MTU 12 V 4000 T94 Operating Instructions Manual Download Page 120

Page: 120 / 197

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

TIM-ID: 0000000022 - 013

Summary of Contents for 12 V 4000 T94

Page 1: ...Operating Instructions Diesel engine 12 V 4000 T94 T94L MS150096 01E...

Page 2: ...ten 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 on...

Page 3: ...ing 41 6 2 Fault messages on the SAM display optional 44 6 3 Fault messages of Engine Control Unit ECU 9 for Series 4000 45 7 Task Description 7 1 Engine 107 7 1 1 Engine Barring manually 107 7 1 2 En...

Page 4: ...rge air coolant Level check 165 7 16 2 Charge air coolant Change 166 7 16 3 Charge air coolant Draining 167 7 16 4 Charge air coolant Filling 169 7 16 5 Charge air coolant pump Relief bore check 172 7...

Page 5: ...it on delivery Any 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 alon...

Page 6: ...to operating maintenance repair and transport personnel at all times Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on explaining safety relevant i...

Page 7: ...ecial packaging with aluminium foil Suspend the engine genset by the lifting eyes on the bearing pedestal or transport by means of handling equipment forklift truck capable of bearing the load Fit the...

Page 8: ...e 2 Starting or barring the engine 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...

Page 9: ...carrier 1 with washer 7 and nut 8 and tighten to the specified tightening torque using the torque wrench Name Size Type Lubricant Value Standard Nut M24 Tightening torque Engine oil 100 Nm 10 Nm 4 Sec...

Page 10: ...gh the openings 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 Tighteni...

Page 11: ...ing brack ets to secure them on the engine Installing guard plates and engine mounting brackets if applicable on driving end KS 1 Install engine mounting brackets 2 on both sides with guard plates 1 w...

Page 12: ...ust 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 recogni...

Page 13: ...ry 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 e...

Page 14: ...ons 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...

Page 15: ...aft 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 elec...

Page 16: ...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 surfac...

Page 17: ...r 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...

Page 18: ...t 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 ri...

Page 19: ...on involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Note This manual contains highlighted safety warnings in accordance...

Page 20: ...designated 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 Other components are numbered in the same way...

Page 21: ...head 16 Oil pan 17 Engine suspension 18 Supplementary fuel filter 19 Fuel priming pump 20 Fuel filter 21 HP fuel pump 22 Lube oil filter 23 Engine mounting 24 Vibration damper 25 Auxiliary PTO 26 Batt...

Page 22: ...ors and injectors Overview 1 B13 Crankshaft speed 2 F70 Water level in fuel prefilter external 3 F57 Charge air coolant level 4 F33 Engine coolant level 22 General Information MS150096 01E 2012 08 TIM...

Page 23: ...sure 6 B88 NOx 7 B16 Engine coolant pressure 8 Y39 B1 B6 Injectors B1 B6 9 B13 Crankshaft speed 10 B10 11 Charge air pressure B side The injectors injection valves 8 are located below the cylinder he...

Page 24: ...filter 9 B34 2 Fuel pressure before filter 10 B34 1 Fuel pressure af ter filter 11 F46 Leak off fuel level 12 B5 3 Lube oil pressure before filter 13 B7 Lube oil tempera ture 14 B44 1 Turbocharger A...

Page 25: ...er filter 4 B33 Fuel temperature Rail 5 B48 Fuel pressure Rail 6 M8 HP fuel pump 7 B1 Camshaft speed 8 B43 Charge air coolant pressure 9 B26 Charge air cool ant temperature 10 B6 Engine coolant temper...

Page 26: ...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 as per IS...

Page 27: ...ge air pressure before cylinder R bar abs 4 1 4 9 Exhaust temperature after turbocharger R C 520 490 Coolant system high temperature circuit Engine model 12V4000 T94 12V4000 T94L Coolant temperature a...

Page 28: ...Lube oil temperature before engine shutdown L C 104 104 Lube oil operating pressure before engine from R bar 6 0 6 0 Lube oil operating pressure before engine to R bar 7 0 7 0 Fuel system Engine model...

Page 29: ...capacity at dipstick mark min standard oil system option max operating inclinations L Liters 170 170 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Lite...

Page 30: ...3 2 Firing order Firing order Num ber of cylin ders Firing order 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 30 Technical Data MS150096 01E 2012 08 TIM ID 0000026627 001...

Page 31: ...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 TIM ID 0000018765 003...

Page 32: ...ystem Check engine oil level Page 146 Bar engine with starting equipment Page 108 Fuel prefilter Fill with fuel if fitted Coolant circuit If engine is out of service for more than one year change engi...

Page 33: ...tartup 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 165 Coolant circuit Preheat coolant with cool...

Page 34: ...visually for leaks and general condition Check engine for abnormal running noises exhaust color and vibrations Air filter Check signal ring position of service indicator on air filter if fitted Batter...

Page 35: ...rotectors Preparation Item Action Operating mode switch if applicable Switch to manual mode Coolant preheating unit if applicable Switch ON Starting the engine Item Action Switchgear cabinet opera tor...

Page 36: ...age to components Before stopping the engine operate it at idle speed until operating temperatures decrease and stable values are indicated Preparation Item Action Engine Operate engine at idling spee...

Page 37: ...f service for an extended period but engine coolant has no antifreeze additive the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insuffici...

Page 38: ...cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental pro tection 2 Prior to putting the cleaning unit into operation read the Operating Instru...

Page 39: ...e fuel filter or fuel filter element Page 126 W1006 Replace fuel injectors Page 120 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 15...

Page 40: ...rews of trunnion bearings for tight fit Page 180 W1636 Reset drift correction parameters CDC and enter code of in jectors IIG Page 182 Table 1 Maintenance task reference table QL1 40 Maintenance MS150...

Page 41: ...manually Contact Service Engine turns but does not fire Component Cause Action Engine Too cold Preheat 40 C Starter Poor rotation by starter Battery low or defective Charge or replace battery see manu...

Page 42: ...Charge air pressure too low Component Cause Action Air supply Air filter clogged Check Intercooler Contaminated Contact Service Exhaust turbocharger Defective Contact Service Coolant discharge at inte...

Page 43: ...ne 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...

Page 44: ...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 Our Service w...

Page 45: ...rective action Fuel tank may be exposed to heat u Contact Service 5 HI T Charge Air ZKP Number 2 0121 931 Charge air temperature too high limit value 1 Yellow alarm warning Cause Corrective action Int...

Page 46: ...Coolant circuit for charge air faulty 1 Check intercooler and coolant cooler 2 Contact Service 15 LO P Lube Oil ZKP Number 2 0100 921 Lube oil pressure too low limit value 1 Yellow alarm warning Caus...

Page 47: ...2 0127 931 Exhaust temperature B 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 22 SS T Exhaust B ZKP Nu...

Page 48: ...51 931 Leak off fuel level too high limit value 1 Yellow alarm warning Cause Corrective action Leak in fuel lines 1 Check fuel system 2 Contact Service 30 SS Engine Overspeed ZKP Number 2 2510 932 Eng...

Page 49: ...filter differential pressure too high limit value 2 Red alarm engine shutdown Cause Corrective action Fuel filter not operating correctly 1 Replace fuel filter Page 126 2 Contact Service 36 HI ETC2 O...

Page 50: ...T Lube Oil ZKP Number 2 0125 932 Lube oil temperature too high limit value 2 Red alarm engine shutdown Cause Corrective action Insufficient oil 1 Check engine oil level Page 146 2 Contact Service 57...

Page 51: ...ge leaks low coolant level 1 Activate fan emergency operating mode if required 2 Allow engine to cool down 3 Check engine coolant cooler clean if dirty 4 Acknowledge alarm 5 Restart engine Page 35 6 C...

Page 52: ...heck fuel lines for leaks 2 Check filter fuel on low pressure side 3 Replace fuel filter Page 126 4 Contact Service 67 HI T Coolant ZKP Number 2 0120 931 Coolant temperature too high limit value 1 Yel...

Page 53: ...n readjusted towards late Cause Corrective action HP fuel block jamming or HP fuel control block wiring faulty 1 Check wiring Page 181 2 Contact Service 83 LO P Fuel Common Rail ZKP Number 2 0104 921...

Page 54: ...d not reached Red alarm warning Cause Corrective action Starter does not rotate or rotates too slowly 1 Observe additional messages 2 Contact Service 93 SS T Preheat ZKP Number 2 1090 922 Preheating t...

Page 55: ...nitoring system Yellow alarm warning Cause Corrective action Hour meter faulty u Contact Service 118 LO ECU Supply Voltage ZKP Number 2 0140 921 Supply voltage too low limit value 1 Yellow alarm warni...

Page 56: ...tact Service 122 HI T ECU ZKP Number 2 0132 921 Electronics temperature too high limit value 1 Yellow alarm warning Cause Corrective action Electronics overheated 1 Reduce power 2 Improve engine room...

Page 57: ...1 Check devices connected to CAN 2 Check wiring Page 181 3 Contact Service 182 AL CAN Wrong Parameters ZKP Number 2 0500 682 Incorrect parameters at CAN Yellow alarm warning Cause Corrective action I...

Page 58: ...necessary 3 Contact Service 187 AL CAN1 Error Passive ZKP Number 2 0500 687 CAN 1 error Yellow alarm warning Cause Corrective action Missing associated nodes minor disruptions or temporary bus overlo...

Page 59: ...Fault is rectified when engine is restarted Page 35 3 Contact Service 202 SD T Fuel ZKP Number 1 8004 572 Fuel temperature sensor signal error Yellow alarm warning Cause Corrective action Fuel tempera...

Page 60: ...d when engine is restarted Page 35 3 Contact Service 206 SD T Exhaust A ZKP Number 1 8004 576 Signal error exhaust temperature sensor on A side Yellow alarm warning Cause Corrective action Exhaust tem...

Page 61: ...ified when engine is restarted Page 35 3 Contact Service 212 SD P Coolant ZKP Number 1 8004 564 Coolant pressure sensor signal error Yellow alarm warning Cause Corrective action Coolant pressure senso...

Page 62: ...ace as necessary Page 181 2 Fault is rectified when engine is restarted Page 35 3 Contact Service 216 SD T Lube Oil ZKP Number 1 8004 575 Lube oil temperature sensor signal error Yellow alarm warning...

Page 63: ...s rectified when engine is restarted Page 35 3 Contact Service 222 SD Level Leak Off Fuel ZKP Number 1 8004 582 Leak off fuel level sensor signal error Yellow alarm warning Cause Corrective action Lea...

Page 64: ...181 2 Fault is rectified when engine is restarted Page 35 3 Contact Service 229 AL Stop Camshaft Sensor Defect ZKP Number 1 8004 562 Stop camshaft sensor signal error Red alarm engine shutdown Cause...

Page 65: ...age 181 2 Fault is rectified when engine is restarted Page 35 3 Contact Service 233 SD Charger 2 Speed ZKP Number 1 3011 129 Secondary turbocharger speed sensor signal error Yellow alarm warning Cause...

Page 66: ...2 Contact Service 266 SD Speed Setting ZKP Number 2 8006 586 Speed setting signal error Red alarm forced idle Cause Corrective action Analog speed setpoint incorrect Short circuit or wire break 1 Che...

Page 67: ...ed transmitter setpoint 3 Contact Service 321 AL Wiring Cylinder A1 ZKP Number 1 8004 520 Wiring faulty cylinder A1 Yellow alarm misfiring Cause Corrective action Short circuit fault in injector wirin...

Page 68: ...ault is rectified when engine is restarted Page 35 3 Contact Service 325 AL Wiring Cylinder A5 ZKP Number 1 8004 524 Wiring faulty cylinder A5 Yellow alarm misfiring Cause Corrective action Short circ...

Page 69: ...ult is rectified when engine is restarted Page 35 3 Contact Service 329 AL Wiring Cylinder A9 ZKP Number 1 8004 528 Wiring faulty cylinder A9 Yellow alarm misfiring Cause Corrective action Short circu...

Page 70: ...ault is rectified when engine is restarted Page 35 3 Contact Service 333 AL Wiring Cylinder B3 ZKP Number 1 8004 532 Wiring faulty cylinder B3 Yellow alarm misfiring Cause Corrective action Short circ...

Page 71: ...ault is rectified when engine is restarted Page 35 3 Contact Service 337 AL Wiring Cylinder B7 ZKP Number 1 8004 536 Wiring faulty cylinder B7 Yellow alarm misfiring Cause Corrective action Short circ...

Page 72: ...t Service 341 AL Open Load Cylinder A1 ZKP Number 1 8004 540 Injector wiring fault cylinder A1 Yellow alarm misfiring Cause Corrective action Disruption fault in injector wiring cylinder A1 1 Check in...

Page 73: ...120 3 Fault rectification after each working cycle 4 Contact Service 345 AL Open Load Cylinder A5 ZKP Number 1 8004 544 Injector wiring fault cylinder A5 Yellow alarm misfiring Cause Corrective action...

Page 74: ...20 3 Fault rectification after each working cycle 4 Contact Service 349 AL Open Load Cylinder A9 ZKP Number 1 8004 548 Injector wiring fault cylinder A9 Yellow alarm misfiring Cause Corrective action...

Page 75: ...120 3 Fault rectification after each working cycle 4 Contact Service 353 AL Open Load Cylinder B3 ZKP Number 1 8004 552 Injector wiring fault cylinder B3 Yellow alarm misfiring Cause Corrective action...

Page 76: ...120 3 Fault rectification after each working cycle 4 Contact Service 357 AL Open Load Cylinder B7 ZKP Number 1 8004 556 Injector wiring fault cylinder B7 Yellow alarm misfiring Cause Corrective action...

Page 77: ...injector if required Page 120 3 Fault rectification after each working cycle 4 Contact Service 361 AL Injector Output Stage Low ZKP Number 1 8004 496 Internal electronic fault Red alarm engine shutdow...

Page 78: ...nnection to ground of one or more injectors Short circuit of negative injector connection or of one or more injectors to ground 1 Check wiring Page 181 2 Engine restart Page 35 3 Replace wiring harnes...

Page 79: ...4 u Check wiring to plant 390 AL MCR Exceeded ZKP Number 1 1085 009 Speed limiter MCR function The maximum continuous rate was exceeded Yellow alarm engine power limited to permissible continuous powe...

Page 80: ...Check wiring Page 181 2 Check target device input 3 Contact Service 403 AL Open Load Digital Input 4 ZKP Number 2 8006 628 Line disruption on digital input 4 Yellow alarm warning Cause Corrective act...

Page 81: ...ring Page 181 2 Check target device input 3 Contact Service 407 AL Open Load Digital Input 8 ZKP Number 2 8006 632 Line disruption on digital input 8 Yellow alarm warning Cause Corrective action Wirin...

Page 82: ...Page 181 2 Check power supply 3 Acknowledge alarm 4 Contact Service 412 HI U PDU ZKP Number 2 0141 931 Injector voltage too high limit value 1 Yellow alarm warning Cause Corrective action Cable damage...

Page 83: ...in intercooler too low limit 2 Red alarm engine shutdown Cause Corrective action Leak in coolant circuit u Top up coolant 417 SD Level Water Fuel Prefilter ZKP Number 1 8004 594 Fuel prefilter water l...

Page 84: ...ower stage supply voltage faulty Yellow alarm warning Cause Corrective action Sensor defect of injector power stage or internal fault of engine governor u Replace engine governor 445 SD P Ambient Air...

Page 85: ...orrective action Input signal for start end torque faulty Short circuit or wire break 1 Check signal transmitter and wiring replace as necessary Page 181 2 Fault is rectified when engine is restarted...

Page 86: ...2 470 SD T ECU ZKP Number 1 8004 587 Engine governor temperature signal error Yellow alarm warning Cause Corrective action Temperature sensor for engine governor faulty Short circuit or wire break 1...

Page 87: ...n Trigger ZKP Number 1 8010 009 Crash recorder was triggered by engine shutdown Yellow alarm warning Cause Corrective action Crash recorder was triggered by engine shutdown u Contact Service 476 AL Cr...

Page 88: ...3014 931 Speed of 2nd secondary turbocharger too high limit value 1 Yellow alarm warning Cause Corrective action Obstructed charge air circuit or fault in turbocharger u Reduce power 489 SS ETC3 Over...

Page 89: ...nection of starter 2 at POM Yellow alarm warning Cause Corrective action Missing consumer Short circuit or wire break u Check connection between POM and starter 502 AL Open Load POM Battery Charging G...

Page 90: ...ring Page 181 507 AL POM Error ZKP Number 1 4500 907 A general POM fault occurred Yellow alarm warning Cause Corrective action Defect in POM u Replace POM 508 AL Incorrect POM ID ZKP Number 1 4500 908...

Page 91: ...lace as necessary Page 181 2 Contact Service 536 AL Wiring PWM_CM1 ZKP Number 1 1041 921 Wiring problem at PWM_CM1 channel Yellow alarm warning Cause Corrective action Cable break or short circuit on...

Page 92: ...BR MCR curve u Reduce power 577 SD T Lube Oil Pan ZKP Number 1 0137 900 Oil pan temperature sensor signal error Yellow alarm warning Cause Corrective action Oil pan temperature sensor faulty Short cir...

Page 93: ...Yellow alarm warning Cause Corrective action Cable break or short circuit on channel PWM_CM4 1 Check wiring to connected device or check connected device itself actuator sensor and replace if necessar...

Page 94: ...for trials The alarm remains set until a series parameter set is loaded u Contact Service 597 AL Wiring PWM_CM5 ZKP Number 1 1041 925 Wiring problem at PWM_CM5 channel Yellow alarm warning Cause Corr...

Page 95: ...ow alarm warning Cause Corrective action ETC speed sensors 1 and 2 faulty Short circuit or wire break 1 Check sensor and wiring replace as necessary Page 181 2 Contact Service 602 AL CAN Engine Start...

Page 96: ...o connected device or check connected device itself actuator sensor and replace if necessary Page 181 2 Contact Service 610 AL Wiring HP Fuel Control Block 1 ZKP Number 1 1301 902 Wiring faulty at HP...

Page 97: ...alve 2 1 Check wiring Page 181 2 Contact Service 614 AL L1 P Fuel Add Filter Diff ZKP Number 2 0119 001 Fuel prefilter differential pressure too high Yellow alarm warning Cause Corrective action Fuel...

Page 98: ...nnected device or check connected device itself actuator sensor and replace if necessary Page 181 2 Contact Service 627 AL Wiring PWM_CM9 ZKP Number 1 1041 929 Wiring problem at PWM_CM9 channel Yellow...

Page 99: ...irculation shutoff flap B or flap mechanical system is defective 1 Replace actuator or flap 2 Contact Service 631 AL Bypass Flap Defect ZKP Number 1 0700 051 Bypass flap is faulty Yellow alarm warning...

Page 100: ...91 Moisture sensor signal error TRICAN HDT2800 Yellow alarm warning Cause Corrective action Moisture sensor TRICAN HDT2800 defective 1 Check sensor and wiring replace as necessary Page 181 2 Contact S...

Page 101: ...r wire break 1 Check sensor and wiring B34 3 replace as necessary Page 181 2 Fault is rectified when engine is restarted Page 35 3 Contact Service 644 AL L1 P Fuel Upstr o F ZKP Number 2 0164 921 Fuel...

Page 102: ...k 1 Check sensor and wiring B10 11 replace as necessary Page 181 2 Fault is rectified when engine is restarted Page 35 662 SD Smart NOx Heating Element ZKP Number 1 0700 141 Smart NOx sensor heating e...

Page 103: ...rective action NOx regulator not active Lambda regulator not active Charge air regulator not active Lambda regulator at stop Charge air pressure regulator at stop NOx regulator at stop 1 Delete all ot...

Page 104: ...ler Check 5 Check coolant pump 6 Contact Service 763 AL OL EASF Limit Switch B ZKP Number 1 2510 121 Wiring error in monitoring line of emergency air shutoff flap B Cause Corrective action Short circu...

Page 105: ...se Corrective action Flaps A and B stuck Flaps A and B were not energized Short circuit or wire break 1 Check flap B Page 140 2 Check wiring Page 181 3 Contact Service 833 AL Emission Warning ZKP Numb...

Page 106: ...her fault codes 2 Check sensor and wiring Page 181 3 Contact Service 839 AL EASF A Not Closed by ECU ZKP Number 1 2510 133 Emergency air shutoff flap A closed without actuation Cause Corrective action...

Page 107: ...ger zone Barring engine manually lateral installation 1 Remove cover from flywheel housing 2 Engage barring device 2 in ring gear and install on flywheel housing Use barring device F6787910 3 Set ratc...

Page 108: ...arring with starting system 1 Release latch of connector X3 Note Seal unused connectors with the supplied protective cap 2 Remove connector from engine governor 3 Bar engine in unloaded condition Pres...

Page 109: ...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 35 2 Perform test run not below 1 3 load and at least...

Page 110: ...ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless even honing pattern First signs of marks left by lower cooling bo...

Page 111: ...Depending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injector...

Page 112: ...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...

Page 113: ...on starting in TDC ring 1 have to be replaced Seizure marks scuff ing Irregular circumference lengths and depths Can be caused either by the piston skirt or the piston crown Material deposits on the l...

Page 114: ...re parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 118 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 115: ...esignation Use Part No Qty Feeler gauge Y20098771 1 Allen key F30002815 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover...

Page 116: ...inder A1 are unloaded the piston is in firing TDC If the rocker arms are under load on cylinder A1 the piston is in overlap TDC 2 Check valve clearance with cold engine Inlet valves long rocker arm 0...

Page 117: ...1 with torque wrench to the specified tightening torque holding the adjusting screw 2 to prevent it from turning Name Size Type Lubricant Value Standard Locknut M16 x 1 5 Tightening torque Engine oil...

Page 118: ...irty cylinder head covers 1 prior to removal 2 Unscrew screws 3 4 and take off with washers 2 5 3 Remove cylinder head cover 1 with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean...

Page 119: ...ils oil vapors are combustible Risk of fire Avoid open flames electric sparks and ignition sources Do not smoke CAUTION Fuel system high pressure pump not filled with engine oil Damage to components m...

Page 120: ...or 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 121 120 Task Description M...

Page 121: ...rench 60 320 Nm F30452768 1 Assembly paste Optimoly Paste White T 40477 1 Grease Kluthe Hakuform 30 10 emulsifier X00029933 1 Engine oil O ring Spare Parts Catalog WARNING Fuels are combustible Risk o...

Page 122: ...inder head 9 Remove O rings 3 and damper ring 4 from injector 10 Clean all mating and sealing surfaces 11 If carbon residue is present Clean sealing face on cylinder head and protective sleeve with mi...

Page 123: ...Screw M12 Preload torque Engine oil 5 Nm to 10 Nm Note Ensure special cleanness 11 Coat thread and sealing cone of adapter 1 with engine oil 12 Install adapter 1 and use torque wrench to tighten to th...

Page 124: ...ion nut thrust screw Tightening torque Engine oil 40 Nm 5 Nm 17 Fit cable connector onto injector Note The CDC parameters must be reset other wise the emission certification of the engine is no longer...

Page 125: ...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...

Page 126: ...osion Avoid open flames electrical sparks and ignition sources Do not smoke Replacing fuel filter 1 Remove easy change filter 2 using filter wrench 2 Clean sealing surface on filter head 1 3 Coat the...

Page 127: ...mes electrical sparks and ignition sources Do not smoke Replacing auxiliary fuel filter 1 Remove easy change filter 2 with filter wrench 2 Clean sealing surface on filter head 1 3 Coat gasket on easy...

Page 128: ...terial Spare parts Designation Use Part No Qty Turbine housing Spare Parts Catalog Exhaust turbocharger low pressure charger u Check turbine housing Page 129 Exhaust turbocharger high pressure u Check...

Page 129: ...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 Removing heat shield 1 Remove...

Page 130: ...exhaust pipe bellows 1 and sealing ring 1 from turbine housing Removing exhaust elbow Note Mark position of clamp 1 Unscrew screws 5 and remove from con sole with spacer sleeves 4 2 Release clamp 2 an...

Page 131: ...d sealing ring 3 on turbine housing and tighten to specified tightening torque Name Size Type Lubricant Value Standard Clamp Tightening torque Assembly paste Ul tra Therm MTU 27 Nm 2 Nm 2 Coat screw t...

Page 132: ...bellows 1 with clamp 2 and sealing ring 3 on turbine housing Installing exhaust pipe insulation u Install insulation 2 on exhaust pipe and secure with clamps 1 Installing heat shield 132 Task Descript...

Page 133: ...htening torque Name Size Type Lubricant Value Standard Screws Tightening torque Engine oil 42 Nm 4 Nm 2 Install holder 6 with washers 5 and screws 4 and tighten 3 Install holder 3 with washers 2 and s...

Page 134: ...ing 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 Removing hea...

Page 135: ...ion 2 Removing exhaust pipe u Release clamp 1 and take off with exhaust pipe 3 and sealing ring 2 from turbine housing Removing insulation of exhaust pipe bellows u Release clamps 1 and remove insula...

Page 136: ...rbine housing from the inside for cracks Note Cracks are only permissible in the direction of circumference of the spiral 2 Cracks larger than max crack length x 30 mm or transverse cracks Replace tur...

Page 137: ...ws and secure with clamps 1 Installing exhaust pipe u Install exhaust pipe 3 with clamp 1 and sealing ring 2 on turbine housing Installing exhaust pipe insulation u Install insulation 2 on exhaust pip...

Page 138: ...d screws 2 and tighten to specified tightening torque Name Size Type Lubricant Value Standard Screws Tightening torque Engine oil 42 Nm 4 Nm 2 Install holder 3 with washers 2 and screws 1 and tighten...

Page 139: ...ask and ear protectors Intercooler Leak check u With the engine at standstill open drain plugs in charge air elbows on left and right engines sides on driving end arrowed and check for coolant dischar...

Page 140: ...mise the engine reduce the overspeed limit value for the functional check Emergency air shutoff flaps Functional check with electric actuation 1 Start engine Page 35 2 Activate the appropriate functio...

Page 141: ...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 TIM ID 0000027110 003...

Page 142: ...1 Bypass flap 142 Task Description MS150096 01E 2012 08 TIM ID 0000027110 003...

Page 143: ...s arrows and make sure that there is no excessive play Result If exhaust flap is sluggish or has too much play Contact Service 4 The internal spring should pull the flap to the fail safe position Fail...

Page 144: ...eck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 181 144 Task Desc...

Page 145: ...Engine is stopped and starting disabled Engine oil Level check at sight glass 1 Engine oil level 2 may be checked in ad vance at sight glass 1 2 Proper engine oil level check must always be carried ou...

Page 146: ...th the engine running 1 After the engine has run for approx 10 minutes at a constant speed of 600 to 900 rpm pull out oil dip stick from guide tube and wipe it 2 Insert dipstick into guide tube up to...

Page 147: ...vapor Oil change without semirotary hand pump Draining oil at drain plug s on oil pan 1 Provide a suitable container in which to collect the engine oil 2 Remove drain plug s and drain engine oil 3 Ins...

Page 148: ...ize Type Lubricant Value Standard Screw M26 x 1 5 Tightening torque Engine oil 100 Nm 10 Nm 7 Screw in drain plug 3 and tighten to specified tightening torque using a torque wrench Name Size Type Lubr...

Page 149: ...protective 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 e...

Page 150: ...y and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 When the engine is running at operating temperat...

Page 151: ...of the new oil filter sealing ring and coat it with engine oil 7 Screw on and tighten new engine oil filter by hand 8 Replace other engine oil filters in the same way 9 After each oil change and filt...

Page 152: ...Emulgier X00029933 1 Filter sleeve 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...

Page 153: ...12 onto rotor lower sec tion 13 13 Insert new filter sleeve 9 with stiffener plate 10 into rotor cap 8 ensuring that smooth surface of filter sleeve 9 faces ro tor cap 8 14 Check sealing ring 11 repl...

Page 154: ...first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check engine coolant level coolant must be visible at the bottom edge of the filler neck s cast...

Page 155: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant Change 1 Drain engine coolant Page 156 2 Fill with engine coolant Page 159 MS150096 01E 2012 08 Task Description...

Page 156: ...ed corrosion inhibitor oil in expansion tank through the filler neck 4 Open drain valves and or drain plugs and drain coolant at the following points At the preheating unit At the elbow of the engine...

Page 157: ...Final steps 1 Close all open drain points 2 Set breather valve onto filler neck and close it MS150096 01E 2012 08 Task Description 157 TIM ID 0000030760 002...

Page 158: ...ble to the other exhaust flaps Over view of exhaust flaps Page 141 Draining coolant Note The respective coolant circuit must be emp tied beforehand Engine coolant Draining Page 156 Charge air coolant...

Page 159: ...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 coolan...

Page 160: ...oper condition of breather valve and clean sealing faces if required 8 Set breather valve onto filler neck and close it 9 Start engine Page 35 and stop it Page 35 after operation in unloaded condition...

Page 161: ...e breather valve onto filler neck and close until first stop is reached 6 Start engine Page 35 and stop it after operation in unloaded condition for 10 sec onds Page 36 7 Turn breather valve countercl...

Page 162: ...ne coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Shut down engine Page 36 and disable engine start observe general safety instruc tions Maintenance and Repair 3 C...

Page 163: ...tective 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 Open drain valve arrowe...

Page 164: ...e Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant filter Replacement 1 Close shut off cock 1 2 Remove engine coolant filter...

Page 165: ...n 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 T...

Page 166: ...ecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 167 2 Fill with charge air coolant Page 169 166 Task Description MS150096...

Page 167: ...ppropriate container to drain the coolant into 2 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 3 Continue to turn breather valve counter...

Page 168: ...termediate cool er B side 9 Drain coolant at bypass flap and EGR shut off flap Page 158 Final steps 1 Close all drain valves and install drain plug with new sealing rings 2 Set breather valve onto fil...

Page 169: ...y and 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 u...

Page 170: ...ge 35 9 After 10 seconds of running the engine without load shut down the engine Page 36 10 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escap...

Page 171: ...Page 35 6 After 10 seconds of running the engine without load shut down the engine Page 36 7 Turn breather valve counterclockwise and remove 8 Check charge air coolant level Page 165 and top up if re...

Page 172: ...ge air coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Shut down engine Page 36 and disable engine start observe general safety instruc tions Maintenance and Repair...

Page 173: ...ed 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 176 Drive belt B Cracks on entire...

Page 174: ...ecking battery charging generator Item Findings Action Ventilation area arrow Clean None Ventilation area arrow Contaminated Clean Cleaning battery charging generator Note Dry clean battery charging g...

Page 175: ...ews 1 and 2 by half a turn Result Belt tensioner moves against the drive belt and tensions it 3 Tighten screw 2 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Sta...

Page 176: ...ighten screw 3 5 Remove the used drive belt 6 Fit new drive belt 7 Slacken screw 3 by half a turn Result Belt tensioner moves against the drive belt and tensions it 8 Tighten screw 3 to specified tigh...

Page 177: ...ver 2 Check belt condition visually Page 173 Result For drive belt replacement Page 179 Checking Vee belt tension 1 Switch on belt tension tester 2 Hold measuring tip of belt tension tester over belt...

Page 178: ...ed 2 Tighten stud 1 until the required frequency is achieved 3 Using a torque wrench tighten screws 2 to the specified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque...

Page 179: ...ve belt Spare Parts Catalog Preparatory steps 1 Remove protective cover 2 Remove fan Replacing drive belt 1 Loosen screws 2 2 Slacken off stud 1 until drive belt can be removed 3 Clean belt pulleys 4...

Page 180: ...em Findings Measure Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service Checking securing screws for engine mounting for firm seating 1 Chec...

Page 181: ...nnot 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 contac...

Page 182: ...parameters must be reset otherwise the emission certification of the engine is no longer appli cable u Reset the CDC parameters with DiaSys Manufacturer s documentation Resetting CDC parameters DiaSy...

Page 183: ...om 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...

Page 184: ...ays 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 connectio...

Page 185: ...des 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 El...

Page 186: ...ll 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...

Page 187: ...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 Posi...

Page 188: ...u either 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 o...

Page 189: ...e 107 Barring device Part No F6555766 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 110 Endoscope Part No Y20097353 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 110...

Page 190: ...4 1 Engine oil filter Replacement Page 150 Qty Used in 1 7 14 2 Centrifugal oil filter Cleaning and filter sleeve replacement Page 152 Qty Used in 1 7 15 8 Engine coolant filter Replacement Page 164 I...

Page 191: ...nd analysis Page 163 Optibell 2 belt tension tester Part No Y4345711 Qty Used in 1 7 19 1 Fan drive option Drive belt check adjustment Page 177 Ratchet Part No F30006212 Qty Used in 1 7 1 1 Engine Bar...

Page 192: ...ntrifugal oil filter Cleaning and filter sleeve replacement Page 152 Ratchet with extension Part No F30006212 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 110 Socket wrench 24 mm Par...

Page 193: ...Page 121 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 7 5 2 Injector Removal and installation Page 121 Torque wrench 10 60 Nm Part No F30510423 Qty Used in 1 1 4 Crankshaft transport locking...

Page 194: ...aning and filter sleeve replacement Page 152 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 115 Qty Used in 1 7 5 2 Injector Removal and instal...

Page 195: ...Torque wrench 80 to 400 Nm Part No F30027338 Qty Used in 1 7 20 1 Engine mounting Check Page 180 MS150096 01E 2012 08 Appendix B 195 DCL ID 0000009793 004...

Page 196: ...d installation 118 Cylinder liner Endoscopic examination 110 Instructions and comments on endoscopic and visual examination 112 D Drive belt Condition check 173 E ECU9 Fault messages 45 Emergency air...

Page 197: ...rs Overview 22 Inspection port cover Explosion hazard 13 Intercooler Leak check 139 M Maintenance work Safety regulations 14 MTU contact persons 188 O Operation Safety regulations 12 Operational check...

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