MTU 12V4000T94 Operating Instructions Manual Download Page 89

Page: 89 / 189

7.6 Injection Valve / Injector

7.6.1 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 90).

MS150096/03E 2015-04

| Task Description | 89

TIM-ID: 0000042329 - 002

Summary of Contents for 12V4000T94

Page 1: ...Operating Instructions Diesel engine 12 V 4000 T94x MS150096 03E...

Page 2: ...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 microfilmin...

Page 3: ...2 Cylinder Liner 77 7 2 1 Cylinder liner Endoscopic examination 77 7 2 2 Instructions and comments on endoscopic and visual examination of cylinder liners 79 7 3 Crankcase Breather 81 7 3 1 Oil mist f...

Page 4: ...Drive belt Condition check 155 7 20 Battery Charging Generator 156 7 20 1 Checking battery charging generator 156 7 20 2 Battery charging generator drive Drive belt tension adjustment 157 7 20 3 Batte...

Page 5: ...with the Spare Parts Catalog MTU contact Service partner In the original as delivered configuration or in a configuration approved by the manufacturer in writ ing including engine control parameters...

Page 6: ...tion authorities The manufacturer does not accept any liability for violations of the emission reg ulations The maintenance schedules of the manufacturer must be observed over the entire life cycle of...

Page 7: ...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 Cen...

Page 8: ...ight 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 imp...

Page 9: ...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 gea...

Page 10: ...er 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...

Page 11: ...l 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...

Page 12: ...ing 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 alternat...

Page 13: ...ruments as well as the monitoring signaling and alarm systems are working properly Safety requirements for operation The operator must be familiar with the controls and displays The operator must be f...

Page 14: ...unts damping elements couplings and V belts must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to sta...

Page 15: ...he power supply master switch Disconnect the battery Separate the electrical ground of electronic equipment from the ground of the unit No other maintenance or repair work must be carried out in the v...

Page 16: ...Always use connector pliers to tighten union nuts on connectors Subject the device as well as the product to a functional testing on completion of all repair work In particular check the function of t...

Page 17: ...lubricants and filters in accordance with local regulations Within the EU batteries can be returned free of charge to the manufacturer where they will be properly recycled Fluids and lubricants auxili...

Page 18: ...spray stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely af fected There must be no naked flames in the vicin...

Page 19: ...medial 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...

Page 20: ...nated 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 21: ...Engine suspension 18 Supplementary fuel filter 19 Fuel priming pump 20 Fuel filter 21 HP fuel pump 22 Lube oil filter 23 Engine mounting 24 Vibration damper 25 Auxiliary PTO 26 Battery charging gener...

Page 22: ...k 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 MS150096 03...

Page 23: ...ors and injectors Overview 1 B13 Crankshaft speed 2 F70 Water level in fuel prefilter external 3 F57 Charge air coolant level 4 F33 Engine coolant level MS150096 03E 2015 04 General Information 23 TIM...

Page 24: ...s sure 6 B88 NOx 7 B16 Engine coolant pres sure 8 Y39 B1 B6 Injectors B1 B6 9 B13 Crankshaft speed 10 B10 11 Charge air pres sure B side The injectors 8 are underneath the cylinder head covers of the...

Page 25: ...ntary filter 9 B34 2 Fuel pressure be fore filter 10 B34 1 Fuel pressure after filter 11 F46 Leak fuel level 12 B5 3 Lube oil pressure before filter 13 B7 Lube oil temperature 14 B44 1 Turbocharger A...

Page 26: ...af ter filter 4 B33 Fuel temperature rail 5 B48 Fuel pressure rail 6 M8 HP fuel pump 7 B1 Camshaft speed 8 B43 Charge air coolant pressure 9 B26 Charge air coolant temperature 10 B6 Engine coolant tem...

Page 27: ...ir temperature C 25 25 Charge air coolant temperature C 45 45 Barometric pressure mbar 1000 1000 Site altitude above sea level m 100 100 Power related data power ratings are net brake power as per ISO...

Page 28: ...520 490 Coolant system high temperature circuit Description 12 V 4000 T94 12 V 4000 T94L Coolant temperature at engine connection outlet to cooling system A C 105 105 Coolant temperature after engine...

Page 29: ...starting L bar 0 1 0 1 Fuel pressure at engine inlet connection max when engine is starting L bar 1 5 1 5 General operating data Description 12 V 4000 T94 12 V 4000 T94L Cold start capability Air tem...

Page 30: ...L Liters 210 210 Weights main dimensions Description 12 V 4000 T94 12 V 4000 T94L Dry engine weight basic configuration engine R kg 7685 7685 Sound Description 12 V 4000 T94 12 V 4000 T94L Exhaust no...

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 MS150096 03E 2015 04 Technical Data 31 TIM ID 0000026627 002...

Page 32: ...3 3 Engine Main dimensions Engine Main dimensions Item Dimensions Length A approx 2685 mm Width B approx 1631 mm Height C approx 1921 mm 32 Technical Data MS150096 03E 2015 04 TIM ID 0000018765 005...

Page 33: ...3 months Item Action Engine Depreserve MTU Preservation and Represervation Specifications A001070 Valve gear Lubricate valve gear every 6 months Page 82 Engine oil system Check engine oil level Page...

Page 34: ...ngine into operation Check the components carrying air and exhaust for corrosion Do not put the engine in operation if corrosion was detected Putting into operation Item Measure Engine oil system Chec...

Page 35: ...ngine 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...

Page 36: ...e 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...

Page 37: ...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 f...

Page 38: ...ve 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 the antifreeze concentration is 50 and...

Page 39: ...ed 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 pr...

Page 40: ...ge 116 W1006 Replace fuel injectors Page 89 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 134 W1009 X Check layer thickness of the o...

Page 41: ...9 W1636 Reset parameters of drift correction CDC and enter coding for injectors IIG Page 161 W1675 X Replace fuel prefilter or its filter element Page 99 W1817 Check clearance of coupling rods for EGR...

Page 42: ...lug in connections loose u Checking plug in connections Page 165 Running gear blocked engine cannot be barred manually u Contact Service Engine turns on starting but does not fire Cause Corrective act...

Page 43: ...efective u Contact Service Air in fuel system u Vent fuel system Page 95 Engine governor defective u Contact Service Charge air temperature too high Cause Corrective action Incorrect coolant concentra...

Page 44: ...n 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 f...

Page 45: ...rvice 5 HI T Charge Air Cause Corrective action The charge air temperature at sensor B9 has exceeded limit value 1 Charge air temperature too high 1 Reduce power 2 Check whether alarms 9 and 10 are pe...

Page 46: ...ue 2 The lube oil pressure is too low 1 Check engine oil level Page 129 2 Contact Service 23 LO Coolant Level Cause Corrective action Coolant level at switch F33 is too low 1 Check engine coolant leve...

Page 47: ...speed is too high Cause Defect or malfunction of another turbocharger 1 Reduce power 2 Contact Service 32 SS ETC1 Overspeed Cause Corrective action The speed of the LP turbocharger A side at sensor B...

Page 48: ...of cooler and fan plant side 3 Check engine coolant level Page 138 4 Contact Service 52 SS T Lube Oil Cause Corrective action The lube oil temperature at sensor B7 has exceeded limit value 2 Lube oil...

Page 49: ...SS P Fuel Cause Corrective action The fuel pressure at sensor B34 1 has undershot limit value 2 Fuel pressure is too low 1 Replace supplementary fuel filter Page 97 2 Replace fuel filter Page 96 3 Rep...

Page 50: ...if necessary Page 96 4 Check fuel prefilter replace if necessary Page 99 5 Observe additional messages 6 Contact Service 91 SS Release Speed Not Reached Cause Corrective action Engine speed has not r...

Page 51: ...rrective action The supply voltage of the ECU has exceeded the specified limit value 1 1 Check charge state of the batteries plant side 2 Check plug connections to engine governor Page 165 3 Check bat...

Page 52: ...202 SD T Fuel Cause Corrective action The HP fuel sensor B33 at HP distributor supplies incorrect signal or no signal 1 Check engine wiring Page 160 2 Contact Service 203 SD T Charge Air Cause Correc...

Page 53: ...Contact Service 213 SD P Coolant Charge Air Cooler Cause Corrective action The coolant pressure sensor B43 supplies incorrect signal or no signal 1 Check engine wiring Page 160 2 Contact Service 214 S...

Page 54: ...Filter Cause Corrective action The oil pressure sensor before the filter B5 3 supplies incorrect signal or no signal 1 Check engine wiring Page 160 2 Contact Service 228 SD P Fuel before Filter Cause...

Page 55: ...orrective action The pressure sensors B34 1 and or B34 2 supply incorrect signal or no signal 1 Check engine wiring Page 160 2 Contact Service 240 SD P Fuel Cause Corrective action The HP fuel sensor...

Page 56: ...ective action Short circuit fault in injector wiring cylinder A5 or injector faulty 1 Check wiring of affected injector Page 160 2 Replace injector Page 89 3 Contact Service 326 AL Wiring Cylinder A6...

Page 57: ...Short circuit fault in injector wiring cylinder B6 or injector faulty 1 Check wiring of affected injector Page 160 2 Replace injector Page 89 3 Contact Service 341 AL Open Load Cylinder A1 Cause Corre...

Page 58: ...er B2 1 Check wiring of affected injector Page 160 2 Contact Service 353 AL Open Load Cylinder B3 Cause Corrective action Disruption fault in injector wiring cylinder B3 1 Check wiring of affected inj...

Page 59: ...ant Charge Air Cooler Cause Corrective action The charge air coolant pressure in the charge air cooler at sensor B43 has undershot limit value 2 Charge air coolant pressure is too low 1 Check relief b...

Page 60: ...at sensor B44 3 has exceeded limit value 1 The turbocharger speed is too high Cause Defect or malfunction of another turbocharger 1 Reduce power 2 Contact Service 536 AL Wiring PWM_CM1 Cause Correctiv...

Page 61: ...supplementary fuel filter Page 97 2 Replace fuel filter Page 96 3 Replace fuel prefilter Page 99 4 Contact Service 615 AL EIL Protection Cause Corrective action Engine number in EIL does not match th...

Page 62: ...ulty 1 Check operation of bypass flap Page 122 2 Contact Service 632 AL Dispenser Flap Defect Cause Corrective action The donor flap M55 is faulty 1 Check operation of donor flap Page 122 2 Contact Se...

Page 63: ...28 AL L2 Delta T LT Charge Air Cooler Cause Corrective action The differential temperature at sensors B26 and B90 has exceeded the limit value The LT coolant inlet temperature is too high in relation...

Page 64: ...ring for emergency air shutoff flap B side Page 160 2 Contact Service 767 AL EASF Closed Cause Corrective action Emergency air shutoff flaps A and B side closed 1 Set emergency air shutoff flaps to ON...

Page 65: ...so trips closing of the A side flap if it is open 1 Check engine wiring Page 160 2 Contact Service 857 AL NOx ATO1 Sensor Defect Cause Corrective action The NOx sensor B88 in the exhaust line after LP...

Page 66: ...on Status information of NOx sensor B88 generated in case of short term implausible measured values or sensor defect 1 Acknowledge alarm 2 Replace NOx sensor Page 166 3 Contact Service 956 AL p5 ctrlv...

Page 67: ...f the lambda sensor can also result in this alarm 1 Check operation of EGR shutoff flap and donor flap Page 122 2 Contact Service 960 AL NOx p5 min BOI max active Cause Corrective action Emission rela...

Page 68: ...4 Exhaust turbocharger HP check turbine housing Page 109 5 Contact Service 964 AL GPS p5 ctrlvar min active Cause Corrective action The required charge pressure could not be reached 1 Check operation...

Page 69: ...Stop on Trigger Crashrecorder Cause Corrective action The alarm indicates that the Crash Recorder was triggered and as a result a start interlock was activated u Contact Service 1097 AL Flap Egr A Co...

Page 70: ...onger detect the donor flap M55 on the bus 1 Check engine wiring Page 160 2 Contact Service 1110 AL Flap DispensTemperature too high Cause Corrective action The internal electronics of the servomotor...

Page 71: ...Bypass A Calibr Drive Err Cause Corrective action The ECU has detected a calibration run error for bypass flap M52 Cause The learned speed range angle during the calibration run is implausible The lea...

Page 72: ...Page 122 3 Contact Service 1188 AL Bypass FlpA Wear Limit2 Cause Corrective action Fast reference run of EGR shutoff flap M52 executed after each ECU restart faulty Limit value 2 1 Check charge state...

Page 73: ...6 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 mak...

Page 74: ...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...

Page 75: ...rom the engine Barring engine with starting system 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 engin...

Page 76: ...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 te...

Page 77: ...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...

Page 78: ...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 P...

Page 79: ...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 m...

Page 80: ...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 inspec...

Page 81: ...ing Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing oil mist fine separator 1 Remove screws 7 9 and remove sensors 8 10 2 Remove screw...

Page 82: ...are parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 86 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 83: ...key F30002815 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 86 2 Install barring device Page 73 Note The OT mark...

Page 84: ...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 feel...

Page 85: ...Final steps 1 Remove barring device Page 73 2 Install cylinder head cover Page 86 3 Enable engine start MS150096 03E 2015 04 Task Description 85 TIM ID 0000026629 003...

Page 86: ...nder head covers 1 if severely soiled prior to removal 2 Remove screws 3 4 with washers 2 5 3 Take cylinder head cover 1 with O ring 6 off cylinder head 7 Installing cylinder head cover 1 Clean mounti...

Page 87: ...rces 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 e...

Page 88: ...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 88 Task Description MS150096 03E 2015 04 TIM ID 0000042838 002...

Page 89: ...ctor 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 90 MS150096 03E 2015 04 Tas...

Page 90: ...end wrench 19 mm F30025897 1 Plug in open end wrench 27 mm F30029816 1 Ratchet F30027341 1 Assembly compound Montagestoff Kluthe Hakuform 30 15 X00067260 1 Assembly paste Optimoly Paste White T 40477...

Page 91: ...emove screw 2 from hold down clamp 1 6 Mount puller 2 on cylinder head 7 Remove injector 1 and hold down clamp with puller 2 8 Remove puller 2 9 Clean all mating and sealing surfaces 10 If carbon resi...

Page 92: ...compound and insert in injector Note New O rings and damping ring are included in the scope of delivery of the injector and are preassembled 4 Fit O rings 2 3 and damping ring on new injector 1 and c...

Page 93: ...wrench to tighten to the specified initial tightening torque Name Size Type Lubricant Value Standard Adapter Preload torque Engine oil 5 Nm to 10 Nm 13 Tighten screw on hold down clamp Step 9 with to...

Page 94: ...t screw Tightening torque Engine oil 40 Nm 5 Nm 17 Fit connectors on injector Note Failure to reset drift compensation CDC will void the emissions certification 18 Reset drift compensation CDC with Di...

Page 95: ...gloves and safety glasses facial protection Venting LP fuel system 1 Open threaded vent plug 1 and connect a suitable hose 2 Provide a suitable container to collect the fuel 3 Unlock fuel priming pump...

Page 96: ...oke Wear protective clothing protective gloves and safety glasses facial protection Fuel filter Replacement 1 Provide a suitable container to collect the fuel 2 Remove easy change filter 2 with filter...

Page 97: ...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 filt...

Page 98: ...lames 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 ve...

Page 99: ...ing 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 coc...

Page 100: ...terial Spare parts Designation Use Part No Qty Turbine housing Spare Parts Catalog Exhaust turbocharger low pressure charger u Check turbine housing Page 101 Exhaust turbocharger high pressure u Check...

Page 101: ...engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Coolant is hot and under pressure Risk of...

Page 102: ...LP left side 1 Release screws on holders 2 3 2 Remove holders 2 3 with coolant vent lines 1 4 from heat shield 3 Remove temperature sensor 1 lambda sensor 2 and measurement line for sen sor B91 3 3 f...

Page 103: ...he turbine housing of the exhaust turbocharger HP re quires special work steps Page 109 Removing heat shield 1 Remove screws 1 and take off with hold er 2 and washers 2 Remove screws 3 and take off wi...

Page 104: ...rom turbine housing 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...

Page 105: ...bracket and tighten to specified tightening torque Name Size Type Lubricant Value Standard Screws Tightening torque Assembly paste Ul tra Therm MTU 42 Nm 4 Nm Installing heat shield 1 Install heat shi...

Page 106: ...ocket for NOx sensor to tighten to specified tightening torque Name Size Type Lubricant Value Standard Sensor M20 x 1 5 Tightening torque 50 Nm 10 Nm 2 Install pipe clamp halves 2 3 and coolant vent l...

Page 107: ...readed adapter 1 of temperature sensor B4 on exhaust elbow and use torque wrench to tight en nut 2 to specified tightening torque Name Size Type Lubricant Value Standard Threaded adapter M14 x 1 5 Tig...

Page 108: ...ent lines 1 4 and hold ers 2 8 on heat shield and tighten screws Final steps general 1 Fill with engine coolant Page 142 2 Fill charge air coolant Page 151 108 Task Description MS150096 03E 2015 04 TI...

Page 109: ...ARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surf...

Page 110: ...LP requires separate activities Page 101 Removing heat shield 1 Remove screws 1 and take off with hold er 2 and washers 2 Remove screws 2 and take off with heat shield 1 and washers Removing exhaust p...

Page 111: ...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 crac...

Page 112: ...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 Inst...

Page 113: ...ws 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 tigh...

Page 114: ...nstall coolant vent lines 2 4 and hold ers 1 3 on heat shield and tighten screws 2 Fill with engine coolant Page 142 3 File charge air coolant Page 151 114 Task Description MS150096 03E 2015 04 TIM ID...

Page 115: ...cid 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 eng...

Page 116: ...acement 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...

Page 117: ...led Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 116 2 After installation of new filter press reset button 1 Result Engaged...

Page 118: ...unctional check Option 1 Check function while engine is running 1 Check both emergency air shutoff flaps and their wiring for mechanical damage 2 Make sure that the pointers 1 of both emergency air sh...

Page 119: ...tart 4 Check the following functions Both emergency air shutoff flaps close immediately when tripped The emergency air shutoff flaps are completely closed and the pointers 1 point to CLOSED OFF Result...

Page 120: ...7 13 Exhaust Gas Recirculation 7 13 1 Exhaust flaps Overview 1 EGR shutoff flap 2 Donor cylinder flap 120 Task Description MS150096 03E 2015 04 TIM ID 0000027110 005...

Page 121: ...1 Bypass flap MS150096 03E 2015 04 Task Description 121 TIM ID 0000027110 005...

Page 122: ...e For installation position of exhaust flaps refer to overview Page 120 1 Remove guard plates of exhaust flaps 2 Check operability and ease of movement of exhaust flaps and control linkage by mov ing...

Page 123: ...g rods bypass and EGR flap mechanical Note For installation position of exhaust flaps refer to overview Page 120 1 Remove guard plates of exhaust flaps 2 Check operability and ease of movement of coup...

Page 124: ...rod 1 by moving it at the speci fied points arrowed and make sure that there is no excessive play Result Replace coupling rod 1 if it is jamming sluggish or features excessive play Page 125 124 Task D...

Page 125: ...ses automatically Risk of crushing hands To carry out the teach in routine keep clear of the safety zone of the actuation mechanism in the intake and exhaust area Switch off the operating voltage of t...

Page 126: ...ew Tightening torque Assembly paste Ul tra Therm MTU 6 Nm 2 Nm 3 Tighten washers 1 and locknuts 2 to the specified tightening torque Name Size Type Lubricant Value Standard Nut Tightening torque Assem...

Page 127: ...specified tightening torque Name Size Type Lubricant Value Standard Nut screw Tightening torque Assembly paste Ul tra Therm MTU 6 Nm 2 Nm 3 Tighten washers 3 and locknuts 4 to the specified tightenin...

Page 128: ...eck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 160 128 Task Desc...

Page 129: ...e 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 carrie...

Page 130: ...ith 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...

Page 131: ...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 Drai...

Page 132: ...icant 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...

Page 133: ...ear 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...

Page 134: ...g 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 di...

Page 135: ...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 1...

Page 136: ...Spare Parts Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear...

Page 137: ...ower rotor sec tion 13 13 Insert new filter sleeve 9 with stiffener plate 10 into rotor cap 8 with the with the smooth paper surface of the filter sleeve 9 facing the rotor cap 8 14 Check sealing ring...

Page 138: ...e 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 E...

Page 139: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 140 2 Fill with engine coolant Page 142 MS150096 03E 2015 04 Task Description...

Page 140: ...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...

Page 141: ...n 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 MS150096 03E 2015 04 Task Description 141 TIM ID 000003076...

Page 142: ...ngine 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...

Page 143: ...ain valve 6 Check proper condition of cap and clean sealing faces if required 7 Position filler neck cap and close it 8 Start engine Page 36 and shut down af ter 10 second of operation without load Pa...

Page 144: ...d 4 Fit cap onto filler neck and turn until the first stop to close 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 Che...

Page 145: ...ng 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 instr...

Page 146: ...st 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 co...

Page 147: ...ecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 148 2 Fill with charge air coolant Page 151 MS150096 03E 2015 04 Task Des...

Page 148: ...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 c...

Page 149: ...oler 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 MS150096 03E 201...

Page 150: ...fully 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...

Page 151: ...ow 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 format...

Page 152: ...op to close 5 Start engine Page 36 6 After 10 seconds of running the engine without load shut down the engine Page 37 7 Turn cap counterclockwise and remove 8 Check charge air coolant level Page 146 a...

Page 153: ...n coolant expansion tank coun terclockwise until the first stop and allow pressure to escape 11 Continue to turn cap counterclockwise and remove 12 Check charge air coolant level Page 146 and top up i...

Page 154: ...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 repa...

Page 155: ...ed 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 158 Drive belt C Chunking Drive belt Belt...

Page 156: ...ask 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 Dr...

Page 157: ...in position Only use specified tools and devices 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 tension...

Page 158: ...3 by half a turn 3 Mount socket or box wrench on screw 1 and press belt tensioner in direction of ar row as far as the stop 4 Tighten screw 3 5 Remove the used drive belt 6 Fit new drive belt 7 Slack...

Page 159: ...dition 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 scre...

Page 160: ...closed and 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...

Page 161: ...set 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 availab...

Page 162: ...voltage of the engine governor before starting the mechanical test Wear protective goggles WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning wo...

Page 163: ...r general condition Heavily contaminated by black ex haust Replace Checking actuators with DiaSys Note For installation position of exhaust flaps refer to overview Page 120 1 Switch on ECU 2 Test actu...

Page 164: ...move 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 labels Heavily contamin...

Page 165: ...table 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 plu...

Page 166: ...ar suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE High voltage Risk of damage to components Switch off ignition before replacing components NOTICE Cera...

Page 167: ...Tightening torque max 12 Nm 2 Remove protective cap on thread of sensor 3 only just before installation Note Do not wipe off the thread lubricant applied by the manufacturer 3 Coat sensor 3 thread wi...

Page 168: ...ore beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE Ceramic cell breakage due to shock or impact Risk of damage to components Avoid...

Page 169: ...t 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 T...

Page 170: ...te 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...

Page 171: ...ons 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...

Page 172: ...rial 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 T...

Page 173: ...2 Check tighten securing screws 1 Name Size Type Lubricant Value Standard Screw M10x50 Tightening torque 79 Nm MS150096 03E 2015 04 Task Description 173 TIM ID 0000057599 001...

Page 174: ...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 coo...

Page 175: ...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 Inj...

Page 176: ...e 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 Boos...

Page 177: ...e 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...

Page 178: ...lve clearance Check and adjustment Page 83 Barring device Part No F6555766 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 77 Barring gear Part No F6792918 Qty Used in 1 7 1 1 Engine Ba...

Page 179: ...ger HP Turbine housing check Page 109 Feeler gauge Part No Y20098771 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 83 Filter wrench Part No F30379104 Qty Used in 1 7 8 1 Fuel filter Re...

Page 180: ...n 1 7 15 4 Engine oil Sample extraction and analysis Page 133 Plug in open end wrench 17 mm Part No F30025896 Qty Used in 1 7 6 2 Injector Removal and installation Page 90 Plug in open end wrench 19 m...

Page 181: ...emoval and installation Page 90 Ratchet Part No F30027341 Qty Used in 1 7 6 2 Injector Removal and installation Page 90 Qty Used in 1 7 15 3 Engine oil Change Page 131 Qty Used in 1 7 20 2 Battery cha...

Page 182: ...or drive Drive belt re placement Page 158 Ratchet adapter Part No F30027340 Qty Used in 1 7 13 4 Exhaust flaps Coupling rod replacement Page 125 Qty Used in 1 7 23 5 NOx sensor Replacement Page 166 Qt...

Page 183: ...Socket for lambda sensor NOx sensor Part No F30453932 Qty Used in 1 7 9 2 Exhaust turbocharger LP Turbine housing check Page 101 Socket wrench 24 mm Part No F30039526 Qty Used in 1 7 4 2 Valve cleara...

Page 184: ...housing check Page 101 Qty Used in 1 7 9 3 Exhaust turbocharger HP Turbine housing check Page 109 Qty Used in 1 7 20 2 Battery charging generator drive Drive belt tension adjustment Page 157 Qty Used...

Page 185: ...il Change Page 131 Torque wrench 40 200 Nm Part No F30027337 Qty Used in 1 7 15 3 Engine oil Change Page 131 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 13 4 Exhaust flaps Coupling rod rep...

Page 186: ...r Removal and installation Page 90 Qty Used in 1 7 9 2 Exhaust turbocharger LP Turbine housing check Page 101 Qty Used in 1 7 9 3 Exhaust turbocharger HP Turbine housing check Page 109 Qty Used in 1 7...

Page 187: ...77 Coolant Change 139 147 Coupling rods Check 123 Replacement 125 Crankshaft Transport locking device Installation 9 Removal 9 Cylinder Designation 20 Cylinder head cover Removal and installation 86 C...

Page 188: ...Injectors Overview 23 Intercooler Leak check 115 L Lambda sensor Replacement 168 M Maintenance Schedule Maintenance task reference table QL1 40 MTU contact persons 177 N NOx sensor Replacement 166 O...

Page 189: ...position check 117 Service partners 177 Spare parts service 177 Starter Condition check 128 T Technical data 27 transport 8 Transport locking device Installation Crankshaft 9 Removal Crankshaft 9 Trou...

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MTU 12V4000T94, Operating Instructions Manual

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