 Use torque wrench to tighten screw 4 to specified tightening torque Name Size Type Lubricant Value Standard Screw M...

Page 137: ...r 2 Check belt condition visually Page 133 Result For drive belt replacement Page 139 Checking Vee belt tension 1 Switch on belt tension tester 2 Hold measuring tip of belt tension tester over belt drive Tap drive belt arrow with a suitable tool 3 Hold belt tension tester over belt drive until the measured value is indicated Initial operation with fan Belt tension adjustment 58 Hz 5 Hz 51 Hz 5 Hz ...

Page 138: ...elt tension 1 Release screws 2 until fan coupling can be moved 2 Tighten stud 1 until the required frequency is achieved 3 Tighten screws 2 to 100 Nm 10 Nm 138 Task Description MS150054 02E 2012 02 TIM ID 0000015308 003 ...

Page 139: ...belt Spare Parts Catalog Preparatory steps 1 Remove protective cover 2 Remove fan Replacing drive belt 1 Release screws 2 2 Slacken off stud 1 until drive belt can be removed 3 Clean belt pulleys 4 Fit new drive belt on belt pulleys ensuring that it is not under tension 5 Adjust belt tension Page 137 MS150054 02E 2012 02 Task Description 139 TIM ID 0000007457 003 ...

Page 140: ...annot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contacts sockets cables and terminals plug in contacts 6 Contact Service if cable conductors are damaged Note Close male connectors that are not plugged in with the protective cap supplied 7 Clean dirty co...

Page 141: ...Cleaning 1 Remove coarse dirt from housing surface with isopropyl alcohol 2 Remove dirt from connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning severely contaminated connectors on the engine governor Note Seal unused connectors with the supplied protective cap 1 Release the latch and pull off connectors 2 Clean connecto...

Page 142: ...ol 2 Remove dirt from connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning severely contaminated EMU connectors 1 Release latches of connectors and withdraw connectors 2 Clean connector housings connector socket housings and all contacts with isopropyl alcohol 3 When connectors sockets and all contacts are dry Fit connect...

Page 143: ...ways 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 1 Check all plug in connections for secure seating 2 Latch connectors if loose MS150054 02E 2012 02 Task Description 143 TIM ID 0000000048 005 ...

Page 144: ...reconditions Engine is stopped and starting disabled EMU checking plug in connections 1 Verify that all plug in connections are securely seated 2 Secure loose connectors and latch 144 Task Description MS150054 02E 2012 02 TIM ID 0000008395 001 ...

Page 145: ...governor from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 2 3 Undo latches 3 of the connectors 4 Remove all connectors 5 Remove screws 1 6 Take off engine governor Installing engine governor on engine 1 Install in reverse order In doing so ensure correct assignment of connectors and sockets 2 Check rubber mount before installation Result If the rubber mount is por...

Page 146: ...all screws 2 3 Undo clips 3 on connectors 4 Disconnect all connectors 5 Remove screws 1 6 Remove ECU 1 with EMU 4 Removing EMU 1 Undo screws on base of EMU 4 2 Remove EMU 4 from ECU 1 Installing EMU 1 Place EMU 4 on ECU 1 2 Screw in and tighten screws on base of EMU 4 Installing ECU with EMU on engine 1 Install in reverse order Ensure correct assignment of connectors and sockets in so doing 2 Chec...

Page 147: ...odes CKT Circuit CLS Coolant Level Sensor Monitors coolant level CPS Coolant Pressure Sensor Monitors coolant pressure CTS Coolant Temperature Sensor Monitors coolant temperature DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Die sel DDL Diagnostic Data Link Diagnostic lines DDR Diagnostic Data Reader Diagnostic unit DIN Deutsches Institut für Normung e V At the same...

Page 148: ...all na tional standardization institutes KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204 KS Kraftseite Engine driving end in accordance with DIN ISO 1204 LED Light Emitting Diode LO Low Alarm Measured value lower than 1st mini mum limit value LOLO Low Low Alarm Measured value lower than 2nd mini mum limit value LSG Limiting Speed Governor N A Not Applicable LP Low Pressure OEM ...

Page 149: ... alarm TBS Turbocharger Boost Sensor Monitors charge air pressure TCI Turbo Compressor Inlet TCO Turbo Compressor Outlet TD Transmitter Deviation Alarm Deviation in transmitter values TPS Throttle Position Sensor TRS Timing Reference Sensor T xyz Temperature xyz Temperature measuring point xyz specifies the measuring point designation UT Unterer Totpunkt Bottom Dead Center BDC VNT Variable Nozzle ...

Page 150: ...r during operation for preventive maintenance corrective work in case of malfunction or changed operating conditions or for spare parts supply Your contact at Headquarters Service support mtu online com Spare parts service Fast simple and correct identification of spare parts for your drive system or vehicle fleet The right spare part at the right time at the right place With this aim in mind we c...

Page 151: ...acement Page 113 Qty Used in 1 7 15 7 Coolant filter Replacement Page 125 Installation removal tool Part No F6789889 Qty Used in 1 7 6 2 Injector Removal and installation Page 79 Milling cutter Part No F30452739 Qty Used in 1 7 6 2 Injector Removal and installation Page 79 MTU test kit Part No 5605892099 00 Qty Used in 1 7 13 3 Engine oil Sample extraction and analysis Page 105 Qty Used in 1 7 15 ...

Page 152: ... F30006212 Qty Used in 1 7 1 1 Engine Barring manually Page 63 Rigid endoscope Part No Y20097353 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 66 Ring socket 24 mm Part No F30039526 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 73 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 14 4 Centrifugal oil filter Cleaning and filter sleeve replacement Page 113 Torq...

Page 153: ...40 200 Nm Part No F30027337 Qty Used in 1 7 13 2 Engine oil Change Page 103 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 3 1 Crankcase breather Oil separator element replacement diaphragm check and replacement Page 70 Torque wrench 60 320 Nm Part No F30047446 Qty Used in 1 1 4 Crankshaft transport locking device Page 8 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 73 Tor...

Page 154: ...l separator element replacement 70 Crankshaft transport locking device Removal installation 8 Cylinder Designations 19 Cylinder head cover Removal and installation 76 Cylinder liner Endoscopic examination 66 Instructions and comments on endoscopic and visual examination 68 D Drive belt Condition check 133 E ECU 7 engine governor Removal and installation 145 Emergency air shutoff flaps Functional c...

Page 155: ...heck 111 Operational checks 34 P Personnel and organizational requirements 6 Putting engine into operation Preparation after extended out of service periods 3 months 30 Putting into operation After scheduled out of service period Preparation 31 Putting the engine into operation after scheduled out of service period 31 R Rubber sleeves between air intake elbow and turbo charger Replacement 96 Rubbe...

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MTU 12 V 4000 G73, Operating Instructions Manual

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