MTU 12 V 4000 T95 x Operating Instructions Manual Download Page 74

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347 – AL Open Load Cylinder A7

ZKP-Number: 1.8004.546

Injector wiring fault, cylinder A7
Yellow alarm - misfiring

Cause

Corrective action

Disruption fault in injector
wiring, cylinder A7.

1. Check injector wiring for disruption.
2. Rule out any disruption in injector solenoid valve, replace

injector if required (→ Page 125).

3. Fault is corrected after every working cycle.
4. Contact Service.

348 – AL Open Load Cylinder A8

ZKP-Number: 1.8004.547

Injector wiring fault, cylinder A8
Yellow alarm - misfiring

Cause

Corrective action

Disruption fault in injector
wiring, cylinder A8.

1. Check injector wiring for disruption.
2. Rule out any disruption in injector solenoid valve, replace

injector if required (→ Page 125).

3. Fault is corrected after every 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

Disruption fault in injector
wiring, cylinder A9.

1. Check injector wiring for disruption.
2. Rule out any disruption in injector solenoid valve, replace

injector if required (→ Page 125).

3. Fault is corrected after every working cycle.
4. Contact Service.

350 – AL Open Load Cylinder A10

ZKP-Number: 1.8004.549

Injector wiring fault, cylinder A10
Yellow alarm - misfiring

Cause

Corrective action

Disruption fault in injector
wiring, cylinder A10.

1. Check injector wiring for disruption.
2. Rule out any disruption in injector solenoid valve, replace

injector if required (→ Page 125).

3. Fault is corrected after every working cycle.
4. Contact Service.

74 | Troubleshooting | MS150120/00E 2014-11

TIM-ID: 0000029153 - 008

Summary of Contents for 12 V 4000 T95 x

Page 1: ...Operating Instructions Diesel engine 12 V 4000 T95 12 V 4000 T95 x MS150120 00E ...

Page 2: ... is protected by copyright and may not be used in any way whether in whole or in part without the prior written consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing transla tion microfilming and storage or processing in electronic systems including databases and online services All information in this publication was the latest information availabl...

Page 3: ...ring engine with starting system 109 7 1 3 Engine Test run 110 7 2 Cylinder Liner 111 7 2 1 Cylinder liner Endoscopic examination 111 7 2 2 Instructions and comments on endoscopic and visual examination of cylinder liners 113 7 3 Crankcase Breather 115 7 3 1 Oil mist fine separator Replacement 115 7 4 Valve Drive 117 7 4 1 Valve gear Lubrication 117 7 4 2 Valve clearance Check and adjustment 118 7...

Page 4: ...ump pressure relief port 188 7 19 Belt Drive 189 7 19 1 Drive belt Condition check 189 7 20 Battery Charging Generator 190 7 20 1 Checking battery charging generator 190 7 20 2 Battery charging generator drive Drive belt tension adjustment 191 7 20 3 Battery charging generator drive Drive belt replacement 192 7 21 Engine Mounting Support 193 7 21 1 Engine mounting Check 193 7 22 Wiring General for...

Page 5: ...iguration approved by the manufacturer in writ ing including engine management parameters In compliance with all safety regulations and in accordance with all warning notices in this manual With maintenance work performed in accordance with the Maintenance Schedule throughout the useful life of the product In compliance with the maintenance and repair instructions contained in this manual in parti...

Page 6: ...ork on or around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Center of the manufacturer Qualified personnel specialized in mechanical and plant engineering The operator must define the responsibilities of the personnel involved in operation maintenance r...

Page 7: ...eight forklift truck Prior to transporting the engine genset system it is imperative to install the transport locking de vice for the crankshaft Prior to transporting the engine genset system it is imperative to install the transport locks for the engine mounts Secure the engine genset system such as to preclude tipping during transport Secure the engine system genset as to preclude slipping and t...

Page 8: ... damage Starting or barring the engine is allowed only with the transport locking device removed If the gener ator gearbox is flanged on make sure that the transport locking device of the generator gearbox is removed as well The transport locking device must be reinstalled according to the instructions prior to every engine transport If the generator gearbox is flanged on and is also going to be m...

Page 9: ...sher 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 5 Lock with nut 3 6 Mark the engine as Fitted with transportation locking device Removing the transport locking device from driving end KS version B 1 Release locknuts 3 on both sides of the flywheel housing remove screws ...

Page 10: ...ll guard plates 3 washers 2 and screws 1 on both sides 5 Tighten screws 1 Fitting the transport locking de vice on driving end KS version B 1 Remove screws 1 with washers 2 and take off guard plates 3 2 Store the removed parts carefully for possi ble reuse 10 Safety MS150120 00E 2014 11 TIM ID 0000027593 005 ...

Page 11: ...ning torque Engine oil 250 Nm 25 Nm 4 Screw nut 3 onto screws 4 up to the end of the thread 5 Fit the holders 1 through the openings of plates 2 and fasten with the screws 4 6 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 7 Screw on nuts 3 of both screws 4 at plates 2 and ...

Page 12: ...tor must be aware of the consequences of any operations he she performs During operation the display instruments and monitoring units must be constantly observed in regard of present operating status limit value violation and warning or alarm messages Malfunctions and emergency stop Emergency procedures in particular emergency stop must be practiced on a regular basis Take the following steps if a...

Page 13: ... starter with compressed air Clean the interior of the flywheel housing with a class H dust extractor Observe the safety data sheet Safety requirements during maintenance and repair work Take special care when removing vent plugs or plug screws from the product Hold a cloth over the screw or plug to prevent discharge of highly pressurized liquids Take care when draining hot fluids and lubricants r...

Page 14: ...e performing necessary welding work Hydraulic installation and removal Check function and satisfactory condition of the jigs and fixtures to be used Use only the specified jigs and fixtures for hydraulic removal installation Observe the max permissible force on pressure specified for the installation removal jig Do not attempt to bend or exert force on HP lines Before starting work pay attention t...

Page 15: ...ment i e protect them against moisture in particular Pack age faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in antistatic foil if necessary Working with laser equipment Always wear special laser protection goggles when working with laser equipment danger due to in tensely focused radiation Laser equipment must be fitted with th...

Page 16: ... are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Noncompliance with these guidelines will invalidate the design type approval issued by the emissions regulation authorities The manufacturer does not accept any liability for violations of the emission regulati...

Page 17: ...o be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting in areas other than spray booths equipped with extractors ensure good ventilation Make sure that neighboring work areas are not adversely affected There must be no naked flames in the vicinity No smoking Observe fire prevention regulati...

Page 18: ...emedial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Safety notices 1 This manual with all safety instructions and safety notices must be issued to all personnel involved in operation maintenance repair or transportation 2 The higher level warning notice is used if several ...

Page 19: ...gnated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1 and letter Bx refers to the cylinders on the right hand side 3 The cylinders of each bank are numbered consecutively starting with x 1 at driving end 4 The numbering of other engine components also s...

Page 20: ...5 Exhaust outlet 6 Engine oil heat exchanger 7 Air intake 8 Cylinder head 9 Oil pan 10 Bypass flap 11 Oil dipstick 12 Oil filler neck 13 Engine lifting equipment 14 Flywheel 15 Exhaust gas recirculation system 16 Intercooler high pressure 17 HT coolant pipework after EGR cooler KS Driving end 20 General Information MS150120 00E 2014 11 TIM ID 0000054361 001 ...

Page 21: ... Battery charging generator 13 Centrifugal oil filter 14 Crankcase breather KGS Free end Engine model designation Key to the engine model designation 12 V 4000 T95 T95L T95R 12 Number of cylinders V Cylinder arrangement V engine 4000 Series T Application Oil Gas onshore 9 Application segment High performance Hydro Frac 5 Design index L L enhanced power speed R R reduced power speed MS150120 00E 20...

Page 22: ...ck Overview 1 Exhaust silencer 2 Rain cap 3 Air filter 4 Air filter 5 Service indicator 6 Combined support for air exhaust system 7 Air intake elbow 8 Exhaust bellows 22 General Information MS150120 00E 2014 11 TIM ID 0000057595 001 ...

Page 23: ...2 4 Sensors and actuators Overview 1 XSY12 Adaption for emergency air shut off flap option 2 B13 Crankshaft speed MS150120 00E 2014 11 General Information 23 TIM ID 0000054363 002 ...

Page 24: ... side 4 B90 Intake air humidity pressure temperature 5 B91 3 Exhaust gas pres sure 6 B50 Crankcase pressure 7 B16 Coolant pressure 8 B97 ESD pressure cylin ders B1 B6 9 B10 2 Charge air pres sure B side 24 General Information MS150120 00E 2014 11 TIM ID 0000054363 002 ...

Page 25: ...vel in fuel filter 10 XF57 Charge air coolant leak level 11 XF33 Engine coolant lev el 12 B97 ESD pressure cylin ders A1 A6 13 B34 3 Fuel pressure be fore optional filter 14 B33 Fuel temperature 15 B34 2 Fuel pressure be fore filter 16 B34 1 Fuel pressure after filter 17 F46 Leak fuel level 18 B5 3 Lube oil pressure before filter 19 B7 Lube oil temperature MS150120 00E 2014 11 General Information ...

Page 26: ...ure af ter filter 5 Y44 2 Fan control exter nal 6 B48 Pressure in HP fuel system 7 M8 HP fuel pump 8 B1 Camshaft speed 9 B43 Charge air coolant pressure 10 B26 Charge air coolant temperature 11 B6 Engine coolant tem perature 26 General Information MS150120 00E 2014 11 TIM ID 0000054363 002 ...

Page 27: ...5 25 Charge air coolant temperature C 45 45 45 Barometric pressure mbar 1000 1000 1000 Site altitude above sea level m 100 100 100 Power related data power ratings are net brake power as per ISO 3046 Description 12 V 4000 T95 12 V 4000 T95L 12 V 4000 T95R Rated engine speed A rpm 1900 1900 1900 Effective power w o fan fuel stop power ISO 3046 A kW 1865 1939 1680 General conditions for max power De...

Page 28: ...aust temperature after turbocharger R C 483 488 459 Coolant system high temperature circuit Description 12 V 4000 T95 12 V 4000 T95L 12 V 4000 T95R Coolant temperature at engine connection outlet to cooling system A C 105 105 105 Coolant temperature after engine warning R C 112 112 112 Coolant temperature after engine shutdown L C 114 114 114 Coolant antifreeze content max L 50 50 50 Pressure loss...

Page 29: ... engine inlet connection min when engine is starting L bar 0 1 0 1 0 1 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 1 5 1 5 General operating data Description 12 V 4000 T95 12 V 4000 T95L 12 V 4000 T95R Cold start capability Air temperature w o start assistance w o coolant preheating R C 0 0 0 Coolant preheating Preheating temperature min R C 40 40 40 Firing speed...

Page 30: ...rs 210 210 210 Weights main dimensions Description 12 V 4000 T95 12 V 4000 T95L 12 V 4000 T95R Dry engine weight basic configuration engine R kg 7990 7990 7990 Noise Description 12 V 4000 T95 12 V 4000 T95L 12 V 4000 T95R Exhaust noise unsilenced BL free field sound pres sure level Lp 1 m distance ISO 6798 3 dB A toler ance R dB A 113 114 112 Exhaust noise unsilenced BL sound power level LW ISO 67...

Page 31: ...3 2 Firing order Firing order Number of cylinders Firing order 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 MS150120 00E 2014 11 Technical Data 31 TIM ID 0000026627 002 ...

Page 32: ...3 3 Engine Main dimensions Engine Main dimensions Item Dimensions Length A approx 2650 mm Width B approx 1635 mm Height C approx 1948 mm 32 Technical Data MS150120 00E 2014 11 TIM ID 0000054364 001 ...

Page 33: ... engine oil level Page 163 Crank engine using starting system Page 109 Fuel prefilter Fill with fuel if fitted see manufacturer s documentation Coolant system If standstill for mote than one year Change engine coolant Page 172 Change charge air coolant Page 181 Coolant system Check engine coolant level Page 171 Check charge air coolant level Page 180 Coolant system Preheat coolant with coolant pre...

Page 34: ... system Check engine oil level Page 163 Coolant circuit Check engine coolant level Page 171 Check charge air coolant level Page 180 Coolant circuit Heat coolant with coolant preheater if available see manufacturer s docu mentation Engine control system Put into operation see manufacturer s documentation 34 Operation MS150120 00E 2014 11 TIM ID 0000002683 006 ...

Page 35: ...Engine operation Visually inspect engine 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 Battery charging generator Check battery charging generator for contamination clean as necessary Page 190 Exhaust system Check exhaust color Page 42 Fuel prefilter Drain wate...

Page 36: ...ge Wear ear protection Preparation Item Measure Coolant preheater Switch on if available see manufacturer s documentation Starting the engine Item Measure Control cabinet operator station etc depending on manufacturer 1 If there is a coolant preheater make sure that the coolant tempera ture 40 C see manufacturer s documentation 2 Press the start key see plant documentation Automatic starting seque...

Page 37: ...o overheating Before stopping the engine operate it in idle mode until the motor temperatures cool off and constant values are displayed Preparation Item Measure Engine Operate engine at idling speed for approx 5 minutes Stopping the engine Item Measure Switch cabinet operator station etc depending on manufacturer Press the stop key see plant documentation Automatic stopping sequence is executed M...

Page 38: ...ive the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tem perature the antifreeze concentration is 50 and the engine room temperature is below 40 C Engine Control System Switch off see manufacturer s documentation Air intake and exhaust sys tem If the engine is to remain out of service for more than one ...

Page 39: ...pressed air gun directly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protection 2 Prior to putting the cleaning unit into operation read the operating instructions of the water steam jet unit carefully and observe the safety precautions 3 For external cleaning of th...

Page 40: ...ilter Page 150 W1006 Replace fuel injectors Page 125 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 167 W1009 X Check layer thickness of the oil residue clean out and re place filter sleeve accomplish together with every oil change at the latest Page 169 W1011 Perform endoscopic examination Page 111 W1024 Check electric function of...

Page 41: ...195 W1675 X Replace fuel prefilter or fuel prefilter element Page 136 W1817 Check coupling rods of EGR flaps for play replace if neces sary Page 156 Page 158 W1854 Check function of charge air throttle not fitted X8100 X Check exhaust silencer condensate drain Page 204 X8101 X Check visually for damage Page 205 X8102 X Check for firm seating Page 206 Table 2 Maintenance task reference table QL1 MS...

Page 42: ...lug in connections loose u Checking plug in connections Page 199 Running gear blocked engine cannot be barred manually u Contact Service Engine turns on starting but does not fire Cause Corrective action Engine Too cold u Preheat 40 C Poor rotation by starter Battery UltraCaps low or faulty u Charge or replace battery UltraCaps manufacturer s documentation Engine wiring faulty u Check Page 194 Air...

Page 43: ...r defective u Contact Service Air in fuel system u Vent fuel system Page 132 Engine governor defective u Contact Service Charge air temperature too high Cause Corrective action Incorrect coolant concentration u Check MTU test kit Intercooler dirty u Contact Service Engine room Air intake temperature too high u Check fans and air supply exhaust ducts Charge air pressure too low Cause Corrective act...

Page 44: ...ton rings or cylinder liner defective u Contact Service White exhaust gas Cause Corrective action Engine is not at operating temperature u Preheat run up to operating temperature Water in fuel u Check fuel system at fuel prefilter manufacturer s documentation Drain water from fuel prefilter manufacturer s documentation Intercooler leaky u Contact Service 44 Troubleshooting MS150120 00E 2014 11 TIM...

Page 45: ...rrective 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 Intercooler not operating correctly 1 Reduce power 2 Check intercooler 3 Contact Service 6 SS T Charge Air ZKP Number 2 0121 932 Charge air temperature too high limit value 2 Red alarm engine shutdown C...

Page 46: ...ce 15 LO P Lube Oil ZKP Number 2 0100 921 Lube oil pressure too low limit value 1 Yellow alarm warning Cause Corrective action Insufficient oil u Check oil level top up as necessary Page 163 16 SS P Lube Oil ZKP Number 2 0100 922 Lube oil pressure too low limit value 2 Red alarm engine shutdown Cause Corrective action Insufficient oil 1 Check oil level top up as necessary Page 163 2 Acknowledge al...

Page 47: ...7 932 Exhaust temperature B side too high limit value 2 Red alarm engine shutdown Cause Corrective action Cable damage 1 Check air filter and wiring Page 194 2 Contact Service 23 LO Coolant Level ZKP Number 2 0152 921 Coolant level too low limit value 1 Yellow alarm warning Cause Corrective action Leak in coolant circuit u Check coolant level in expansion tank Page 171 25 HI P Diff Lube Oil ZKP Nu...

Page 48: ...2 Red alarm engine shutdown Cause Corrective action No fuel injection 1 Restart engine Fault can possibly be eliminated through restart Page 36 2 Contact Service 31 HI ETC1 Overspeed ZKP Number 2 3011 931 Speed of primary turbocharger too high limit value 1 Yellow alarm warning Cause Corrective action Obstructed charge air circuit or fault in turbocharger 1 Reduce power 2 Check air filter 3 Contac...

Page 49: ...bocharger too high limit value 1 Yellow alarm warning Cause Corrective action Obstructed charge air circuit or fault in turbocharger 1 Reduce power 2 Contact Service 37 SS ETC2 Overspeed ZKP Number 2 3013 912 Speed of 1st secondary turbocharger too high limit value 2 Red alarm engine shutdown Cause Corrective action Obstructed charge air circuit or fault in turbocharger u Contact Service 44 LO Coo...

Page 50: ...nt oil 1 Check engine oil level Page 163 2 Contact Service 57 LO P Coolant ZKP Number 2 0101 921 Coolant pressure too low limit value 1 Yellow alarm warning Cause Corrective action Leak in coolant circuit 1 Check coolant level Page 171 2 Check coolant circuit 58 SS P Coolant ZKP Number 2 0101 922 Coolant pressure too low limit value 2 Red alarm engine shutdown or reduced injection quantity Cause C...

Page 51: ... 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 36 6 Contact Service 63 HI P Crankcase ZKP Number 2 0106 931 Crankcase pressure too high limit value 1 Yellow alarm warning Cause Corrective action Crankcase extraction system obstructed or leaking 1 Reduce power 2...

Page 52: ...Check fuel lines for leaks 2 Check filter fuel on low pressure side 3 Replace fuel filter Page 133 4 Contact Service 67 HI T Coolant ZKP Number 2 0120 931 Coolant temperature too high limit value 1 Yellow alarm warning Cause Corrective action Coolant circuit not operating correctly e g damage leaks low coolant level 1 Reduce power 2 Check coolant circuit 68 SS T Coolant ZKP Number 2 0120 932 Coola...

Page 53: ...on readjusted towards late Cause Corrective action HP fuel block jamming or HP fuel control block wiring faulty 1 Check wiring Page 194 2 Contact Service 83 LO P Fuel Common Rail ZKP Number 2 0104 921 Rail pressure set value Red alarm DBR limitation Cause Corrective action HP fuel control block faulty or leakage in HP fuel system u Contact Service 89 SS Engine Speed Too Low ZKP Number 2 2500 030 E...

Page 54: ...ed 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 temperature too low limit value 2 Red alarm engine start interlock Cause Corrective action Preheater not working 1 Check preheater 2 Contact Service 94 LO T Preheat ZKP Number 2 1090 921 Preheating te...

Page 55: ...onitoring 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 warning Cause Corrective action Supply voltage at engine governor too low 1 Check engine governor supply voltage 2 Contact Service 119 LOLO ECU Supply Voltage ZKP Number 2 0140 922 Supply voltage too low ...

Page 56: ...ntact 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 ventilation 141 AL Power Too High ZKP Number 1 1088 007 Maximum value exceeded Yellow alarm warning Cause Corrective action Average power value has exceeded the defined maximum value over the last 24...

Page 57: ...d 1 Check devices connected to CAN 2 Check wiring Page 194 3 Contact Service 182 AL CAN Wrong Parameters ZKP Number 2 0500 682 Incorrect parameters at CAN Yellow alarm warning Cause Corrective action Incorrect parameter values entered in data record u Contact Service 183 AL CAN No PU Data ZKP Number 2 0500 683 CAN PU data not present or available Yellow alarm warning Cause Corrective action The se...

Page 58: ...f 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 overload 1 Check CAN bus for short circuit rectify short circuit as required 2 Check shielding improve shielding if necessary 3 Contact Service 188 AL CAN2 Bus Off ZKP Number 2 0500 688 CAN controller 2 is...

Page 59: ...Fault is corrected after engine is restarted Page 36 3 Contact Service 202 SD T Fuel ZKP Number 1 8004 572 Fuel temperature sensor signal error Yellow alarm warning Cause Corrective action Fuel temperature sensor faulty Short circuit or wire break 1 Check sensor and wiring B33 replace as necessary Page 194 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 203 SD T Charge Air...

Page 60: ...d after engine is restarted Page 36 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 temperature sensor on A side faulty Short circuit or wire break 1 Check sensor and wiring B4 21 replace as necessary Page 194 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 207...

Page 61: ...ected after engine is restarted Page 36 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 sensor faulty Short circuit or wire break 1 Check sensor and wiring B16 replace as necessary Page 194 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 213 SD P Coolant Intercooler ...

Page 62: ...ace as necessary Page 194 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 216 SD T Lube Oil ZKP Number 1 8004 575 Lube oil temperature sensor signal error Yellow alarm warning Cause Corrective action Lube oil temperature sensor faulty Short circuit or wire break 1 Check sensor and wiring B7 replace as necessary Page 194 2 Fault is corrected after engine is restarted Page 3...

Page 63: ...s corrected after engine is restarted Page 36 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 Leak off fuel level sensor faulty Short circuit or wire break 1 Check sensor and wiring F46 replace as necessary Page 194 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 223 SD ...

Page 64: ... 194 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 229 AL Stop Camshaft Sensor Defect ZKP Number 1 8004 562 Stop camshaft sensor signal error Red alarm engine shutdown Cause Corrective action Camshaft sensor faulty and a prior camshaft sensor fault in the same operating cycle 1 Check sensor and wiring to connector B1 replace as necessary Page 194 2 Fault is corrected aft...

Page 65: ...Page 194 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 233 SD Charger 2 Speed ZKP Number 1 3011 129 Secondary turbocharger speed sensor signal error Yellow alarm warning Cause Corrective action Speed sensor of secondary turbocharger faulty Short circuit or wire break 1 Check sensor and wiring B44 2 replace as necessary Page 194 2 Fault is corrected after engine is restar...

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 Check speed setting transmitter and wiring replace as necessary Page 194 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 268 SD Skidding Analog Value ZKP Number 2 8006 591 Skid s...

Page 67: ...peed 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 wiring cylinder A1 1 Check injector solenoid valve replace injector if required Page 125 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 322 AL Wiring Cylinder A2 ZKP Number 1 80...

Page 68: ...ault is corrected after engine is restarted Page 36 3 Contact Service 325 AL Wiring Cylinder A5 ZKP Number 1 8004 524 Wiring faulty cylinder A5 Yellow alarm misfiring Cause Corrective action Short circuit fault in injector wiring cylinder A5 1 Check injector solenoid valve replace injector if required Page 125 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 326 AL Wiring C...

Page 69: ...ult is corrected after engine is restarted Page 36 3 Contact Service 329 AL Wiring Cylinder A9 ZKP Number 1 8004 528 Wiring faulty cylinder A9 Yellow alarm misfiring Cause Corrective action Short circuit fault in injector wiring cylinder A9 1 Check injector solenoid valve replace injector if required Page 125 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 330 AL Wiring Cy...

Page 70: ...ault is corrected after engine is restarted Page 36 3 Contact Service 333 AL Wiring Cylinder B3 ZKP Number 1 8004 532 Wiring faulty cylinder B3 Yellow alarm misfiring Cause Corrective action Short circuit fault in injector wiring cylinder B3 1 Check injector solenoid valve replace injector if required Page 125 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 334 AL Wiring C...

Page 71: ...ault is corrected after engine is restarted Page 36 3 Contact Service 337 AL Wiring Cylinder B7 ZKP Number 1 8004 536 Wiring faulty cylinder B7 Yellow alarm misfiring Cause Corrective action Short circuit fault in injector wiring cylinder B7 1 Check injector solenoid valve replace injector if required Page 125 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 338 AL Wiring C...

Page 72: ...act 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 injector wiring for disruption 2 Rule out any disruption in injector solenoid valve replace injector if required Page 125 3 Fault is corrected after every working cycle 4 Contact Service 342 AL Open L...

Page 73: ... 125 3 Fault is corrected after every 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 Disruption fault in injector wiring cylinder A5 1 Check injector wiring for disruption 2 Rule out any disruption in injector solenoid valve replace injector if required Page 125 3 Fault is corrected...

Page 74: ...125 3 Fault is corrected after every 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 Disruption fault in injector wiring cylinder A9 1 Check injector wiring for disruption 2 Rule out any disruption in injector solenoid valve replace injector if required Page 125 3 Fault is corrected ...

Page 75: ... 125 3 Fault is corrected after every 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 Disruption fault in injector wiring cylinder B3 1 Check injector wiring for disruption 2 Rule out any disruption in injector solenoid valve replace injector if required Page 125 3 Fault is corrected...

Page 76: ... 125 3 Fault is corrected after every 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 Disruption fault in injector wiring cylinder B7 1 Check injector wiring for disruption 2 Rule out any disruption in injector solenoid valve replace injector if required Page 125 3 Fault is corrected...

Page 77: ... injector if required Page 125 3 Fault is corrected after every working cycle 4 Contact Service 361 AL Injector Output Stage Low ZKP Number 1 8004 496 Internal electronic fault Red alarm engine shutdown possible Cause Corrective action Electronics possibly faulty 1 Start ITS 2 Replace engine governor if required 3 Check additional fault messages if ITS indicates Electronics OK e g wiring faulty 4 ...

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 194 2 Restart engine Page 36 3 Replace wiring harness if necessary 4 Contact Service 381 AL Wiring TOP 1 ZKP Number 2 8006 638 Line disruption on digital input 1 Yellow alarm warning Cause Corrective action Short circuit or broken wire on transistor ou...

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 power Cause Corrective action Excessive permanent engine load u If the alarm remains contact Service 400 AL Open Load Digital Input 1 ZKP Number 2 8006 625 Line disruption on digital input 1 Yellow alarm...

Page 80: ...1 Check wiring Page 194 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 action Wiring faulty No resistance over switch 1 Check wiring Page 194 2 Check target device input 3 Contact Service 404 AL Open Load Digital Input 5 ZKP Number 2 8006 629 Line disruption on digital inp...

Page 81: ...iring Page 194 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 Wiring faulty No resistance over switch 1 Check wiring Page 194 2 Check target device input 3 Contact Service 408 AL Open Load Emergency Stop Input ESI ZKP Number 2 8006 633 Open circuit at input for emer...

Page 82: ... Page 194 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 or faulty power supply 1 Check wiring Page 194 2 Check power supply 3 Contact Service 413 HIHI U PDU ZKP Number 2 0141 932 Injector voltage too high limit value 2 Red alarm engine shutdown Cause Cor...

Page 83: ... in intercooler too low limit 2 Red alarm engine shutdown Cause Corrective action Leak in coolant circuit u Top up charge air coolant Page 185 417 SD Level Water Fuel Prefilter ZKP Number 1 8004 594 Fuel prefilter water level sensor signal error Yellow alarm warning Cause Corrective action Water level sensor of fuel prefilter is faulty Short circuit or wire break 1 Check sensor and wiring replace ...

Page 84: ... voltage faulty Yellow alarm warning Cause Corrective action Sensor defect of injector power stage or internal fault of engine governor 1 Replace engine governor 2 Contact Service 445 SD P Ambient Air ZKP Number 1 8004 580 Ambient air pressure sensor signal error Yellow alarm warning Cause Corrective action Ambient air pressure sensor faulty 1 Replace engine governor 2 Contact Service 446 SD P HD2...

Page 85: ...Corrective action Input signal for start end torque faulty Short circuit or wire break 1 Check signal transmitter and wiring replace as necessary Page 194 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 454 SS Power Limitation Active ZKP Number 2 7000 011 Derating has been activated Red alarm derating has been activated Cause Corrective action Engine operation outside stan...

Page 86: ...lace as necessary Page 194 2 Contact Service 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 Check sensor and wiring replace as necessary Page 194 2 Restart engine Page 36 3 Contact Service 471 SD Suction Restrictor ZKP Number 1 8004 592 Signal error ...

Page 87: ...wn 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 Crash Rec Init Error ZKP Number 1 8010 007 Initialization error of crash recorder Cause Corrective action Initialization error of crash recorder u Contact Service 478 AL Yellow Summary Alarm Plant ZKP ...

Page 88: ...2 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 Overspeed ZKP Number 2 3014 932 Speed of 2nd secondary turbocharger too high limit value 2 Red alarm engine shutdown Cause Corrective action Obstructed charge air circuit or fault in turbocharger u Reduc...

Page 89: ...nnection 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 Generator ZKP Number 1 4500 902 Open circuit at battery charging generator connection to POM Yellow alarm warning Cause Corrective action Wiring faulty or no resistance over switch u Check connection ...

Page 90: ...iring Page 194 507 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 POM sends a different ID number than expected Yellow alarm warning Cause Corrective action If alarm 504 also appears the resistance in the POM wiring is missing u Check POM wiring harness 510 AL Ove...

Page 91: ...place as necessary Page 194 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 channel PWM_CM1 1 Check wiring to connected device or check connected device itself actuator sensor and replace if necessary Page 194 2 Contact Service 549 AL Voltage interruption ZKP Number 2 7001 9...

Page 92: ...DBR 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 circuit or wire break u Check sensor and wiring replace as necessary Page 194 581 AL Wiring PWM_CM3 ZKP Number 1 1041 923 Wiring problem at PWM_CM3 channel Yellow alarm warning Cause Corrective action C...

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 necessary Page 194 2 Contact Service 588 SD P Oil Replenishment Pump ZKP Number 1 0159 910 Replenishment pump oil pressure sensor signal error Yellow alarm warning Cause Corrective action Pressure sensor fau...

Page 94: ...d 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 Corrective action Cable break or short circuit on channel PWM_CM5 1 Check wiring to connected device or check connected device itself actuator sensor and replace if necessary Page 194 2 Contact Service 5...

Page 95: ...low 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 194 2 Contact Service 602 AL CAN Engine Start Lock ZKP Number 2 1090 930 Start interlock signal from plant pending Yellow alarm warning Cause Corrective action Start interlock initiated by plant u The alarm is reset by canceling the engine start...

Page 96: ...to connected device or check connected device itself actuator sensor and replace if necessary Page 194 2 Contact Service 610 AL Wiring HP Fuel Control Block 1 ZKP Number 1 1301 902 Wiring faulty at HP fuel control block 1 Yellow alarm warning Cause Corrective action Cable break or short circuit on PWM channel HP fuel control block 1 1 Check wiring Page 194 2 Contact Service 611 AL Wiring HP Fuel C...

Page 97: ...valve 2 1 Check wiring Page 194 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 prefilter not operating correctly 1 Replace fuel prefilter 2 Contact Service 615 AL EIL Protection ZKP Number 2 0610 951 Alarm for Protection module Red alarm warning Cause Corrective action Incorrec...

Page 98: ...onnected device or check connected device itself actuator sensor and replace if necessary Page 194 2 Contact Service 627 AL Wiring PWM_CM9 ZKP Number 1 1041 929 Wiring problem at PWM_CM9 channel Yellow alarm warning Cause Corrective action Cable break or short circuit on channel PWM_CM9 1 Check wiring to connected device or check connected device itself actuator sensor and replace if necessary Pag...

Page 99: ...circulation 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 Cause Corrective action Actuator fault at bypass flap or flap mechanical system defective 1 Replace actuator or flap 2 Contact Service 632 AL Dispenser Flap Defect ZKP Number 1 0700 071 Dispenser fl...

Page 100: ...091 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 194 2 Contact Service 636 SD Level Lube Oil J1939 ZKP Number 1 0700 105 Oil level sensor J1939 signal error Yellow alarm warning Cause Corrective action Oil level sensor J1939 faulty 1 Check sensor and wiring repla...

Page 101: ...r wire break 1 Check sensor and wiring B34 3 replace as necessary Page 194 2 Fault is corrected after engine is restarted Page 36 3 Contact Service 644 AL L1 P Fuel Upstr o F ZKP Number 2 0164 921 Fuel supply pressure before optional filter too low limit value 1 Yellow alarm warning Cause Corrective action Leaking or obstructed fuel lines or fuel tank empty u Check filter fuel low pressure side 64...

Page 102: ...ak 1 Check sensor and wiring B10 11 replace as necessary Page 194 2 Fault is corrected after engine is restarted Page 36 662 SD Smart NOx Heating Element ZKP Number 1 0700 141 Smart NOx sensor heating element signal error Yellow alarm warning Cause Corrective action Smart NOx heating element faulty Short circuit or wire break 1 Check sensor and wiring replace as necessary Page 194 2 Contact Servic...

Page 103: ...se Corrective 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 other fault codes Page 194 2 Check Lambda sensor and wiring Page 194 3 Check charge air pressure sensor and wiring Page 194 4 Check NOx sensor and wiring Page 194 5 Check bypass EGR and dispenser ...

Page 104: ...oler 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 circuit or wire break 1 Check wiring Page 194 2 Contact Service 764 AL EASF B to A Open ZKP Number 1 2510 125 Emergency air shutoff flap B closed but emergency air shutoff flap A remained open Cause Corre...

Page 105: ...use Corrective action Flaps A and B stuck Flaps A and B were not energized Short circuit or wire break 1 Check flap B Page 152 2 Check wiring Page 194 3 Contact Service 833 AL Emission Warning ZKP Number 2 1600 008 Emission warning Yellow alarm warning Cause Corrective action NOx regulator not active Lambda regulator not active Charge air regulator not active Lambda regulator at stop Charge air pr...

Page 106: ...other fault codes 2 Check sensor and wiring Page 194 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 Emergency air shutoff flap A was closed manually Short circuit or wire break 1 Check flap A Page 152 2 Check wiring Page 194 3 Contact Service 840 AL EASF B Not Closed by ECU ZKP Number 1 2510 135 ...

Page 107: ...66 1 Ratchet with extension F30006212 1 DANGER Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone Barring engine manually on gear 1 Loosen screws 1 and remove end cov er 2 from flywheel housing MS150120 00E 2014 11 Task Description 107...

Page 108: ... in reverse Barring engine manually through starter opening 1 Loosen screws 1 and remove end cov er 2 from flywheel housing Note Use barring gear F6792918 2 Engage barring gear 2 in ring gear and mount on flywheel housing 3 Fit ratchet 1 with socket onto barring gear 2 Note No resistance other than compression re sistance may be encountered 4 Rotate crankshaft in engine direction of ro tation Resu...

Page 109: ...rom the engine Barring engine with starting sys tem 1 Release latch 1 of connector X3 2 Note Seal unused connectors with the supplied protective cap 2 Remove connector from engine governor 3 Turn engine in unloaded condition Press START button 4 Let the crankshaft rotate until oil pressure is indicated 5 Engine start is interrupted automatically af ter the max permissible time 6 Repeat this proced...

Page 110: ... no persons in the en gine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine Test run 1 Start engine Page 36 2 Perform test run not below 1 3 load and at least until steady state temperature is reached 3 Carry out operational checks Page 35 4 Stop engine Page 37 110 Task Description MS150120 00E 2014 11 TIM ID 000000087...

Page 111: ...n top piston 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 bores Running pattern seems darker No actions required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined and do not cov...

Page 112: ...pending 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 126 2 Install cylinder head cover Page 121 112 Task Description MS150120 00E 2014 11 TIM ID 0000003304 006 ...

Page 113: ...und the liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and may be interrupted Findings not critical Corrosion fields spots Corrosion fields spots result from water condensed water with the valves in the overlap open position They are clearly visible due to the...

Page 114: ...ation are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspection be carried out after further operation of the engine 114 Task Description MS150120 00E 2014 11 TIM ID 0000000014 015 ...

Page 115: ...Catalog Locknut Spare Parts Catalog Washer 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 Oil mist fine separator Re placement 1 Remove line 1 from oil heat exchanger 2 Remove pipe clamps 2 3 Remove screws 4 with w...

Page 116: ...ng 5 if necessary 10 Remove sealing ring 5 cover 4 and filter cover 3 11 Fit new locknut 1 and new washer 2 and tighten locknut 1 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Locknut M10 Tightening torque 10 Nm 3 Nm 12 Replace further oil mist fine separators in the same way 116 Task Description MS150120 00E 2014 11 TIM ID 0000054365 003 ...

Page 117: ...ts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head upper section Page 121 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 upper section Page 121 MS150120 00E 2014 11 Task Description 117 TIM ID 0000055644 001 ...

Page 118: ...F30002815 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head upper section Page 121 2 Install barring device Page 107 Note The OT mark 1 if fitted on the flywheel must not be used for reference 3 Rotate crankshaft with barring device in en gine direction of rotation until OT A1 mark and pointer are aligned 118 Task Description ...

Page 119: ...ge to determine the distance between valve bridge and rocker arm 5 If the deviation from the set value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Release locknut 1 2 Insert feeler gauge 3 between valve bridge and rocker arm 3 Using Allen key set adjusting screw 2 so that the specified valve clearance is provid ed Note Feeler gauge must just pass through the gap 4 Insert feel...

Page 120: ...Final steps 1 Remove barring device Page 107 2 Install cylinder head upper section Page 121 3 Enable engine start 120 Task Description MS150120 00E 2014 11 TIM ID 0000055645 001 ...

Page 121: ...g cylinder head cover 1 Clean very dirty cylinder head cover upper section 2 prior to removal 2 Remove screws 4 5 with washers 3 6 3 Take off cylinder head cover upper sec tion 2 with sealing ring 1 from cylinder head cover lower section 7 4 Screw out ESD connector 8 from cylinder head cover lower section 7 5 Remove screws 4 5 with washers 3 6 6 Take off cylinder head cover lower sec tion 2 with s...

Page 122: ...ector 8 in cylinder head cover lower section 7 and use torque wrench to tighten it to the specified tightening torque Name Size Type Lubricant Value Standard Nut Tightening torque 6 Nm 1 Nm 7 Check sealing ring 1 for damage replace if necessary 8 Coat sealing ring 1 with assembly compound 9 Place sealing ring 1 and cylinder head cover upper section 2 onto cylinder head cover lower sec tion 7 10 In...

Page 123: ...urces Do not smoke WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE HP fuel pump not filled with engine oil Damage to components major material damage Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation Preparatory steps u Loosen nut 2 and remove the...

Page 124: ...Filling HP pump 1 Remove plug screw 1 2 Use pump oiler to fill HP pump with engine oil until engine oil emerges 3 Screw in plug screw 1 124 Task Description MS150120 00E 2014 11 TIM ID 0000042838 002 ...

Page 125: ...lacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 126 MS150120 00E 2014 11 Task Description 125 TIM ID 0000042329 002 ...

Page 126: ...2768 1 Assembly paste Optimoly Paste White T 40477 1 Assembly compound Kluthe Hakuform 30 15 X00067260 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 Nameplate 1 DMC Data Matrix Code 2 Serial number 3 L Orange part number 4 MTU part number 5 EIM ID Preparatory steps 1 Shut off fu...

Page 127: ...rom rail 4 and cylinder head Note While the adapter is removed the injector is drained 3 Provide suitable container to collect escap ing fuel 4 Remove adapter 1 5 Loosen union nuts and remove return line 6 6 Remove screw 2 from hold down clamp 1 MS150120 00E 2014 11 Task Description 127 TIM ID 0000053873 001 ...

Page 128: ...g cutter 13 Fit the cap of the new injector on the old injector to seal it 14 Cover all connections and bores or seal with suitable plugs Installing injector Note Do not remove plug for HP line until direct ly before assembly of the adapter 1 Prior to installation remove plug 2 Coat injector with assembly paste at the seat of the nozzle retaining nut Note A new sealing ring is included in the scop...

Page 129: ... with hold down clamp into cylinder head ensuring that the high pressure fuel line connection is aligned correctly 6 Press in injector 1 and hold down clamp with installation removal jig 2 7 Remove force in tool 8 Coat screw head mating face on hold down clamp 1 and screw head mating face and thread of screw 2 with engine oil MS150120 00E 2014 11 Task Description 129 TIM ID 0000053873 001 ...

Page 130: ...ter 1 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Adapter M18 Tightening torque Engine oil 100 Nm 10 Nm Note Ensure special cleanness 14 Coat thread and sealing cone of HP line 3 with engine oil 15 Use torque wrench to tighten union nuts 2 5 on HP line 3 to specified tightening torque Tightening sequence 1 Nut on adapter 2 2 Nut on rail 5 Name Size...

Page 131: ...r Note If the CDC parameters are not reset the emission certification of the engine be comes invalid 19 Reset CDC parameters Page 195 Final steps 1 Install cylinder head cover Page 121 2 Open fuel supply to engine MS150120 00E 2014 11 Task Description 131 TIM ID 0000053873 001 ...

Page 132: ... of severe component damage and other severe damage Avoid naked flames electrical sparks and ignition sources Do not smoke Venting LP fuel system 1 Open threaded vent plug 1 and connect a suitable hose 2 Provide suitable container to collect escap ing fuel 3 Unlock fuel priming pump screw out han dle 2 by turning it counterclockwise 4 Operate the pump with the handle 2 until bubble free fuel emerg...

Page 133: ...TICE Fuels are flammable and explosive Risk of severe component damage and other severe damage Avoid naked flames electrical sparks and ignition sources Do not smoke Fuel filter Replacement 1 Provide a suitable container to collect the fuel 2 Remove easy change filter 2 with filter wrench 3 Clean sealing surface on filter head 1 4 Coat seal on easy change filter 2 slightly with engine oil arrow 5 ...

Page 134: ...gnition sources Do not smoke Additional fuel filter Replace ment 1 Provide suitable container to collect escap ing fuel 2 Remove easy change filter 2 with filter wrench 3 Clean sealing surface on filter head 1 4 Coat gasket on easy change filter 2 slight ly with engine oil arrow 5 Screw on easy change filter 2 by hand un til the seal makes contact with the filter head and tighten manually 6 Replac...

Page 135: ...flames electrical sparks and ignition sources Do not smoke Preparatory steps 1 Shut off fuel supply to the engine 2 Provide suitable container to collect escaping fuel Fuel prefilter Draining 1 Open vent plug 1 2 Open drain valve 2 3 Drain water and dirt until clean fuel emerg es 4 Close drain cock 2 5 Close vent plug 1 Final steps u Open up fuel supply to engine MS150120 00E 2014 11 Task Descript...

Page 136: ...cing filter element 1 Close shut off valve in fuel supply line 2 Open vent plug 1 of the filter 3 Unlock drain cock 2 by pressing toggle and open it 4 Drain water and dirt from filter 5 Close drain cock 2 6 Remove screws 6 securing the cover 1 and take off cover 7 Remove spring 2 and filter element 3 8 Insert new filter element 3 and spring housing 2 9 Fill filter housing with clean fuel 10 Insert...

Page 137: ...aterial Spare parts Designation Use Part No Qty Turbine housing Spare Parts Catalog Exhaust turbocharger low pressure charger u Check turbine housing Page 138 Exhaust turbocharger high pressure u Check turbine housing Page 143 MS150120 00E 2014 11 Task Description 137 TIM ID 0000026625 003 ...

Page 138: ... Component is hot Risk of burning Wear protective gloves WARNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Note The following activity steps are only described for one exhaust turbocharger LP The description ap plies inversely to the other side Checking of the turbine housing of the HP exhaust turb...

Page 139: ...screws 2 3 and take off with heat shield 1 and washers Removing exhaust elbow Note Mark position of clamp 1 Unscrew screws 4 and remove from con sole with spacer sleeves 5 2 Release clamp 2 and take off with sealing ring 3 and exhaust elbow 1 from turbine housing MS150120 00E 2014 11 Task Description 139 TIM ID 0000054791 001 ...

Page 140: ...w 1 with clamp 2 and 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 threads of screw 4 with assembly paste prior to installation 3 Install screws 4 and spacer sleeves 5 on console and tighten to specified tightening torque Name Size Type Lubricant Value St...

Page 141: ...ghtening torque Name Size Type Lubricant Value Standard Screws Tightening torque Engine oil 42 Nm 4 Nm 2 Install holder 4 with washers and screws 3 and washers and tighten 3 Install holder 2 with washers and screws 1 and washers and tighten MS150120 00E 2014 11 Task Description 141 TIM ID 0000054791 001 ...

Page 142: ...4 Install retainers 4 and lashing plate 2 5 Install spacer sleeves 3 and screws 1 and tighten 142 Task Description MS150120 00E 2014 11 TIM ID 0000054791 001 ...

Page 143: ...atalog WARNING Component is hot Risk of burning Wear protective gloves WARNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Note The procedure is only described for the exhaust turbocharger HP Checking of the exhaust turbocharg er turbine housing LP requires separate activities Page 138 Removing lashi...

Page 144: ... with hold er 2 and washers 4 Remove screws 2 and take off with heat shield 1 and washers Removing exhaust pipe insula tion u Release clamps 1 and remove insula tion 2 144 Task Description MS150120 00E 2014 11 TIM ID 0000054792 001 ...

Page 145: ...1 and remove insulation 2 Checking turbine housing Note Cracks are only permissible in the direction of circumference of the spiral u Check turbine housing from the inside for cracks Result If the crack is larger than the maximum permissible crack length x 30 mm or if transverse cracks are present contact Service MS150120 00E 2014 11 Task Description 145 TIM ID 0000054792 001 ...

Page 146: ...p 2 with torque wrench to specified tightening torque Name Size Type Lubricant Value Standard Nut Tightening torque Assembly paste Ul tra Therm MTU 27 Nm 2 Nm Installing exhaust pipe insula tion u Install insulation 2 on exhaust pipe and secure with clamps 1 146 Task Description MS150120 00E 2014 11 TIM ID 0000054792 001 ...

Page 147: ...ews 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 2 with washers and screws 1 and washers and tighten MS150120 00E 2014 11 Task Description 147 TIM ID 0000054792 001 ...

Page 148: ...3 Install retainers 4 and lashing plate 2 4 Install spacer sleeves 3 and screws 1 and tighten 148 Task Description MS150120 00E 2014 11 TIM ID 0000054792 001 ...

Page 149: ...id Risk of chemical burns Wear protective goggles Wear protective gloves Intercooler Leak check 1 With the engine at standstill open the plug screws in the charge air elbows on the left and right engine sides on driving end ar rows 2 If necessary use a suitable tool to remove obstructions and check the openings for coolant discharge Result If a large amount of coolant is discharged contact Service...

Page 150: ...lacement 1 Release latches 1 2 Remove cover 2 3 Remove filter insert 3 and filter ele ment 4 4 Wipe out filter housing 5 and cover 2 with a damp cloth 5 Insert new filter element 4 and filter in sert 3 6 Installation is in reverse sequence of re moval 150 Task Description MS150120 00E 2014 11 TIM ID 0000057592 001 ...

Page 151: ...bled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 150 2 After installation of new filter press reset button 1 Result Engaged piston with signal ring moves back to initial position MS150120 00E 2014 11 Task Description 151 TIM ID 0000005484 009 ...

Page 152: ...th emergency air shutoff flaps and their wiring for mechanical damage 2 Make sure that the pointers 1 of both emergency air shutoff flaps are pointing to OPEN ON and the emergency air shutoff flaps are open 3 Start engine Page 36 4 Reduce the overspeed limit 5 Run up the engine without a load 6 Check the following functions Close both emergency air shutoff flaps at latest when a speed of approx 90...

Page 153: ...engine 4 Check the following functions Both emergency air shutoff flaps close immediately when triggered The emergency air shutoff flaps are completely closed and the pointers 1 point to CLOSED OFF Result If one or both emergency air shutoff flaps do not completely close or don t close at all shut off the engine and notify Service If necessary observe the fault message er ror log 5 Before starting...

Page 154: ...7 13 Exhaust Gas Recirculation 7 13 1 Exhaust flaps Overview 1 EGR shutoff flap 2 Donor cylinder flap 154 Task Description MS150120 00E 2014 11 TIM ID 0000027110 005 ...

Page 155: ...1 Bypass flap MS150120 00E 2014 11 Task Description 155 TIM ID 0000027110 005 ...

Page 156: ...st flaps 2 Check operability and ease of movement of coupling rod 1 by moving it at the speci fied points arrows and make sure that there is no excessive play Result Replace coupling rod 1 if it is jamming sluggish or features excessive play Page 158 3 Check whether the internal spring pulls the flap into the F position Fail safe position for bypass flap and EGR shutoff flap opened Fail safe posit...

Page 157: ... rod 1 by moving it at the speci fied points arrows and make sure that there is no excessive play Result Replace coupling rod 1 if it is jamming sluggish or features excessive play Page 158 MS150120 00E 2014 11 Task Description 157 TIM ID 0000044535 002 ...

Page 158: ...ARNING Exhaust flaps air flaps close rapidly Risk of crushing Using a suitable tool check exhaust flaps air flaps by pressing the actuating linkage to its limit several times and releasing it WARNING Component is hot Risk of burns Wear protective goggles Removing coupling rods bypass and EGR shutoff flaps Note For installation position of exhaust flaps refer to overview Page 154 1 Remove guard pla...

Page 159: ...g rod donor cylinder flap Note For installation position of exhaust flaps refer to overview Page 154 1 Remove guard plates of exhaust flap 2 Remove locknuts 4 3 Remove washers 3 4 Remove locking screw 1 and locknut 2 Result Lever detached from actuator output shaft 5 Remove coupling rod and lever 6 Take off washers 5 Installing coupling rod donor cylinder flap 1 Insert coupling rod and washers 5 2...

Page 160: ...lowing each change to the mechanism of the exhaust recirculation system an actuator test teach in routine with DiaSys must be carried out Page 196 160 Task Description MS150120 00E 2014 11 TIM ID 0000044549 003 ...

Page 161: ...heck 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 194 MS150120 00E 2014 11 Task Description 161 TIM ID 0000000905 017 ...

Page 162: ...ne is stopped and starting disabled Engine oil level check at sight glass 1 Make a preliminary visual check of oil lev el 2 at the sight glass 1 2 A proper engine oil level check must al ways be carried out using the oil dipstick Page 163 162 Task Description MS150120 00E 2014 11 TIM ID 0000038098 002 ...

Page 163: ...with 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 dipstick from guide tube and wipe it 2 Insert dipstick into guide tube up to the stop pull out after approx 10 seconds Check oil level on the dipstick side marked IDLE 3 Oil level must not be lower than the min mark 4 If necessary top up to max mark Page 164 Checking oil leve...

Page 164: ...k of burns Risk of poisoning Wear protective clothing protective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil 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 plugs 1 on driving and free end and drain engine oil 3 Fit drain plugs 1 on drivin...

Page 165: ...ricant Value Standard Screw M18 x 1 5 Tightening torque Engine oil 50 Nm 10 Nm 6 Screw in drain plugs 2 4 and tighten with torque wrench to the specified torque Name Size 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 Lubricant Value Standard Screw M48 x ...

Page 166: ...Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine oil Sample extraction and analysis 1 With the engine running at operating tem perature open screw 1 on flange of cen trifugal oil filter by 1 to 2 rotations 2 Drain approx 2 liters ...

Page 167: ...ng Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Stop engine and disable engine start 2 After warning up and directly stopping the engine open the vent plug 1 on the oil heat exchanger 3 Wait 5 minutes until the oil system is vent ed and the oil has drained off Note Always use a new sealing ring for the vent ...

Page 168: ...d safety valve 7 Check condition of the new oil filter sealing ring and coat it with engine oil 8 Screw the engine oil filter on and tighten by hand 9 Replace other engine oil filters in the same way 10 Bar the engine using the starting system Page 109 11 Check engine oil level Page 163 168 Task Description MS150120 00E 2014 11 TIM ID 0000028834 005 ...

Page 169: ... 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 gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing ri...

Page 170: ...ush standpipe 11 onto rotor lower sec tion 9 13 Insert the new filter sleeve with stiffener plate in rotor cap 12 with the smooth sur face facing the rotor cap 14 Check sealing ring 10 fit new one if nec essary Coat sealing ring with grease and insert in groove of rotor cap 12 15 Place rotor cap 12 onto standpipe 11 16 Hold rotor assembly 12 firmly in position with filter wrench and tighten knurle...

Page 171: ...ue to turn cap counterclockwise and remove 3 Check engine coolant level engine coolant must be visible at bottom edge of cast in eye of filler neck Checking engine coolant level at remote cooler Note Engine coolant must be visible at marker plate 1 Check engine coolant level 2 Top up engine coolant as necessary Page 175 3 Check and clean cap 4 Place cap on filler neck and close Checking engine coo...

Page 172: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 173 2 Fill with engine coolant Page 175 172 Task Description MS150120 00E 2014 11 TIM ID 0000000036 031 ...

Page 173: ...2 Turn cover on coolant expansion tank counterclockwise until the first stop and allow pressure to es cape 3 Continue to turn cover counterclockwise and remove 4 Extract remaining engine coolant in the coolant expansion tank via the filler neck 5 Drain engine coolant at preheating unit ex ternal 6 Open drain valve 2 and drain engine cool ant at elbow on engine coolant pump 7 Open drain valves 1 on...

Page 174: ...in remaining engine coolant at EGR cooler A and B side arrow Final steps 1 Close all open drain points 2 Fit cover on filler neck and close it 174 Task Description MS150120 00E 2014 11 TIM ID 0000030760 005 ...

Page 175: ...engine to cool down Wear protective clothing protective gloves and safety glasses facial protection NOTICE Filling cold coolant into a hot engine can result in thermal stress Danger of crack formation in engine Only fill or top up coolant with the engine cold Preparatory steps 1 Turn cap 1 of coolant expansion tank ex ternal counterclockwise until the first stop and allow pressure to escape 2 Cont...

Page 176: ...alve 6 Check proper condition of cap and clean sealing faces if required 7 Put on filler neck cap and close it 8 Start engine Page 36 and shut down af ter 10 second of operation without load Page 36 9 Continue to turn pressure cap counter clockwise and remove 10 Check engine coolant level Page 171 and top up coolant if necessary a Fill in coolant in expansion tank until the coolant level at top ed...

Page 177: ... 4 Place cover onto filler neck and close until first stop is reached 5 Start engine Page 36 and shut down af ter 10 second of operation without load Page 37 6 Turn cap counterclockwise and remove 7 Check engine coolant level Page 171 and top up coolant if necessary a Repeat the steps from Start engine Step 5 until no more engine coolant needs to be topped up b Check proper condition of cap and cl...

Page 178: ...ing damage Wear ear protection Engine coolant pump Relief bore check 1 Check relief bore arrow for oil and coolant discharge 2 Stop engine Page 37 and disable en gine start observe general safety instruc tions Maintenance and Repair 3 Clean 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 the number o...

Page 179: ...o cool down Wear protective clothing protective gloves and safety glasses facial protection WARNING Loud engine noises with the engine running Risk of hearing damage Wear ear protection Engine coolant Sample extrac tion 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...

Page 180: ...rst stop and allow pressure to escape 2 Continue to turn cap counterclockwise and remove Note Charge air coolant must be visible at mark er plate 3 Check charge air coolant level 4 Top up charge air coolant as necessary Page 185 5 Check that cap is in serviceable condition 6 Clean sealing surfaces as necessary 7 Fit cap and close tight Checking charge air coolant level by means of level sensor Not...

Page 181: ...pecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 182 2 Fill with charge air coolant Page 185 MS150120 00E 2014 11 Task Description 181 TIM ID 0000000041 011 ...

Page 182: ...n Wear protective clothing protective gloves and safety glasses facial protection Charge air coolant Draining 1 Provide a suitable container in which to collect the charge air coolant 2 Turn cover on coolant expansion tank counterclockwise until the first stop and allow pressure to es cape 3 Continue to turn cover counterclockwise and remove 4 Extract remaining charge air coolant in the coolant ex...

Page 183: ...ooler high pressure arrow 8 Drain remaining charge air coolant at inter cooler low pressure A side arrows 9 Drain remaining charge air coolant at inter cooler low pressure B side arrow MS150120 00E 2014 11 Task Description 183 TIM ID 0000026956 006 ...

Page 184: ...efully pull the coolant line 3 out of the union 12 Loosen the union nut 1 of the upper cool ant line 2 13 Pull the coolant line 2 somewhat out of the union Note Wait until no more coolant comes out of the lines 14 Tighten the union nuts 1 4 of the coolant lines 2 3 again Final steps 1 Close all drain valves and screw in drain plugs with new sealing rings 2 Fit cap on filler neck and close it 184 T...

Page 185: ...w engine to cool down Wear protective clothing protective gloves and safety glasses facial protection NOTICE Filling cold coolant into a hot engine can result in thermal stress Danger of crack formation in engine Only fill or top up coolant with the engine cold Preparatory steps 1 Turn cover 1 of coolant expansion tank external counterclockwise until the first stop and allow pressure to escape 2 C...

Page 186: ...d 5 Start engine Page 36 6 After 10 seconds of running the engine without load shut down the engine Page 37 7 Turn cover counterclockwise and remove 8 Check charge air coolant level Page 180 and top up if required a Repeat the steps from Start engine Step 5 until charge air coolant no longer needs to be topped up b Check proper condition of cover and clean sealing faces if required c Place cover o...

Page 187: ...ant expansion tank counterclockwise until the first stop and al low pressure to escape 11 Continue to turn cover counterclockwise and remove 12 Check charge air coolant level Page 180 and top up if required a Fill charge air coolant into expansion tank until the coolant level at top edge of filler neck remains constant b Place cover on filler neck and close c Repeat the steps from Start engine Ste...

Page 188: ... protectors Checking charge air coolant pump pressure relief port 1 Check pressure relief port arrow for oil and coolant discharge Note Observe safety regulations when carrying out maintenance and repair work Page 13 2 Shut down engine Page 37 and disable engine start 3 Clean the pressure relief port with a wire if it is dirty Permissible coolant discharge up to 10 drops per hour Permissible oil d...

Page 189: ...led Guard is removed Drive belt Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace Page 192 Drive belt C Chunking Drive belt Belt is oily shows signs of over heating MS150120 00E 2014 11 Task Description 189 TIM ID 0000000920 011 ...

Page 190: ...mask and ear protectors Checking battery charging generator Item Findings Action Ventilation area arrow Clean None Ventilation area arrows Contaminated Clean Cleaning battery charging generator Note Dry clean battery charging generator only Do not insert sharp objects into the ventilation holes 1 Remove coarse dirt from battery charging generator 2 Blow out ventilation area arrow with compressed a...

Page 191: ...specified tool and equipment Adjusting belt tension 1 Remove protective cover 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 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M10 Tightening torque 60 Nm 5 Nm 4 Tighten screw 1 with torque wrench to the specified tightening...

Page 192: ...apter or box wrench on screw 1 and press belt tensioner in the di rection indicated by the arrow as far as it will go 4 Tighten 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 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Sc...

Page 193: ...ndition Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace Contact Service Check securing screws for firm seating 1 Check securing screws 1 2 for firm seat ing 2 Tighten loose threaded connections with torque wrench to specified tightening torque Name Size Type Lubricant Value Standard Screw M16 Control torque Engine oil 250 Nm 25 N...

Page 194: ...clips are closed and intact 4 Replace faulty cable clips 5 Check that cable clamps are firm tighten loose cable clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical line components for damage Connector housing Contacts Sockets Cables and terminals Plug in contacts Result Contact Service if cable conductors are damaged Note Close male connectors that are not plugged in w...

Page 195: ...eset the emission certification becomes invalid Resetting parameters for drift correction CDC with DiaSys 1 Use DiaSys to reset the CDC parameters Dialog system DiaSys E531920 2 If no DiaSys is available contact Service Entering the codes for the injectors IIG with DiaSys 1 Use DiaSys to enter the IIG Dialog system DiaSys E531920 2 If no DiaSys is available contact Service MS150120 00E 2014 11 Tas...

Page 196: ...ibrating Switch off the Engine Control Unit operating voltage when performing mechanical tests Wear protective gloves WARNING Component is hot Risk of burns Wear protective goggles Checking actuators visually Item Findings Action Corrugated pipe 1 Damaged holes or cracks Replace Coolant connections 2 3 Traces of coolant leaks Replace Output shaft 4 Damaged Replace 196 Task Description MS150120 00E...

Page 197: ...rrect ly Actuator general condition Heavily contaminated by black ex haust Replace Checking actuators with DiaSys Note For installation position of exhaust flaps refer to overview Page 154 1 Switch on ECU 2 Carry out actuator test with DiaSys teach in routine manufacturer s documentation MS150120 00E 2014 11 Task Description 197 TIM ID 0000044543 003 ...

Page 198: ... surface using a cloth moistened with isopropyl alcohol 2 Remove dirt from the 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 connector housings con...

Page 199: ...itable test probe e g test prod The contacts in the plug connection can be bent Carry out check of plug connection only with test connectors Checking plug connections at engine governor 1 Check all plug connections for secure seating 2 Latch loose connectors MS150120 00E 2014 11 Task Description 199 TIM ID 0000000048 008 ...

Page 200: ...rotective gloves NOTICE High voltage Risk of damage to components Switch off ignition before replacing components NOTICE Ceramic cell breakage due to shock or impact Risk of damage to components Avoid shocks and impacts Exercise extreme care when handling sensors Removing NOx sensor Note Observe arrangement and position of sen sor Page 23 1 Disconnect and remove male connector 2 from control unit ...

Page 201: ... sen sor 3 only just before installation Note Do not wipe off the thread lubricant applied by the manufacturer 3 Coat sensor 3 thread with specified as sembly compound as required 4 Screw in sensor 3 by hand 5 Tighten nut 3 with torque wrench to specified tightening torque Name Size Type Lubricant Value Standard Nut M20 x 1 5 Tightening torque Assembly compound Molykote P 37 50 Nm 10 Nm 6 Fit male...

Page 202: ...hot Risk of burning Wear protective gloves NOTICE Ceramic cell breakage due to shock or impact Risk of damage to components Avoid shocks and impacts Exercise extreme care when handling sensors NOTICE High voltage Risk of damage to components Switch off ignition before replacing components Removing Lambda sensor 1 Observe the following general information Layout and position of sensor Page 23 2 Dis...

Page 203: ...e off the thread lubricant applied by the manufacturer 2 Coat sensor thread with specified assembly compound as required 3 Screw in sensor by hand 4 Tighten nut 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M18 x 1 5 Tightening torque Assembly compound Molykote P 37 40 Nm to 60 Nm 5 Fit connector 1 and lock it MS150120 00E 2014 11 Task Description 203 TIM ...

Page 204: ...ate drain check 1 Provide a suitable container to collect the condensate 2 Open drain plug 1 3 Allow the condensate to drain off 4 Close drain plug 1 5 If the drain point is connected to a perma nently installed waste water line check the line for obstructions clean it if necessary 204 Task Description MS150120 00E 2014 11 TIM ID 0000057594 001 ...

Page 205: ...ions Engine is stopped and starting disabled Back Pack Visual inspection of securing screws Item Findings Measure Check securing screws for damage and de formation Damaged deformation visi ble Replace MS150120 00E 2014 11 Task Description 205 TIM ID 0000057596 001 ...

Page 206: ...erial Spare parts Designation Use Part No Qty Torque wrench 10 60 Nm F30452769 1 Torque wrench 60 320 Nm F30452768 1 Check securing screws for firm seating 1 Check tighten securing screws 1 Name Size Type Lubricant Value Standard Screw M12x75 Tightening torque 137 Nm 206 Task Description MS150120 00E 2014 11 TIM ID 0000057599 001 ...

Page 207: ...2 Check tighten securing screws 1 Name Size Type Lubricant Value Standard Screw M10x50 Tightening torque 79 Nm MS150120 00E 2014 11 Task Description 207 TIM ID 0000057599 001 ...

Page 208: ... as soon as possible 2nd function Read out fault codes CCT Circuit CLS Coolant Level Sensor Monitors coolant level CM Current Measurement Current measured value CPS Coolant Pressure Sensor Monitors coolant pressure CR Common Rail CTS Coolant Temperature Sensor Monitors coolant temperature DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel DDL Diagnostic Data Link ...

Page 209: ... exceeds 1st maximum limit HIHI High High Alarm Measured value exceeds 2nd maximum limit HP High Pressure HT High Temperature IDM Interface Data Module Memory module for interface data IIG Initiale Injektorgleichstellung Initial input of injector code with DiaSys in engine governor INJ Injector ISO International Organization for Standardiza tion International umbrella organization for all national...

Page 210: ...ne and rectify fault 2nd function Read out fault codes SID System Identifier SRS Synchronous Reference Sensor TDC cylinder 1 SS Safety System Security Shutdown Safety system alarm TBS Turbocharger Boost Sensor Monitors charge air pressure TCI Turbo Compressor Inlet TCO Turbo Compressor Outlet TD Transmitter Deviation Alarm Sensor comparison fault TPS Throttle Position Sensor TRS Timing Reference S...

Page 211: ...ve work in case of malfunction or changed operating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541 9077778 Asia Pacific 65 6100 2688 North and Latin America 1 248 560 8000 Spare parts service Fast simple and correct identification of spare parts for your drive system or vehicle fleet The right sp...

Page 212: ...lve clearance Check and adjustment Page 118 Barring device Part No F6555766 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 111 Barring gear Part No F6792918 Qty Used in 1 7 1 1 Engine Barring manually Page 107 212 Appendix B MS150120 00E 2014 11 DCL ID 0000033031 002 ...

Page 213: ...er HP Turbine housing check Page 143 Feeler gage Part No Y20098771 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 118 Filter wrench Part No F30379104 Qty Used in 1 7 8 1 Fuel filter Replacement Page 133 Qty Used in 1 7 8 2 Additional fuel filter Replacement Page 134 Qty Used in 7 16 1 Engine oil filter Replacement Page 167 Qty Used in 1 7 16 2 Centrifugal oil filter and filter sleev...

Page 214: ...e extraction and analysis Page 166 Qty Used in 1 7 17 6 Engine coolant Sample extraction and analysis Page 179 Ratchet Part No F30027341 Qty Used in 1 7 15 3 Engine oil Change Page 164 Qty Used in 1 7 20 2 Battery charging generator drive Drive belt tension adjustment Page 191 Qty Used in 1 7 20 3 Battery charging generator drive Drive belt re placement Page 192 Qty Used in 1 7 21 1 Engine mountin...

Page 215: ...r drive Drive belt re placement Page 192 Qty Used in 1 7 23 5 NOx sensor Replacement Page 200 Ratchet adapter Part No F30027340 Qty Used in 1 7 13 3 Exhaust flaps Coupling rod replacement Page 158 Qty Used in 1 7 23 6 Lambda sensor Replacement Page 202 Ratchet adapter Part No F30027339 Qty Used in 1 7 16 2 Centrifugal oil filter and filter sleeve Cleaning and replacement Page 169 MS150120 00E 2014...

Page 216: ...11 Socket for lambda sensor NOx sensor Part No F30453932 Qty Used in 1 7 9 2 Exhaust turbocharger LP Turbine housing check Page 138 Socket wrench 24 mm Part No F30039526 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 118 Steam jet cleaner Part No Qty Used in 1 4 7 Plant Cleaning Page 39 216 Appendix B MS150120 00E 2014 11 DCL ID 0000033031 002 ...

Page 217: ...xhaust turbocharger LP Turbine housing check Page 138 Qty Used in 1 7 9 3 Exhaust turbocharger HP Turbine housing check Page 143 Qty Used in 1 7 20 2 Battery charging generator drive Drive belt tension adjustment Page 191 Qty Used in 1 7 20 3 Battery charging generator drive Drive belt re placement Page 192 Qty Used in 1 7 23 5 NOx sensor Replacement Page 200 Qty Used in 1 7 23 6 Lambda sensor Rep...

Page 218: ... and installation Page 121 Torque wrench 40 200 Nm Part No F30027337 Qty Used in 1 7 15 3 Engine oil Change Page 164 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 13 3 Exhaust flaps Coupling rod replacement Page 158 Qty Used in 1 7 16 2 Centrifugal oil filter and filter sleeve Cleaning and replacement Page 169 218 Appendix B MS150120 00E 2014 11 DCL ID 0000033031 002 ...

Page 219: ...Page 138 Qty Used in 1 7 9 3 Exhaust turbocharger HP Turbine housing check Page 143 Qty Used in 1 7 20 2 Battery charging generator drive Drive belt tension adjustment Page 191 Qty Used in 1 7 20 3 Battery charging generator drive Drive belt re placement Page 192 Qty Used in 1 7 24 3 Back Pack Checking securing screws for firm seating Page 206 Torque wrench 80 to 400 Nm Part No F30027338 Qty Used ...

Page 220: ...Removal 8 Cylinder Designation 19 Cylinder head cover Removal and installation 121 Cylinder liner Endoscopic examination 111 Instructions and comments on endoscopic and visual examination 113 D Drive belt Condition check 189 E ECU9 Fault messages 45 Emergency air shutoff flaps Functional check 152 Engine Barring Manually 107 With starting system 109 Main dimensions 32 Mounting check 193 Overview 2...

Page 221: ... Maintenance schedule Maintenance task reference table QL1 40 MTU contact persons 211 N NOx sensor Replacement 200 O Oil mist fine separator Replacement 115 Operational checks 35 Overview Back Pack 22 P Parameters for drift correction CDC Reset 195 Plant Cleaning 39 Pump Charge air coolant Pressure relief port check 188 Engine coolant Relief bore check 178 Fuel high pressure Filling 123 R Recommis...

Page 222: ...ce 211 Starter Condition check 161 T Technical data 27 transport 7 Transport locking device Installation Crankshaft 8 Removal Crankshaft 8 Troubleshooting 42 Turbine housing Check 137 V Valve clearance Adjustment 118 Check 118 Valve gear Lubrication 117 W Wiring Check On engine 194 222 Appendix B MS150120 00E 2014 11 DCL ID 0000033031 002 ...

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MTU 12 V 4000 T95 x, Operating Instructions Manual

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