MTU 12V4000G15S Operating Instructions Manual Download Page 214

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9.6 Injector

9.6.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injector

(→ Spare Parts Catalog)

Injector – Replacement

Remove injector and install new one (→ Page 213).

212 | Injector | MS15065/01E 2019-01

TIM-ID: 0000042329 - 002

Summary of Contents for 12V4000G15S

Page 1: ...Operating Instructions Diesel Engine with Exhaust Gas Aftertreatment 12V4000Gx5S MS15065 01E...

Page 2: ...is protected by copyright and may not be used in any way whether in whole or in part without the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distr...

Page 3: ...an enclosed area vent the exhaust to the outside x Do not modify or tamper with the exhaust system x Do not idle the engine except as necessary WA WAR W W W W W W W W W W W W W W W W W W W W W W W W W...

Page 4: ......

Page 5: ...stem 61 4 2 12 Engine management and monitoring 64 4 2 13 Sensors and actuators Overview 67 4 3 Exhaust Gas Aftertreatment 71 4 3 1 Exhaust gas aftertreatment system Overview 71 4 3 2 DPF System 72 4...

Page 6: ...nt replacement 239 9 8 8 Fuel prefilter switchable Filter element replacement 241 9 8 9 Fuel prefilter Venting 244 9 9 Charge Air Cooling 246 9 9 1 Charge air cooler Leak check 246 9 9 2 Throttle flap...

Page 7: ...ort 316 9 19 1 Engine mounting Checking resilient element 316 9 19 2 Engine mounting Checking securing screws for firm seating 317 9 19 3 Generator mounting Check 319 9 19 4 Generator mounting Securin...

Page 8: ...s Emission related components must only be serviced ex changed or repaired if the components used for this purpose are approved by the manufacturer Noncompliance with these specifications will invalid...

Page 9: ...sed military applications other than by US government agen cies Please note the following when replacing components with emission labels The relevant emission labels must be affixed to the spare part...

Page 10: ...ponents have hot surfaces e g exhaust system exhaust turbo chargers exhaust aftertreatment system engine oil system cooling system which can cause injury to per sons who approach or touch them danger...

Page 11: ...a safe shutdown of fuel injection takes place on a diverse redundant path and thus results in engine standstill Through an ap propriate design of the engine generator set or whole plant the operator o...

Page 12: ...lfills the conditions for such use and approval has been granted The section below applies to applications deployed in regions under the jurisdiction of the EPA Use of EPA Tier 2 and Tier 3 certified...

Page 13: ...lified personnel only Training at the Training Center of the manufacturer Qualified personnel from the areas mechanical engineering plant construction and electrical engineering and also for work with...

Page 14: ...battery terminals generator terminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity fuel line reduction agent line supply return Immediatel...

Page 15: ...ids and lubricants immediately or soak up with a suitable binding agent Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrica...

Page 16: ...e fitted Attach Do not operate sign in the operating area or to control equipment Disconnect the battery cables or actuate the battery isolating switch if fitted Lock circuit breakers Before starting...

Page 17: ...ent contact with other components Do not place fuel or oil lines near hot components Miscellaneous Sufficient ventilation must be guaranteed during the work Wear a breathing mask offering protection a...

Page 18: ...d the pipework at the relevant designated points For hydraulic installation screw on the jig with the piston retracted For hydraulic removal screw on the jig with the piston extended For a hydraulic i...

Page 19: ...properly prior to replacement i e protect them against moisture in particular Package faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrap...

Page 20: ...Ensure that suitable extinguishing agents fire extinguishers are always available and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always w...

Page 21: ...tands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected Avoid open flames in the surrounding area No smokin...

Page 22: ...Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in...

Page 23: ...1 9 Guards on the engine Overview 1 Throttle flap guard plate 2 Flywheel housing guard plate 3 Generator guard cover MS15065 01E 2019 01 Safety 21 TIM ID 0000083980 001...

Page 24: ...Generator guard cover 2 Flywheel housing guard plate 3 Throttle flap guard plate The engine may only be operated with the protective guards installed 22 Safety MS15065 01E 2019 01 TIM ID 0000083980 00...

Page 25: ...exhaust gas aftertreatment system engine 8 Always raise lower the exhaust gas aftertreatment system engine slowly The lifting ropes or chains must not touch the exhaust gas aftertreatment system engin...

Page 26: ...able ladders or work platforms Use personal protective equipment DANGER The load can slip or tip over Danger of crushing limbs and body parts Secure the load When securing the load only used the permi...

Page 27: ...t bears the loads required and that it is designed adequately for the loads to be lifted A crossbeam may be used Ensure that the lifting equipment does not damage components Set the engine down on the...

Page 28: ...enter of gravity and outer edge of DPF system D Distance between center of gravity and bottom edge of DPF system E Distance between center of gravity and outer edge of DPF system a Max 10 Max permissi...

Page 29: ...the instructions below when lifting the exhaust gas aftertreatment system Attach lifting equipment chains to the upper fixtures only Always use all four fixtures at once The elongated opening must be...

Page 30: ...k of falling or overturning due to lack of stability Risk of crushing body or limbs Use appropriate lifting gear and appliances Wear safety shoes RA tank optional Transport The following conditions mu...

Page 31: ...the engine as long as possible 2 Never start or bar the engine with the crankshaft transport locking device installed If the generator is al ready mounted on the engine ensure that the transport lock...

Page 32: ...ear 6 Install screw 1 into the bore of retainer 3 until the retainer 3 is locked in position Note The screw 1 must be tightened alternately on both sides of the flywheel housing 7 Tighten screw 1 to s...

Page 33: ...4 Install guard plate 3 on flywheel housing 4 5 Install screws 2 with washers 1 and tight en MS15065 01E 2019 01 Transport 31 TIM ID 0000035999 005...

Page 34: ...port locking device must be installed on all resilient mounts according to the instructions before transporting Removing engine mount trans portation locks 1 Slacken nuts 2 2 Undo nut 3 and unscrew an...

Page 35: ...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...

Page 36: ...system Main components DPF system including diesel oxidation catalyst DOC SCR system with downstream ammonia slip catalyst ASC and integrated mixing channel Reducing agent dosing system RA comprising...

Page 37: ...unit 2 HP reducing agent line 3 Supply unit 4 Pressure relief valve The operating pressure in the reducing agent supply lines between supply unit and dosing unit is 10 bar The pressure relief valve op...

Page 38: ...with a diesel oxidation catalyst DOC and an SCR system selective catalytic reduction to moder ate emissions The use of approved fuels lube oils and reducing agents as listed in the MTU Fluids and Lubr...

Page 39: ...sing system RA comprising pre feed module PFM supply unit SU and dosing unit DU Engine Control Unit ECU to control the diesel engine and EGAT system Distributed Control Modules DCMs serving as input o...

Page 40: ...of supply MTU Series 4000 engine Rated speed 1800 rpm 60 Hz Electronic engine management system Electrical starter on the left and right A and B sides Exhaust gas aftertreatment system Jacketed diese...

Page 41: ...ion Nameplates on diesel engine The illustration applies similarly to other cylinder configurations 1 Emissions label EPA 2 Engine nameplate 3 Instruction plate MS15065 01E 2019 01 Diesel Engine with...

Page 42: ...designation Key to the engine model designation 12 Number of cylinders V Cylinder arrangement V engine 4000 Series G Application G Genset x Application segment 5 Design index S Additional feature S 60...

Page 43: ...rottle flap after intercool er 4 Cylinder head cover 5 Additional fuel filter 6 Fuel filter 7 HP fuel pump 8 Lube oil filter 9 Vibration damper 10 Centrifugal oil filter option 11 Coolant distribution...

Page 44: ...Single stage supercharging system with four exhaust turbochargers Exhaust gas aftertreatment with SCR catalyst and passively regenerating diesel particulate filter DPF Page 72 Engine management with E...

Page 45: ...nically controlled common rail injection Exhaust turbocharging with charge air cooling Dual cooling system LT Low temperature circuit with coolant for charge air cooling HT High temperature circuit wi...

Page 46: ...earcase and coolant distribution housing are installed on the face at the free end KGS The flywheel housing is located on the driving end KS The cylinder heads and engine lifting points are mounted le...

Page 47: ...3 and camshaft 15 bearings are inside the crankcase The crankcase incorporates bores to route lube oil and engine coolant lines 2 4 6 7 and for the cylin der liners 5 The oil pan 11 serves as a lube o...

Page 48: ...ment pump Gear train The gear train comprises the drive and idler gears installed in the gearcase Technical data Gears with straight toothing Benefits Low wear power transmission Low maintenance No ax...

Page 49: ...tion damper and pistons Carefully matched components ensure maximum performance and minimum wear Technical data Piston Aluminum solid skirt piston with integrated cooling duct Two compression rings on...

Page 50: ...umption Function The forces generated in the combustion chambers of the cylinders are transmitted from the pistons 3 and conrods 4 to the crankshaft 2 The crankshaft transforms these forces into a rot...

Page 51: ...ed from the crank case Fuel is supplied to the injectors by the HP fuel pump via a common pressure accumulator Fuel flows to through HP lines to the injectors Technical data Individual cylinder heads...

Page 52: ...ing an air fuel mixture which ignites sponta neously under compression When the exhaust valves 9 open exhaust gas created by the combustion process flows via the outlet duct to the exhaust manifold le...

Page 53: ...shaft supports with the rocker arms are mounted on the cylinder heads Technical data Centrally arranged camshaft lubrication of sleeve bearings from the crankcase The drive gear of the camshaft is dir...

Page 54: ...e camshaft to actuate the valves is transferred by swing followers 3 4 pushrods 6 and rocker arms 8 11 onto the valve bridges 13 of the intake and exhaust valves The valves open against spring pressur...

Page 55: ...r Fuel system with Common Rail injection The fuel system consists of a low pressure system and a high pressure system Common Rail system The Common Rail system is controlled by the engine governor Inj...

Page 56: ...talled in the injectors 1 and controlled by the engine electronics The fuel quantity required for the injection process and to maintain the system pressure of up to 1800 bar is preset by a restrictor...

Page 57: ...xhaust duct Charge air and exhaust system The charge air and exhaust system components are installed at the driving end KS and on top of the en gine The high power and load application requirements of...

Page 58: ...sembly before being routed out to the atmosphere via the exhaust outlet 2 and the exhaust system Charge air system The compressor wheel which is arranged on the same shaft of the rotor assembly draws...

Page 59: ...rings 21 Crankshaft support bearing driving end 22 Mechanical coupling gener al option 23 Camshaft bearing 24 Spray nozzles for piston cooling 25 Shutoff valve 26 Cylinder head 27 Main oil gallery 28...

Page 60: ...ust bearings 28 Cylinder head 26 Camshaft bearings 23 Crankshaft support bearing driving end 21 Crankshaft thrust bearings 20 Exhaust turbocharger bearings 1 2 The lube oil pump 12 is a gear pump It i...

Page 61: ...r 5 Connection for fuel inlet 6 Centrifugal fan with fan guard a Fuel b Air Technical data Highly efficient centrifugal fan driven by an electric motor Heat exchanger made of pressure and heat resista...

Page 62: ...thdraws heat from the fuel After passing through the heat exchanger 4 comprising a pipe bundle the air cooled fuel is returned to the fuel tank via the fuel outlet 2 The centrifugal fan 6 is driven by...

Page 63: ...ine coolant expansion tank HT 15 Engine coolant pump 16 Engine coolant drain plug 17 Restrictor 18 Lube oil heat exchanger 19 Crankcase 20 Engine coolant preheater in let 21 Coolant manifold 22 Interc...

Page 64: ...ows to the thermostat 4 via the coolant collecting lines 1 on the left and right The thermostat 4 diverts the engine coolant to the external engine coolant cooler when the engine is under load warm en...

Page 65: ...oolant coming from the charge air coolant cooler flows to the charge air coolant pump 5 The thermostat 6 leads the charge air coolant directly to the charge air coolant pump 5 when the engine is cold...

Page 66: ...gement system controls e g the injection timing injection duration and the resulting injec tion quantity for each ignition and for each cylinder It controls among other thing the speed and high pres s...

Page 67: ...outputs Higher accuracy Internal ambient air sensor Lambda sensor acquisition 10 banks for multiple injection 5 fold Angle input OL detection adjustable hysteresis Fast data communication via RS485 S...

Page 68: ...ressure fuel rail Fuel pressure after filter Fuel pressure before additional filter Fuel temperature rail Oil temperature Oil pressure oil refill pump Lube oil pressure differential downstream of filt...

Page 69: ...rs Overview Plan view B4 21 Exhaust bulk temperature A side B4 22 Exhaust bulk temperature B side B44 1 Turbocharger speed A side B44 2 Turbocharger speed B side MS15065 01E 2019 01 Series 4000 Engine...

Page 70: ...ge air A side B38 Fuel supply temperature B34 1 Fuel pressure after filter B34 3 Fuel pressure before sup plementary filter B48 1 HP fuel system pressure A side M58 1 Connector for throttle flap A sid...

Page 71: ...pressure B side B90 H T P moisture sensor air quality M58 2 Connector for throttle flap B side XA80 Connector for adaption EGAT XB533 H Coolant HT ext expan sion tank XB557 H Coolant LT ext expan sion...

Page 72: ...ssure before fil ter B6 Coolant temperature B7 Lube oil temperature B26 Charge air coolant tempera ture B50 Crankcase pressure B54 Oil refill pump pressure op tional XB54 Connector for optional oil re...

Page 73: ...xhaust outlet from exhaust gas aftertreatment system 6 Supply units 7 Fixed bearings 8 Tank sensors 9 Tank 10 DCM tank 11 Pre feed module 12 DCM pre feed module 13 DCM exhaust gas aftertreat ment syst...

Page 74: ...and continuously regenerating diesel particulate filter which utilizes the so called CRT effect Continuous Regeneration Trap With this method the prevailing exhaust temperatures experienced in normal...

Page 75: ...el oxidation catalyst DOC first produces nitrogen dioxide NO2 from the nitrogen monoxide NO in the exhaust gas Sooty deposits in the DPF are steadily burnt off with the aid of the NO2 thus gained see...

Page 76: ...r elements can be removed to clean ash the DOC filter elements can be removed for visual inspection The DPF system is jacketed and insulated to avoid heat loss and minimize surface temperature The exh...

Page 77: ...n Before the raw exhaust gas is vented to atmosphere it is routed via bellows dual flow into the two DPF systems 1 Depending on engine power the exhaust gas is then routed to a number of DOC DPF eleme...

Page 78: ...y active surface The process is expedited by continuously injecting a reducing agent 32 5 solution of ultra pure urea in de ionized water into the exhaust flow This reducing agent RA reacts with the e...

Page 79: ...re jacketed and include insulation to minimize heat loss and moderate the surface temperature to approx 200 C The DCMs supply and dosing units SU DU RA lines exhaust sensors and electrical wiring harn...

Page 80: ...CR system 1 is designed to mix NH3 with the exhaust gas and distribute the exhaust gas evenly over the substrate to best advantage The SCR system incorporates the reducing agent dosing units 2 the mix...

Page 81: ...as an option Technology Pre feed module PFM Supply units SU Dosing units DU Loop Supply and return line Tank system supplied by the customer or by MTU as an option Heated RA dosing system Benefits ai...

Page 82: ...m One or two plug play SCR systems offer a modular design for the RA lines The RA lines of the two SCR systems are simply interconnected in this dual flow system The ECU controls all the functions of...

Page 83: ...irements stipulated in DIN 70070 ISO 222 41 1 is mandatory SCR systems from MTU are designed for a concentration of 32 5 urea Mis filling with diesel fuel may damage seals and hoselines resulting in l...

Page 84: ...ogether with the DCM and wiring harness on a common mounting plate Sensors 3 9 monitor pressure temperature and the concentration of the reducing agent A pressure maintaining valve is installed in the...

Page 85: ...The pump must always run whenever the SUs are in operation in order to cool the DUs It must keep running until the exhaust temperature upstream of the SCR system has fallen below 110 C even after the...

Page 86: ...r housing Technical data Operating pressure 10 bar abs RA dosing volume Max 11 kg h Suction head Max 0 1 bar 1 m Rated supply voltage 24 VDC Protection class IP69 K Ambient temperature 40 C to 60 C wi...

Page 87: ...aphragm pump The dosing quan tity is controlled by the opening time of the solenoid valve The DU is cooled by the return flow independently of the dosing quantity The dosing system is a so called airl...

Page 88: ...pped with an SAE J2044 quick disconnect couplings QC and corrugated tubing for protection All RA lines are electrically heated RA lines 2 and 4 have an inner diameter of 5 5 mm RA lines 5 and 6 have a...

Page 89: ...rator 1 level sensor Indicating the minimum level for DU circulation cooling RA dosing stops at this level and the final warn ing is raised 1 temperature sensor Identifying frozen RA both for heated a...

Page 90: ...A tank main heating control is not included in this heating zone PFM heating zone Including the PFM and the RA lines between the PFM and the SCR system This heating zone is triggered by the temperatur...

Page 91: ...are tested for open load and short circuit when activated as soon as the ECU is powered up and is ready for operation prior to engine start up Any malfunction occurring in the heating system which di...

Page 92: ...treatment before DPF B91 2 Exhaust gas pressure DPF B88 7 NOx before DPF B85 5 Exhaust temperature EGAT before SCR B88 8 NOx after SCR B82 Ambient temperature B85 6 Exhaust temperature EGAT after SCR...

Page 93: ...PFM DCM 5 Connector cable for DCM tank 6 PFM DCM 7 DCM tank E3 1 Heater supply line E3 2 Heater return line B106_E7 PFM RA temperature B102 PFM pressure to filter B103 PFM RA quality M81 1 PFM pump 1...

Page 94: ...physical interfaces of the connected RA components according to the information sent by the ECU Each DCM location in the electronic system is coded by the cabling thus defining its role and configura...

Page 95: ...fter SCR system Exhaust gas temperature before diesel particulate filter Exhaust gas pressure before diesel particulate filter Soot particle volume in diesel particulate filter Ambient temperature of...

Page 96: ...ing cable flow A 10000 383R 121R C Connecting cable flow B 10000 787R 121R D Connecting cable PFM Tank 10000 Without 121R The devices are equipped with a CAN bus for transmitting data between the indi...

Page 97: ...he specified value Actual value must be less than the specified value Not sufficiently validated value 10 tolerance Not sufficiently validated value 5 tolerance ID Product type Application Speed List...

Page 98: ...el temperature at engine inlet connection max L C 55 55 Consumption ID 1 2 Specific fuel consumption be 100 BL 5 EN 590 42 8 MJ kg R g kWh 208 202 Fuel consumption at zero load R kg h 36 36 Model rela...

Page 99: ...max L 50 50 Lube oil system ID 1 2 Lube oil temperature before engine limit 1 L C 99 99 Lube oil temperature before engine limit 2 L C 101 101 General operating data ID 1 2 High idling speed max stat...

Page 100: ...6710 6710 Dry engine weight with standard accessories installed incl cou pling R kg 6742 6742 EGAT 1 mass per flow R kg 1050 Noise ID 1 2 Exhaust noise attenuated EGAT 1 BL free field sound pres sure...

Page 101: ...d value 10 tolerance Not sufficiently validated value 5 tolerance ID Product type Application Speed List perform ance 1 12V4000G15S Power generation 3F mains backup mode unlimited ICXN 1800 rpm 60 Hz...

Page 102: ...l consumption at zero load R kg h 36 36 Model related data basic design ID 1 2 Engine with exhaust turbocharging ETC and charge air cooling intercooler X X Uncooled exhaust lines X X Operating method...

Page 103: ...1 2 High idling speed max static L rpm 1900 1900 Limit speed for overspeed signal emergency shutdown L rpm 1950 1950 Limit speed for overspeed signal L rpm 1950 1950 Firing speed from R rpm 80 80 Firi...

Page 104: ...es sure level Lp 1 m distance ISO 6798 3dB A tolerance R dB A 73 73 Exhaust noise attenuated EGAT 1 BL sound power level LW ISO 6798 3dB A tolerance R dB A 86 87 Structure borne noise level of pre fee...

Page 105: ...ns 12V engine Engine model Length A Width B Height C 12V4000Gx5S with 2 cylinder HP pump 2433 mm 1660 5 mm 2176 5 mm 12V4000Gx5S with 4 cylinder HP pump 2495 mm 1660 5 mm 2176 5 mm MS15065 01E 2019 01...

Page 106: ...ensions DPF module Engine model Length A Length B Height C Width D Height E Height F 12V4000Gx5S 1414 7 mm 1375 mm 206 mm 1246 mm 706 mm 982 75 mm 104 Technical Data MS15065 01E 2019 01 TIM ID 0000075...

Page 107: ...Main dimensions SCR module Width A Height B Length C Height D Height E 1124 1 mm 771 mm 1774 5 mm 1626 1 mm 1161 mm MS15065 01E 2019 01 Technical Data 105 TIM ID 0000075685 002...

Page 108: ...imensions exhaust gas aftertreatment system 12V Engine model Length A Height B Width C Height D 12V4000Gx5S 3436 6 mm 992 8 mm 2656 mm 1636 1 mm 106 Technical Data MS15065 01E 2019 01 TIM ID 000007568...

Page 109: ...s Item Dimensions Length A Approx 3437 mm Width B Approx 1246 mm Height of SCR system C Approx 1636 mm Height of DPF system D Approx 993 mm Table 2 DPF system with SCR system Main dimensions MS15065 0...

Page 110: ...mensions Length A Approx 3680 mm Width B Approx 1360 mm Height C Approx 1761 mm Table 3 DPF system with SCR system on module frame Main dimensions 108 Technical Data MS15065 01E 2019 01 TIM ID 0000078...

Page 111: ...Item Dimensions Length A Approx 2043 mm Width B Approx 1000 mm Height C Approx 1335 mm Table 4 RA tank Main dimensions MS15065 01E 2019 01 Technical Data 109 TIM ID 0000078598 003...

Page 112: ...5 5 Firing order Firing order Number of cylinders Firing order 12 V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 110 Technical Data MS15065 01E 2019 01 TIM ID 0000010709 002...

Page 113: ...for more than one year change engine coolant Page 282 Change charge air coolant Page 306 Coolant circuit Check engine coolant level Page 280 Check charge air coolant level Page 304 Coolant circuit He...

Page 114: ...lant with coolant preheater Fuel prefilter Drain water Page 233 Page 235 Monitoring system Carry out lamp test see manufacturer s documentation Engine generator control system Switch on Select operati...

Page 115: ...emission label for intactness 3 Check that emission label is fully legible 4 Check content of emission label Does the label on the engine match the label document in the Business Portal Equipment Does...

Page 116: ...ine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suitable hearing protec...

Page 117: ...g this the exhaust aftertreatment system must be regenerated Regeneration must be completed in full Engine Max continuous op erating period at power 30 kW cyl The continuous minimum power of 30 kW cyl...

Page 118: ...ified or eliminated contact Service Note If an engine has been shutdown by a fault red alarm the engine may only be re started when the fault has been identified and eliminated Procedure following an...

Page 119: ...when a pushbutton is provided Safety system Override Item Action Switchgear cabinet control panel etc depending on manufacturer Activate pushbutton for Override input of the ECU Certain shutdown crite...

Page 120: ...rger turbine housings may be red hot If the maximum exhaust temperatures are not exceeded no restrictions in en gine operation are required Check for abnormal running noises and vibration Fuel prefilt...

Page 121: ...ms will be disregarded Severe material damage Initiate emergency start only in emergency situations Preparation Item Action Operating mode selector switch Change to Override mode Manual mode if applic...

Page 122: ...thermal and mechanical stress es Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant lev...

Page 123: ...subjects the engine system to an extremely high load Risk of overheating damage to components Trigger an emergency stop only in emergency situations Emergency engine stop Item Action Emergency stop pu...

Page 124: ...he engine Engine remains ready for operation After stopping the engine Item Action Engine generator pump control Select operating mode e g MANUAL AUTOMATIC OPERATION 122 Operation MS15065 01E 2019 01...

Page 125: ...o the coolant the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is...

Page 126: ...gun directly at seals or electronic components such as connectors or ECUs Cleaning the plant 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental prot...

Page 127: ...ag ing effects of sooting Regeneration is performed when the exhaust gas aftertreatment system has been running at its normal op erating temperature for an adequately long period of time see regenerat...

Page 128: ...em if applicable 3 Contact Service 5 HI T Charge Air Cause Corrective action The charge air temperature at sensor B9 has violated limit value 1 The charge air temperature is too high 1 Reduce power 2...

Page 129: ...low 1 Check engine oil level Page 271 2 Contact Service 19 HI T Exhaust A Cause Corrective action The exhaust gas temperature at sensor B4 has violated limit value 1 The exhaust gas temperature is to...

Page 130: ...as violated the limit value or the engine overspeed test has been tripped Engine emergency stop has been tripped 1 If an emergency stop has been tripped by the engine overspeed test restart the engine...

Page 131: ...act Service 37 SS ETC2 Overspeed Cause Corrective action The speed of the LP turbocharger B side at sensor B44 2 has violated limit value 2 The exhaust turbocharger speed is too high Cause Fault or ma...

Page 132: ...3 HI P Crank Case Cause Corrective action The crankcase pressure at sensor B50 has violated limit value 1 The crankcase pressure is too high 1 Stop engine 2 Contact Service 64 SS P Crank Case Cause Co...

Page 133: ...pressure is too low u Contact Service 89 SS Engine Speed too Low Cause Corrective action The engine speed has violated the limit value Engine emergency stop has been tripped 1 Acknowledge alarm 2 Chec...

Page 134: ...e action The oil pressure at sensor B5 1 has violated the specified value The specified oil pressure was not reached The start procedure was terminated 1 Check engine cabling Page 321 2 Contact Servic...

Page 135: ...or missing 1 Check engine cabling Page 321 2 Contact Service 202 SD T Fuel Cause Corrective action The signal from the fuel temperature sensor B33 on the HP distributor is faulty or missing 1 Check e...

Page 136: ...g Page 321 2 Contact Service 214 SD P Crankcase Cause Corrective action The signal form the crankcase pressure sensor B50 is faulty or missing 1 Check engine cabling Page 321 2 Contact Service 215 SD...

Page 137: ...vice 227 SD P Lube Oil before Filter Cause Corrective action The signal from the oil pressure sensor before filter B5 3 is faulty or missing 1 Check engine cabling Page 321 2 Contact Service 229 AL St...

Page 138: ...n The signal from the fuel pressure sensor after main fuel filter B34 1 is faulty or missing 1 Check engine cabling Page 321 2 Contact Service 245 SD ECU Power Supply Voltage Cause Corrective action T...

Page 139: ...ve action Short circuit fault in the injector wiring for cylinder A5 or injector faulty 1 Check wiring of affected injector Page 321 2 Replace injector Page 212 3 Contact Service 326 AL Wiring Cylinde...

Page 140: ...ion Short circuit fault in the injector wiring for cylinder B2 or injector faulty 1 Check wiring of affected injector Page 321 2 Replace injector Page 212 3 Contact Service 333 AL Wiring Cylinder B3 C...

Page 141: ...in injector wiring cylinder B9 or injector faulty 1 Check wiring of affected injector Page 321 2 Replace injector Page 212 3 Contact Service 340 AL Wiring Cylinder B10 Cause Corrective action Short ci...

Page 142: ...r A7 1 Check wiring of affected injector Page 321 2 Contact Service 348 AL Open Load Cylinder A8 Cause Corrective action Disruption fault in injector wiring to cylinder A8 1 Check wiring of affected i...

Page 143: ...er B5 1 Check wiring of affected injector Page 321 2 Contact Service 356 AL Open Load Cylinder B6 Cause Corrective action Disruption fault in injector wiring to cylinder B6 1 Check wiring of affected...

Page 144: ...and replace as necessary 3 Contact Service 449 SS P Charge Air Cause Corrective action The charge air pressure at sensor B10 1 has violated limit value 2 The charge air pressure is too high 1 Power r...

Page 145: ...Cause Corrective action Disruption or short circuit in wiring to servomotor of thermomanagement flap 1 M58 1 1 Check engine cabling Page 321 2 Contact Service 609 AL Wiring PWM_CM7 Cause Corrective ac...

Page 146: ...anagement flap 1 M58 1 is faulty u Contact Service 723 AL_SD_T_Exh_DPFsys_inl_F1 Cause Corrective action The signal from the exhaust gas temperature sensor B4 33 before the DOC is faulty or missing 1...

Page 147: ...rvice 730 AL_HI2_T_Exh_DPFsys_inl_F1 Cause Corrective action The exhaust gas temperature before the DOC measured at sensor B4 33 has violated limit value 2 The exhaust gas temperature before the DOC i...

Page 148: ...The DPF soot load calculated on the basis of the differential pressure measured at sensor B91 2 has violated limit value 1 Soot loading is high u Contact Service 738 AL L2 P DPF 1 Norm Difference Caus...

Page 149: ...vely u Contact Service 745 AL Emission Fault Cause Corrective action Emission fault summary alarm 1 Check for additional messages 2 Contact Service 748 AL_SD_T_Exh_SCRsys_inl_F1 Cause Corrective actio...

Page 150: ...s for the reducing agent pump was exceeded Cooling for the reducing agent nozzles was inadmissibly terminated too often u Contact Service 759 AL L1 T Fuel b Engine Cause Corrective action The charge a...

Page 151: ...ct Service 838 AL ash volume Cause Corrective action The ash volume determined from the differential pressure through the DPF following complete regeneration compared with the differential pressure of...

Page 152: ...21 2 Contact Service 920 AL_HI1_T_Exh_SCRsys_inl_F1 Cause Corrective action The exhaust gas temperature before SCR inlet 1 flow 1 at sensor B85 5 has violated limit value 1 The exhaust gas temperature...

Page 153: ...1 Reduce power 2 Contact Service 926 AL_HI1_T_Exh_SCRsys_outl_F2 Cause Corrective action The exhaust gas temperature after SCR outlet 2 flow 2 at sensor B85 6 has violated limit value 1 The exhaust g...

Page 154: ...t loading in the DPF has reached the limit Regeneration has been initiated automatically u No action required 967 AL_SU_priming_request_revocation_F1 Cause Corrective action The supply unit flow 1 has...

Page 155: ...act Service 2 Contact Service 1072 AL_Exp_T_Exh_SCRsys_outl_F1 Cause Corrective action The exhaust gas temperature after SCR measured at sensor B85 6 deviates from expected value u Contact Service 107...

Page 156: ...violated the lower range setting u Contact Service 1086 AL_HI1_T_RA_SUDU_F2 Cause Corrective action The temperature of the reducing agent measured at one of the dosing units flow 2 has violated the l...

Page 157: ...it value 1 The intake air differential pressure is too high 1 Check air filter plant side for contamination 2 Contact Service 1116 AL Difference P0 P1 Intake Air L2 Cause Corrective action The differe...

Page 158: ...ling Page 321 2 Check sensor B106 and replace as necessary 3 Contact Service 1140 AL_LO1_p_RA_prefeed_module Cause Corrective action The pressure of the reducing agent in the pre feed module measured...

Page 159: ...cable 3 Contact Service 1208 AL L1 P DPF 2 Norm Difference Cause Corrective action Soot loading of DPF flow 2 has violated limit value 1 Soot loading is high u Contact Service 1211 AL_CommLost_DCM_ID7...

Page 160: ...he configuration is flawed u Contact Service 1218 AL_DCM_ID3_Config_Failed Cause Corrective action The DCM designated ID3 is incompatible or the configuration is flawed u Contact Service 1219 AL_DCM_I...

Page 161: ...O1_U_DCM_ID5 Cause Corrective action The operating voltage for the DCM designated ID5 is too low 1 Check engine cabling Page 321 2 Check plant supply voltage 3 Check DCM replace as necessary 4 Contact...

Page 162: ...to all DCMs in the system via a PWM output The DCM designated ID3 signals a voltage of below 4V at the ignition port 1 Check engine cabling Page 321 2 Check plant supply voltage 3 Check DCM replace as...

Page 163: ...DCM designated ID5 signals a voltage of below 4V at the ignition port 1 Check engine cabling Page 321 2 Check plant supply voltage 3 Check DCM replace as necessary 4 Contact Service 1249 AL_DCM_ID7_8...

Page 164: ...e action Heating of RA line PFM return is faulty 1 Check component s and wiring replace as necessary 2 Contact Service 1311 AL_RA_ring_line_feed_SCR_F1_defect Cause Corrective action Heating of RA lin...

Page 165: ...Check component s and wiring replace as necessary 2 Contact Service 1325 AL_RA_ring_line_return_SCR_F3_defec Cause Corrective action The heating of RA line Flow 3 loop return is faulty 1 Check compon...

Page 166: ...e action The signal from the ambient air temperature sensor at the SCR system flow 2 B82 is faulty or missing 1 Check engine cabling Page 321 2 Contact Service 1346 AL_SD_T_AmbientAir_SCRsys_F3 Cause...

Page 167: ...external heating relay B29 2 for the reducing agent tank is faulty 1 Check relay replace as necessary 2 Check engine cabling Page 321 3 Contact Service 1354 AL_Invalid_PFM_Configuration Cause Correcti...

Page 168: ...1 Cause Corrective action The turning range on homing thermal management flap 1 M58 1 has violated limit value 1 The flap mechanism is beginning to wear u Contact Service 1401 AL Flap Intakeair Wear L...

Page 169: ...ty insulation defective seals signs of sooting 2 Contact Service 1441 AL Act Intake Air Voltage Supply Cause Corrective action The supply voltage of the servomotor for the thermomanagement flap 1 M58...

Page 170: ...ential pressure sensor at the pre feed module of the DOC DPF B91 2 is faulty or missing 1 Check pressure sensor differential pressure sensor B91 2 and replace as necessary 2 Check engine cabling Page...

Page 171: ...pressure sensor differential pressure sensor at the pre feed module of the DOC DPF B91 2 is faulty or missing 1 Check pressure sensor differential pressure sensor B91 2 and replace as necessary 2 Chec...

Page 172: ...e before the DOC measured at sensor B4 33 has violated limit 2 for the set time The exhaust gas temperature before the DOC was is too high 1 Check sensor B4 33 and replace as necessary 2 Contact Servi...

Page 173: ...ve action The signal from the NOx sensor after SCR outlet 2 flow 2 B88 8 is faulty or missing 1 Check engine cabling Page 321 2 Contact Service 1486 AL_CommLost_NOx_EGAT_outl_F2 Cause Corrective actio...

Page 174: ...artridge_defect_SU2 Cause Corrective action The heating cartridge power supply or the heating cartridge in supply unit M80 2X3 is faulty 1 Check component s and wiring replace as necessary 2 Contact S...

Page 175: ...ction The ECU can no longer detect supply unit dosing unit 5 M80 1X1 flow 3 of the SCR system on the CAN bus 1 Check component s and wiring replace as necessary 2 Contact Service 1502 AL_dosing_unit_d...

Page 176: ...n This alarm is set in the fault memory if homing of thermal management flap 2 M58 2 was not successful when initiated with the engine at standstill 1 Check state of charge of batteries plant side 2 C...

Page 177: ...Contact Service 1514 AL Flap Intake B restricted Limit 2 Cause Corrective action The turning range on homing thermal management flap 2 M58 2 has violated limit value 2 Flap travel is restricted u Con...

Page 178: ...to ECU Cause Corrective action The servomotor of thermal management flap 2 M58 2 does not receive any ECU data via the CAN bus 1 Check engine cabling Page 321 2 Contact Service 1520 AL Act Intake Air...

Page 179: ...t PO2 of the DCM ID7 8 reducing agent tank 1 Check component s and wiring replace as necessary 2 Contact Service 1541 AL_HI1_T_RA_prefeed_module Cause Corrective action The temperature of the reducing...

Page 180: ...osition The difference between target position and actual position exceeds limit value 2 u Contact Service 1566 AL_HI1_Level_RA_Leakage_RA_tank Cause Corrective action The leakage system sensor B36 at...

Page 181: ...DCMs transmit messages with the same CAN address The DCM role is configured with the role resistor in connector XRD1 u Contact Service 1582 AL_DCM_ID3_Role_Conflict Cause Corrective action There is a...

Page 182: ...ated limit value 1 The RA concentration is too high 1 Check composition of reducing agent tank content 2 Contact Service 1589 AL_HI2_c_RA Cause Corrective action The RA concentration measured at senso...

Page 183: ...tive action The OBD system of RA dosing system 2 has signaled one or more fault states in the supply unit The fault may lead to dosing circulation cooling failure u Contact Service 1705 AL_hydraulics_...

Page 184: ...orrective action The OBD system of RA dosing system 4 has signaled one or more hydraulic fault states The fault may lead to dosing circulation cooling failure u Contact Service 1710 AL_supply_unit_def...

Page 185: ...t sensor B103 is below the limit value The temperature is too low u Check heating system 1738 AL P5 Or P6 Implausible Cause Corrective action The deviation between charge air pressure B10 1 or the mea...

Page 186: ...ufacturer s documentation Engine governor Plug in connections loose u Check plug in connections Page 323 Running gear blocked engine can not be barred manually u Contact Service Engine turns on starti...

Page 187: ...nit faulty u Contact Service Charge air temperature too high Cause Corrective action Engine coolant mixture incorrect u Check MTU test kit Intercooler contaminated u Contact Service Engine room Air in...

Page 188: ...n fuel prefilter switchable Page 235 Intercooler leaking u Contact Service Water condenses and forms an odorless vapor 1 Run to warm up engine and EGAT following warm up table as necessary 2 May occur...

Page 189: ...hickness of oil residue layer clean replace paper element accomplish at each engine oil change at the latest X Page 277 WM00069 LUBE OIL PUMP WITH DRIVE Inspect pump visually X Page 274 WM00050 ENGINE...

Page 190: ...PLY SYSTEM Check reading on vacuum gauge X Page 238 WM00215 FUEL SUPPLY SYSTEM Drain off water and contamination from fuel prefilter X Page 233 Page 235 WM00214 FUEL SUPPLY SYSTEM Replacing filter ele...

Page 191: ...chet 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...

Page 192: ...sistance other than compression resist ance must be encountered 4 Rotate crankshaft in engine direction of rota tion Result If the resistance exceeds the normal com pression resistance contact Service...

Page 193: ...ge 111 Before starting the engine in a contingency situation to maintain operation of a leaking intercooler Page 246 Cranking engine on starting system Note The engine must not start and no fuel may b...

Page 194: ...isoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of heari...

Page 195: ...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 lowe...

Page 196: ...epending 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 197: ...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 interrup...

Page 198: ...ks 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 inspectio...

Page 199: ...ING Oil is hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protec...

Page 200: ...sealing ring and cover 1 10 Screw on new nut 2 with new washers and tighten nut 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut Tightening torque 10 Nm 2 Nm 11...

Page 201: ...mm Y20000918 1 Measuring jig 2 optional Y4350010 1 Preparatory steps 1 Remove cylinder head covers Page 208 2 Remove guard plate and install barring tool Page 189 3 Turn crankshaft in direction of ro...

Page 202: ...r head 3 4 Turn measuring unit screws 1 into the threads provided for the cylinder head cover and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M10 Ti...

Page 203: ...sured value is 95 8 mm 5 Install valve bridge 6 Adjust valve clearance Page 204 Step 2 optional Measure valve protrusion at the valve stem with measuring jig 2 1 Check TDC position of piston in cylind...

Page 204: ...ricant Value Standard Screw M10 Tightening torque 20 Nm 6 Determine the values with all dial gages The valve protrusion value must be 2 mm Have the affected cylinder head replaced by expert personnel...

Page 205: ...rts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 208 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjusting...

Page 206: ...r F30002815 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head covers Page 208 2 Remove guard plate and install barring tool Page...

Page 207: ...er of the flywheel 4 The additional OT A1 mark 1 if applicable on the outer perimeter of the flywheel must not be used for reference Diagram for 8V engines Two crankshaft positions Diagram for 12V eng...

Page 208: ...ance adjustment with cold engine Inlet valves long rocker arm 0 2 mm 0 05 mm Exhaust valves short rocker arm 0 5 mm 0 05 mm 3 Check all valve clearances in two crankshaft positions firing TDC and over...

Page 209: ...t just pass through the gap 4 Pass valve setting gauge 3 between valve bridge and rocker arm 5 Tighten locknut 1 to specified torque using a torque wrench holding the adjusting screw 2 in place to pre...

Page 210: ...3 4 with washers 2 5 3 Take off cylinder head cover with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean installation surface 2 Check O ring 6 for damage replace as necessary 3 Co...

Page 211: ...s If contact is made with skin wash off with water and soap Keep the engine room well ventilated at all times WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C...

Page 212: ...led or put into operation NOTICE Contamination of components Risk of damage to component Seal off components with suitable covers Check components for special cleanliness prior to installation assembl...

Page 213: ...rque wrench to tighten to specified tightening torque Name Size Type Lubricant Value Standard Neck M16x1 5 Tightening torque 40 Nm Final steps u Install oil line MS15065 01E 2019 01 Injection Pump HP...

Page 214: ...Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 213 212 Injector MS15065 01E 20...

Page 215: ...ia e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale va...

Page 216: ...ns the following infor mation 1 DMC Data Matrix Code 2 L Orange part number 3 MTU part number 4 IIG code Initial Injector Equalization 5 EMI ID code 6 Serial number 7 Date of manufacture Preparatory s...

Page 217: ...6 Install installation removal jig on the cylinder head 7 Remove injector with installation removal jig 8 Remove the installation removal jig 9 Remove sealing ring 2 from injector 1 or use a self made...

Page 218: ...g face on cylinder head and pro tective sleeve by removing carbon deposits with a milling cutter 4 Coat damper ring 2 with Assembly com pound Molykote P 37 5 Coat O rings 3 and 5 with Assembly com pou...

Page 219: ...ype Lubricant Value Standard Screw M12 Tightening torque Engine oil 100 Nm 10 Nm 17 Use a torque wrench and long socket to tighten adapter 3 to specified tightening torque Name Size Type Lubricant Val...

Page 220: ...reset the emission certification becomes invalid u Reset drift compensation CDC using DiaSys and enter injector code IIG Dialog system DiaSys E531920 If DiaSys is not available contact Service Final...

Page 221: ...xplosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING Liquid or gaseous media e g fuel...

Page 222: ...to component Seal off components with suitable covers Check components for special cleanliness prior to installation assembly and clean if necessary Nameplate u The nameplate contains the following i...

Page 223: ...1 5 Install installation removal jig on the cylinder head 6 Remove injector with installation removal jig 7 Remove the installation removal jig 8 Remove sealing ring 4 from injector or use a self made...

Page 224: ...ct Note Only remove plug from injector immediately prior to assembling the adapter 2 Remove plug 3 Clean sealing face on cylinder head and pro tective sleeve by removing carbon deposits with a milling...

Page 225: ...me Size Type Lubricant Value Standard Screw M12 Tightening torque Engine oil 100 Nm 10 Nm 17 Use a torque wrench and long socket to tighten adapter 3 to specified tightening torque Name Size Type Lubr...

Page 226: ...not reset drift correction CDC after re in stalling a used injector 23 After fitting new injectors Page 213 Final steps 1 Install cylinder head cover Page 208 2 Open fuel supply to engine 224 Injector...

Page 227: ...are poisonous Escaping vapors of highly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention...

Page 228: ...rom threaded vent plug 5 Close threaded vent plug 6 Continue to operate the pump until resist ance is noticeable at least 50 times to ach ieve full filling height Note See figure c 7 Lock hand pump Sl...

Page 229: ...ors of highly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce...

Page 230: ...to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves and safety glasses If contact is made with skin was...

Page 231: ...avoid damage to cooling elements only aim water jet parallel to the cooling fins applying moderate pressure To improve the cleaning effect add a suitable degreasing agent to the water in accordance w...

Page 232: ...h swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protectiv...

Page 233: ...poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves and safety...

Page 234: ...engine room well ventilated at all times Pressure ratios Note If the fuel prefilter is above the full level of the fuel tank during engine operation the fuel pressure in the filter is lower than ambi...

Page 235: ...engine room well ventilated at all times WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair lea...

Page 236: ...Vent fuel prefilter Page 244 Draining fuel prefilter in case of high pressure version B Note The fuel prefilter can be drained during engine operation or with the engine at a standstill 1 Provide a s...

Page 237: ...d soap Keep the engine room well ventilated at all times WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all...

Page 238: ...ilter module 2 is cut out 3 Open threaded vent plug 1 of filter to be serviced 4 Open drain plug 1 5 Allow water to drain until fuel emerges 6 Close drain plug 2 again 7 Drain the second filter on the...

Page 239: ...chover during engine operation and at engine stand still 1 Provide a suitable container to collect the water 2 Take care when opening drain plug 1 be cause fuel or water can spurt out 3 Allow water to...

Page 240: ...eading at low pressure gauge 3 Red zone 1 1 0 bar to 0 4 bar low pressure Green zone 2 0 4 bar to 0 5 bar nor mal operation 2 Switch over the fuel prefilter or replace a fil ter element Page 241 when...

Page 241: ...tion to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves and safety glasses If contact is made with skin...

Page 242: ...element 3 from filter housing 4 7 Unclip filter element 3 from filter cover 1 8 Install new O ring 2 on filter cover 1 9 Coat new O rings on filter cover and filter ele ment with fuel 10 Clip new filt...

Page 243: ...es and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off...

Page 244: ...is opened absolute cleanness is imperative Carefully extract the filter element straight up avoiding contact with the upper edge of the cylinder if at all possible to prevent contamination of the fuel...

Page 245: ...ible to prevent contamination of the fuel remaining in the filter housing 6 Unscrew filter cover 1 and withdraw with fil ter element 3 from filter housing 4 7 Unclip filter element 3 from filter cover...

Page 246: ...well ventilated at all times WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust...

Page 247: ...eaded vent plugs 2 3 Note Never actuate the handle with the threaded vent plugs closed 5 Move handle 1 of fuel priming pump back and screw in 6 Close threaded vent plugs 2 3 and tighten by hand Ventin...

Page 248: ...ctions and check the openings for coolant discharge Result If a large amount of coolant is discharged contact Service 4 Insert plug screw 1 and use torque wrench to tighten to specified tightening tor...

Page 249: ...that the engine can not be started After completion of work make sure that all protective devices are installed Throttle flap after intercooler checking lever position u Check position of lever 2 at d...

Page 250: ...them Functional capability and wear are also established in the course of the teach in routine The teach in routine is initiated automatically when the Engine Control Unit is connected to the power su...

Page 251: ...Material Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Air filter Replacement 1 Remove air filter and install new one Page 251 2 Reset signal ring of service indicator Page 2...

Page 252: ...l Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Checking air filter 1 Check entire circumference of air filter for damage 2 Fit new air filter if damaged Page 249 250 Air Filt...

Page 253: ...otective gloves safety goggles respiratory protection etc is to be used NOTICE Stepping or climbing on the genset to perform installation tasks is to be avoided Otherwise there is a risk of component...

Page 254: ...the equipment always use suitable ladders or work platforms Use personal protective equipment WARNING Heavy part risk of falling or overturning due to lack of stability Risk of crushing body or limbs...

Page 255: ...Remove cover 2 3 Remove filter insert 3 and filter element 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 Assemble in reverse order MS...

Page 256: ...rting disabled Checking signal ring position 1 When the yellow piston 2 has reached the red shaded Service lettering 3 replace air filter Page 249 2 After installation of new filter press reset button...

Page 257: ...d poisoning Avoid contact with eyes or skin Do not inhale vapors or smoke Never eat drink or smoke when handling reducing agent e g AdBlue DEF Wear protective clothing protective gloves and safety gog...

Page 258: ...feed module to RA tank 2 Take photos or use the Spare Parts Catalog to identify and arrange the RA lines 3 Provide suitable containers to collect escaping reducing agent 4 Remove reducing agent lines...

Page 259: ...e that all mating connectors are clean and free of deposits e g urea crystals 2 Install new reducing agent lines in reverse order 3 Open supply and return line from pre feed module to RA tank before s...

Page 260: ...dders or work platforms Use personal protective equipment WARNING Ammonia is created in case of fire or overheating Risk of poisoning if reducing agent e g AdBlue DEF is swallowed Risk of skin irritat...

Page 261: ...RA tank Note Clean with high pressure cleaner steam jet cleaner as necessary 2 Clean supply unit externally prior to opening Note Small amounts of reducing agent may escape on removing the filter hou...

Page 262: ...g 1 4 Sealing bead of the frost compensation diaphragm 3 must be seated all round completely and firmly in the groove of the pump housing 1 5 Spray the full circumference of the frost compensation dia...

Page 263: ...ms Use personal protective equipment WARNING Ammonia is created in case of fire or overheating Risk of poisoning if reducing agent e g AdBlue DEF is swallowed Risk of skin irritation and eye injury on...

Page 264: ...in opening of insulation paneling 3 Secure dosing unit with screw 4 4 Then thread in screw 1 and finally the upper screw 3 5 Coat screws 1 3 4 with assembly com pound 6 Use a torque wrench to tighten...

Page 265: ...oisoning if reducing agent e g AdBlue DEF is swallowed Risk of skin irritation and eye injury on contact with reducing agent e g AdBlue DEF Risk of injury and poisoning Avoid contact with eyes or skin...

Page 266: ...y before opening it 4 Undo filter housing 2 with filter wrench and drain reducing agent into a suitable contain er 5 Remove filter element by pulling it down wards 6 Replace O ring 7 Insert new filter...

Page 267: ...work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Components have sharp edges Risk of injury Wear protective gloves WARNING Soot dust fibers a...

Page 268: ...ion unit 2 2 Unscrew evaluation unit 2 Note If the sensor head is stuck do not use oil containing silicon or magnesium to release it Do not attempt to release it by knocking with a hammer or other too...

Page 269: ...e moved twice After being exposed to any impact the sensor is considered to be faulty and may not be used Do not wipe off thread grease of manufac turer If necessary apply a thin coat of Molykote P 37...

Page 270: ...tive clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames e...

Page 271: ...for unsched uled engine oil change 1 Provide a suitable container to collect the en gine oil 2 Remove drain plug 1 and drain engine oil from engine oil heat exchanger and from en gine oil filter 3 Rem...

Page 272: ...engine oil level Page 271 Note Observe the following instructions to avoid engine damage Adequate oil pressure for an engine start is only provided when the quick start function is deactivated 5 Make...

Page 273: ...check oil level Note After extended standstill the oil level may be up to 2 cm above mark 1 This may be caused e g by oil from oil filters and heat ex changers flowing back into the oil pan After ext...

Page 274: ...ning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil v...

Page 275: ...ent Fuel dilution Engine oil sample extraction and analysis 1 With the engine running at operating temper ature open screw 1 on carrier of centrifugal oil filter support by 1 to 2 rotations 2 Drain ap...

Page 276: ...ect oil priming pump and connections for firm seating and leaks Retighten loose threaded connections as necessary 2 Check leak telltale bore 2 for oil discharge Result If oil emerges the gear pump 1 u...

Page 277: ...protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks...

Page 278: ...d tighten engine oil filter by hand 6 Replace other engine oil filters in the same way Note Observe the following instructions to avoid engine damage Adequate oil pressure for an engine start is only...

Page 279: ...hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves...

Page 280: ...ugal oil filter 1 Coat new sealing rings 9 and 10 with as sembly compound and insert in grooves on bearing shaft 11 2 Assemble rotor tube 7 conical disk 8 and rotor base 13 with new sealing ring 12 No...

Page 281: ...ame Size Type Lubricant Value Standard Clamp Tightening torque 20 Nm 3 Nm 12 Use a torque wrench to tighten cover nut 2 to specified tightening torque Name Size Type Lubricant Value Standard Screw Tig...

Page 282: ...kin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when working with antifreeze Wear protective clothing protective gloves and goggles safety mask Wipe up escaped spille...

Page 283: ...y means of level sensor 1 Switch on engine control system and check readings on the display 2 Top up coolant if necessary Page 285 MS15065 01E 2019 01 Coolant System General High Temperature Circuit 2...

Page 284: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 283 2 Fill with engine coolant Page 285 282 Coolant System General High Temperature Circuit...

Page 285: ...les safety mask Wipe up escaped spilled coolant immediately Preparatory steps 1 Provide a suitable container to catch the coolant 2 Switch off preheater Draining engine coolant 1 Turn valve cover of c...

Page 286: ...2 Close all other open drain points 3 Position valve cover on filler neck and close 284 Coolant System General High Temperature Circuit MS15065 01E 2019 01 TIM ID 0000000960 005...

Page 287: ...d under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Coolant contains antifreeze and is toxic Risk of poisoning and sli...

Page 288: ...ributor arrowed Note Important Fill engine only from below 2 Connect appropriate pump with hose to drain valve of engine coolant pump 1 3 Open shutoff cock on elbow of engine cool ant pump 2 and pump...

Page 289: ...lant expansion tank counterclockwise until the first stop and allow pressure to es cape 12 Continue to turn valve cover counterclockwise and remove 13 Check coolant level Page 280 and top up coolant a...

Page 290: ...ion tank counterclockwise until the first stop and release pressure 9 Turn valve cover 1 counterclockwise and re move 10 Check coolant level Page 280 and top up with coolant through the filler neck if...

Page 291: ...p the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suitable heari...

Page 292: ...fety mask WARNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke...

Page 293: ...f cock 2 to specified tightening torque Name Size Type Lubricant Value Standard Spindle 11 A F Tightening torque 12 Nm 5 Using the equipment and chemicals from the MTU test kit examine coolant for ant...

Page 294: ...t 6 Intake 7 Safety thermostat 8 Housing cover 9 Pump Arrow Flow direction Variant Heating output Rated voltage Frequency Phases 1 9 kW 400 V 50 Hz 3 2 9 kW 480 V 60 Hz 3 3 12 kW 400 V 50 Hz 3 4 12 kW...

Page 295: ...ng protection Do not eat drink smoke when working with antifreeze Wear protective clothing protective gloves and goggles safety mask Wipe up escaped spilled coolant immediately Function check Note The...

Page 296: ...onnected Replacing solenoid switch u Replace solenoid switch Page 295 Cleaning heating element and replacing gasket u Clean heating element and housing and check Page 297 Replacing thermostat u Replac...

Page 297: ...tifreeze and is toxic Risk of poisoning and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when working with antifreeze Wear pr...

Page 298: ...ip with a screwdriver and slide the solenoid switch off the rail 5 Fit a new solenoid switch on the rail and fully engage the spring clip 6 Connect up all wires as marked previously 7 Close the contro...

Page 299: ...essure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoi...

Page 300: ...d or new heating element into housing 7 Install electrical part 2 and tighten screws 1 Installing coolant lines 1 Clean drain plug and screw in thread arrow at preheater 2 Coat drain plug with screw l...

Page 301: ...Final steps 1 Connect preheater power sources 2 Switch on preheater MS15065 01E 2019 01 Coolant System General High Temperature Circuit 299 TIM ID 0000081913 004...

Page 302: ...hermal gloves Avoid unprotected contact with hot surfaces WARNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles saf...

Page 303: ...suring unit 2 4 Undo thermostat clip 1 and remove safety thermostat 5 Insert new safety thermostat in recess 6 Secure thermostat clip 7 Connect cable 8 Fit cover and tighten screws Replacing control t...

Page 304: ...l thermo stat 1 5 Install new control thermostat 1 with screws 2 6 Connect cable 7 Fit housing cover and tighten screws Final steps 1 Connect preheater to power supply 2 Switch on preheater 302 Coolan...

Page 305: ...fety mask Preparatory steps u Switch off preheater Replacing valve cover Note Schematic diagram Design may deviate 1 Turn valve cover 1 on coolant expansion tank counterclockwise until the first stop...

Page 306: ...and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when working with antifreeze Wear protective clothing protective gloves and...

Page 307: ...rge air coolant level is monitored automatically by the engine control system 1 Switch on engine control system and check readings on the display 2 Top up with charge air coolant as necessary Page 309...

Page 308: ...al tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 307 2 Fill with charge air coolant Page 309 306 Low Temperature Circuit MS15...

Page 309: ...goggles safety mask WARNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat...

Page 310: ...a torque wrench to tighten drain valve on charge air coolant pump to specified tightening torque Name Size Type Lubricant Value Standard Spindle 11 A F Tightening torque 12 Nm 9 Screw in drain screws...

Page 311: ...lant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Coolant contains antifreeze and is toxic Risk of poi...

Page 312: ...illing coolant with pump 1 Connect appropriate pump with hose to drain valve 1 2 Release the vent line union at the distributor piece 1 3 Open drain valve and pump coolant into en gine at 0 5 bar mini...

Page 313: ...1 Release the vent line union at the distributor piece 1 2 Top up coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant 3 Tighten union arrowed if...

Page 314: ...ation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suita...

Page 315: ...onents Never operate the engine without protective covers or safety guards which meet applicable accident prevention regulations Ensure that the safety guards can prevent body parts from being drawn i...

Page 316: ...0 1 WARNING Belt tensioner spring is pretensioned Risk of hands being crushed Lock belt tensioner in position Only use specified tools and devices Adjusting belt tension 1 Slacken screws 1 and 2 by ha...

Page 317: ...belt replacement 1 Remove protective cover 2 Loosen screws 2 and 3 by half a turn 3 Mount socket or box wrench on screw 1 and press belt tensioner in direction of arrow as far as the stop 4 Tighten s...

Page 318: ...ife or destruction of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them Engine mounting Check Item...

Page 319: ...a torque wrench to tighten loose screw connections 1 to specified tightening torque Name Size Type Lubricant Value Standard Screw M20 Control torque Engine oil 500 Nm 50 Nm 3 Use a torque wrench to ti...

Page 320: ...fied tightening torque Name Size Type Lubricant Value Standard Screw M20 Control torque Engine oil 500 Nm 50 Nm 3 Use a torque wrench to tighten loose screw connections 3 to specified tightening torqu...

Page 321: ...ll Risk of shorter service life or destruction of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them...

Page 322: ...ing check Preconditions Engine is stopped and starting disabled Generator mounting securing screw firm seating check 1 Check securing screws for firm seating 2 Tighten loose screws 320 Engine Mounting...

Page 323: ...intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector...

Page 324: ...propyl alcohol to remove coarse dirt from housing surface 2 Use isopropyl alcohol to remove dirt from the connector and cable surfaces 3 Check legibility of cable labels Clean or replace illegible lab...

Page 325: ...management system is de energized Checking plug connections at Engine Control Unit 1 Check all plug connections for firm seating 2 Lock loose connectors 3 Check dust cap on ECU connectors for damage a...

Page 326: ...1 Note or mark assignment of cables and plugs 2 Remove all screws 2 3 Undo clips 3 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Installing engine governor on...

Page 327: ...p Data Module Data backup module BHP Brake Horse Power BMEP Brake Mean Effective Pressure BR Baureihe Series BTU British Thermal Unit British unit for heat energy BV Betriebsstoffvorschrift MTU Fluids...

Page 328: ...ter Nominal Nominal pipe diameter DPF Diesel Particulate Filter DU Dosing Unit ECM Electronic Control Module Electronic control unit ECU Engine Control Unit Engine governor EGAT Exhaust Gas Aftertreat...

Page 329: ...andardization institutes ITS Integrated Test System KGS Kupplungsgegenseite Engine free end as per DIN ISO 1204 KS Kupplungsseite Engine driving end as per DIN ISO 1204 LCD Liquid Crystal Display LED...

Page 330: ...ionsmittel Reducing agent RMS Root Mean Square Mathematical value RPM Revolutions Per Minute Unit of frequency 1 rpm 1 60 Hz RTC Real Time Clock RTD Resistance Temperature Detector Resistance thermome...

Page 331: ...Caps UltraCaps modules Starting system capacitors UPS Uninterruptible Power Supply USV Unterbrechungsfreie Stromversorgung Uninterruptible Power Supply UT Unterer Totpunkt Bottom Dead Center VAwS Vero...

Page 332: ...Unit B in2 645 16 mm2 ft2 0 0929 m2 yd2 0 8361 m2 stat mile2 2 59 km2 Unit B multiplied by factor Unit A mm2 0 00155 in2 m2 10 764 ft2 m2 1 1960 yd2 km2 0 3861 stat mile2 Volume Unit A multiplied by...

Page 333: ...t mile h mph 1 609 km h knot UK 1 852 km h Unit B multiplied by factor Unit B m s 3 281 ft s km h 0 6214 stat mile h mph km h 0 54 knot UK Mass Unit A multiplied by factor Unit B lb 0 4536 kg oz 28 35...

Page 334: ...95 bar lbf ft2 psf 47 88 Pa inHg 0 03386 bar inHg 345 3 kp m2 mmH2O Unit B multiplied by factor Unit A atm 760 mmHg atm 1 0133 bar atm 10332 kp m2 mmH2O atm 1 0332 kp cm2 at atm 14 696 lbf in2 psi bar...

Page 335: ...8598 kcal h lbf ft s 0 0018 HP Temperature Celsius Kelvin x C x 273 15 K x K x 273 15 C x F 5 9 x 32 C 5 9 x 32 273 15 K x R 5 4x C 5 4x 273 15 K Fahrenheit R aumur x C 9 5x 32 F 4 5x R x K 9 5 x 273...

Page 336: ...of a malfunction for information on changes in conditions of use and for supplying spare parts Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax...

Page 337: ...4 Barring tool Part No F6555766 Qty Used in 1 9 1 1 Engine Barring manually Page 189 Qty Used in 1 9 2 1 Cylinder liner Endoscopic examination Page 193 Crossbeam Part No T80092360 Qty Used in 1 2 1 Tr...

Page 338: ...ion Page 193 Feeler gauge Part No Y20098771 Qty Used in 1 9 4 3 Valve clearance Check and adjustment Page 204 Filter wrench Part No F30379104 Qty Used in 1 9 8 1 Fuel filter Replacement Page 230 Qty U...

Page 339: ...h pressure cleaner Part No Qty Used in 1 6 13 Plant Cleaning Page 124 High pressure cleaner steam jet cleaner Part No Qty Used in 1 9 12 2 Supply unit Filter element replacement Page 258 Installation...

Page 340: ...Milling cutter Part No F30452739 Qty Used in 1 9 6 2 Injector Removal and installation Page 213 Qty Used in 1 9 6 3 Injector rings Replacement Page 219 MTU test kit Part No F6798833 Qty Used in 1 9 1...

Page 341: ...Used in 1 9 8 8 Fuel prefilter switchable Filter element replace ment Page 241 Qty Used in 1 9 12 3 Dosing unit Replacement Page 261 Qty Used in 1 9 14 2 Centrifugal oil filter Cleaning and filter sl...

Page 342: ...t tension ad justment Page 314 Qty Used in 1 9 18 2 Battery charging generator drive Drive belt re placement Page 315 Qty Used in 1 9 19 2 Engine mounting Checking securing screws for firm seating Pag...

Page 343: ...46 Part No F30006128 Qty Used in 1 9 12 2 Supply unit Filter element replacement Page 258 Torque screwdriver 1 5 Nm Part No F30452774 Qty Used in 1 9 6 2 Injector Removal and installation Page 213 Qt...

Page 344: ...Replacement Page 265 Qty Used in 1 9 14 2 Centrifugal oil filter Cleaning and filter sleeve re placement Page 277 Qty Used in 1 9 18 1 Battery charging generator Drive belt tension ad justment Page 3...

Page 345: ...Page 204 Qty Used in 1 9 6 2 Injector Removal and installation Page 213 Qty Used in 1 9 6 3 Injector rings Replacement Page 219 Qty Used in 1 9 12 2 Supply unit Filter element replacement Page 258 Qt...

Page 346: ...ed in 1 9 8 8 Fuel prefilter switchable Filter element replace ment Page 241 Torque wrench 8 40 Nm Part No F30043446 Qty Used in 1 9 12 3 Dosing unit Replacement Page 261 Valve setting gauge Part No Y...

Page 347: ...282 306 Filling 285 309 Coolant expansion tank Valve cover replacement 303 Cooling system 61 Crankcase 44 Crankcase breather Filter element replacement 197 Crankshaft transport locking device Installa...

Page 348: ...275 Engine oil level Check 271 Engine sides Designation 33 Exhaust gas aftertreatment Overview 71 Exhaust gas aftertreatment management 92 Exhaust gas aftertreatment monitoring 92 Exhaust gas aftertre...

Page 349: ...eck 293 Leak check 293 Overhaul 294 Overview 292 Replacement Solenoid switch 295 Thermostat 300 Pre feed module Filter element Replacement 263 Pre feed module PFM 82 Product Summary 34 Product data 12...

Page 350: ...rs NOx Replacement 265 Overview 67 Service indicator Check 254 Service partners 334 Shipping lock Engine mount Installation 32 Removal 32 Solenoid switch Replacement Preheater 295 Spare parts service...

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MTU 12V4000G15S, Operating Instructions Manual

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