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MTU M015710/04E, Руководство по эксплуатации

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Table of Contents

1 Safety
1.1 General conditions

5

1.2 Personnel and organizational requirements

6

1.3 Transport

7

1.4 Crankshaft transport locking device

8

1.5 Safety regulations for startup and operation

11

1.6 Explosion hazard when removing

inspection port cover on engine

12

1.7 Safety regulations for maintenance and

repair work

13

1.8 Auxiliary materials, fluids and lubricants,

fire prevention and environmental

protection

16

1.9 Conventions for safety instructions in the

text

18

2 General Information
2.1 Engine side and cylinder designations

19

2.2 Engine layout

20

2.3 Sensors, actuators and injectors –

Overview

21

3 Technical Data
3.1 16 V 4000 Gx3 engine data: Continuous

operation 3A, optimized fuel consumption

25

3.2 12 V 4000 Gx3 engine data: Continuous

operation, variable 3B, optimized fuel

consumption

28

3.3 12 V 4000 Gx3 engine data: Continuous

operation, variable 3B, optimized exhaust

emissions (TA-Luft)

32

3.4 16 V 4000 Gx3 engine data: Continuous

operation, variable 3B, optimized fuel

consumption

36

3.5 12/16 V 4000 Gx3 engine data: Continuous

operation, variable 3B, optimized exhaust

emissions (EPA stage 2)

40

3.6 12V 4000 Gx3 engine data: Standby

operation 3D, optimized fuel consumption

44

3.7 16 V 4000 Gx3 engine data: Standby

operation 3D, optimized fuel consumption

48

3.8 12/16 V 4000 Gx3 engine data: Standby

operation 3D, optimized exhaust emissions

(EPA stage 2)

52

3.9 16 V 4000 G83L engine data: Standby

operation 3D, optimized fuel consumption

56

3.10 16 V 4000 G83L engine data: Standby

operation 3D, optimized exhaust emissions

(EPA stage 2)

60

3.11 Final compression pressure

64

3.12 Firing order

65

3.13 Engine – Main dimensions

66

4 Operation
4.1 Putting the engine into operation after

extended out-of-service periods (>3

months)

67

4.2 Putting the engine into operation after

scheduled out-of-service-period

68

4.3 Start engine in manual mode (testing

mode)

69

4.4 Safety system – Override

70

4.5 Starting the engine in emergency situations

(override mode)

71

4.6 Operational checks

72

4.7 Stop engine in manual mode (testing

mode)

73

4.8 Emergency stop

74

4.9 After stopping the engine – Engine remains

ready for operation

75

4.10 After stopping the engine – putting the

engine out of service

76

4.11 Plant cleaning

77

5 Maintenance
5.1 Maintenance task reference table [QL1]

78

6 Troubleshooting
6.1 Troubleshooting

79

6.2 Engine governor ADEC (ECU 7) for Series

4000 genset engines – Fault messages

82

7 Task Description
7.1 Engine

131

7.1.1 Engine – Barring manually

131

7.1.2 Engine – Barring with starting system

132

7.1.3 Engine – Test run

133

M015710/04E 2012-09 | Table of Contents | 3

DCL-ID: 0000007500 - 002

Содержание M015710/04E

Страница 1: ...Operating Instructions Diesel engine 12 V 4000 G23 G43 G63 G83 16 V 4000 G23 G43 G63 G83 G83L M015710 04E...

Страница 2: ...3 7 16 V 4000 Gx3 engine data Standby operation 3D optimized fuel consumption 48 3 8 12 16 V 4000 Gx3 engine data Standby operation 3D optimized exhaust emissions EPA stage 2 52 3 9 16 V 4000 G83L en...

Страница 3: ...7 13 2 Engine oil Level check 169 7 13 3 Engine oil Sample extraction and analysis 170 7 14 Oil Filtration Cooling 171 7 14 1 Engine oil filter Replacement 171 7 14 2 Oil indicator filter Check 172 7...

Страница 4: ...designated A and those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving end Other components are numbered in the same way...

Страница 5: ...ankcase 13 Engine oil filter 14 Fuel filter 15 HP fuel pump 16 Battery charging gener ator 17 Centrifugal oil filter 18 Oil heat exchanger 19 Crankcase breather Engine model designation Key to the eng...

Страница 6: ...der exhaust gas B4 1 to B4 8 engine side A 2 Sensor B34 fuel pres sure after filter 3 M8 HP fuel pump ac tuator The injectors Y39 1 to Y39 8 engine side A are underneath the cylinder head covers of th...

Страница 7: ...ilter 4 B33 fuel temperature in common rail 5 B07 lube oil tempera ture 6 B01 camshaft speed 7 B48 fuel pressure in common rail 8 B43 charge air coolant pressure 9 B26 charge air coolant temperature 1...

Страница 8: ...nt pressure 3 B10 charge air pres sure 4 B09 charge air temper ature The injectors Y39 11 to Y39 18 engine side B are underneath the cylinder head covers of the cylinder Injector replacement and requi...

Страница 9: ...1 B13 crankshaft speed 24 General Information M015710 04E 2012 09 TIM ID 0000000954 003...

Страница 10: ...p 3A 3A 3A Intake air temperature C 25 25 25 Charge air coolant temperature C 55 55 55 Barometric pressure mbar 1000 1000 1000 Site altitude above sea level m 100 100 100 Power related data power rati...

Страница 11: ...temperature after engine shutdown L C 104 104 104 Coolant antifreeze content max L 50 50 50 Pressure loss in off engine cooling system max L bar 0 7 0 7 0 7 Coolant system LT circuit Number of cylinde...

Страница 12: ...for initial filling standard oil system option max operating inclinations R Liters 300 300 300 Oil change quantity max standard oil system op tion max operating inclinations R Liters 240 240 240 Oil p...

Страница 13: ...air coolant tempera ture C 55 55 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 Power related data power...

Страница 14: ...77 Total displacement Liters 57 2 57 2 57 2 57 2 57 2 Compression ratio 16 5 16 5 16 5 16 5 16 5 Cylinder heads individual cylinder heads X X X X X Cylinder liners wet replace able X X X X X Inlet val...

Страница 15: ...before engine from R C 88 88 88 88 88 Lube oil operating tempera ture before engine to R C 98 98 98 98 98 Lube oil temperature before engine warning R C 99 99 99 99 99 Lube oil temperature before engi...

Страница 16: ...antity max standard oil system option max operating inclinations R Liters 260 260 260 260 260 Oil pan capacity at dipstick mark min standard oil system option max oper ating inclinations L Liters 160...

Страница 17: ...mperature C 25 25 25 Charge air coolant temperature C 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 Site altitude above sea level m 100 100 100 Power related data powe...

Страница 18: ...5 Cylinder heads individual cylinder heads X X X Cylinder liners wet replaceable X X X Inlet valves per cylinder 2 2 2 Exhaust valves per cylinder 2 2 2 Standard housing connecting flange engine main...

Страница 19: ...before engine shut down L bar Fuel system Number of cylinders 12 12 12 Fuel pressure at engine inlet connection min when engine is starting L bar 0 1 0 1 0 1 Fuel pressure at engine inlet connection m...

Страница 20: ...00 Weights main dimensions Number of cylinders 12 12 12 Engine dry weight basic engine configuration ac cording to scope of delivery specifications R kg 6200 6200 6200 Acoustics Number of cylinders 12...

Страница 21: ...5 25 Charge air coolant temperature C 55 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 Power related data power ra...

Страница 22: ...Cylinder heads individual cylinder heads X X X X Cylinder liners wet replaceable X X X X Inlet valves per cylinder 2 2 2 2 Exhaust valves per cylinder 2 2 2 2 Standard housing connecting flange en gi...

Страница 23: ...e before en gine from R bar 4 2 4 7 4 2 4 7 Lube oil operating pressure before en gine to R bar 5 5 6 5 5 5 6 5 Lube oil operating pressure before en gine warning R bar Lube oil operating pressure bef...

Страница 24: ...system option max oper ating inclinations L Liters 210 210 210 210 Oil pan capacity at dipstick mark max standard oil system option max oper ating inclinations L Liters 240 240 240 240 Weights main di...

Страница 25: ...25 25 25 25 Charge air coolant temperature C 45 45 45 45 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 Power related data...

Страница 26: ...Cylinder heads individual cylinder heads X X X X Cylinder liners wet replaceable X X X X Inlet valves per cylinder 2 2 2 2 Exhaust valves per cylinder 2 2 2 2 Standard housing connecting flange en gi...

Страница 27: ...re before en gine from R bar 5 0 5 0 4 7 4 7 Lube oil operating pressure before en gine to R bar 7 0 7 0 6 5 6 5 Lube oil operating pressure before en gine warning R bar Lube oil operating pressure be...

Страница 28: ...em option max oper ating inclinations L Liters 160 160 210 210 Oil pan capacity at dipstick mark max standard oil system option max oper ating inclinations L Liters 200 200 240 240 Weights main dimens...

Страница 29: ...temperature C 25 25 25 25 Charge air coolant temperature C 55 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 Power...

Страница 30: ...Cylinder heads individual cylinder heads X X X X Cylinder liners wet replaceable X X X X Inlet valves per cylinder 2 2 2 2 Exhaust valves per cylinder 2 2 2 2 Standard housing connecting flange en gi...

Страница 31: ...ure before en gine from R bar 5 0 5 0 5 0 5 0 Lube oil operating pressure before en gine to R bar 7 0 7 0 7 0 7 0 Lube oil operating pressure before en gine warning R bar Lube oil operating pressure b...

Страница 32: ...tion max oper ating inclinations L Liters 160 160 160 160 Oil pan capacity at dipstick mark max standard oil system option max oper ating inclinations L Liters 200 200 200 200 Weights main dimensions...

Страница 33: ...temperature C 25 25 25 25 Charge air coolant temperature C 55 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 Power...

Страница 34: ...Cylinder heads individual cylinder heads X X X X Cylinder liners wet replaceable X X X X Inlet valves per cylinder 2 2 2 2 Exhaust valves per cylinder 2 2 2 2 Standard housing connecting flange en gi...

Страница 35: ...e before en gine from R bar 4 2 4 7 4 2 4 7 Lube oil operating pressure before en gine to R bar 5 5 6 5 5 5 6 5 Lube oil operating pressure before en gine warning R bar Lube oil operating pressure bef...

Страница 36: ...ystem option max oper ating inclinations L Liters 210 210 210 210 Oil pan capacity at dipstick mark max standard oil system option max oper ating inclinations L Liters 240 240 240 240 Weights main dim...

Страница 37: ...take air temperature C 25 25 25 25 Charge air coolant temperature C 45 45 45 45 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 1...

Страница 38: ...Cylinder heads individual cylinder heads X X X X Cylinder liners wet replaceable X X X X Inlet valves per cylinder 2 2 2 2 Exhaust valves per cylinder 2 2 2 2 Standard housing connecting flange en gi...

Страница 39: ...re before en gine from R bar 5 0 5 0 4 7 4 7 Lube oil operating pressure before en gine to R bar 7 0 7 0 6 5 6 5 Lube oil operating pressure before en gine warning R bar Lube oil operating pressure be...

Страница 40: ...m option max oper ating inclinations L Liters 160 160 210 210 Oil pan capacity at dipstick mark max standard oil system option max oper ating inclinations L Liters 200 200 240 240 Weights main dimensi...

Страница 41: ...6V 4000G83L Application group 3D Intake air temperature C 25 Charge air coolant temperature C 45 Raw water inlet temperature C Barometric pressure mbar 1000 Site altitude above sea level m 100 Power r...

Страница 42: ...alves per cylinder 2 Standard housing connecting flange engine main PTO SAE 00 Flywheel interface DISC 21 Combustion air Exhaust gas Number of cylinders 16 Charge air pressure before cylinder BL R bar...

Страница 43: ...ty air temperature w o start aid w o preheating case A R C 10 Coolant preheating preheating temperature min R C 32 Firing speed from R rpm 80 Firing speed to R rpm 120 Capacities Number of cylinders 1...

Страница 44: ...Exhaust noise unsilenced BL sound power level LW ISO 6798 3 R dB A 130 Engine surface noise with attenuated intake noise filter BL sound power level LW ISO 6798 R dB A 126 M015710 04E 2012 09 Technic...

Страница 45: ...model 16V 4000G83L Application group 3D Intake air temperature C 25 Charge air coolant temperature C 45 Raw water inlet temperature C Barometric pressure mbar 1000 Site altitude above sea level m 100...

Страница 46: ...alves per cylinder 2 Standard housing connecting flange engine main PTO SAE 00 Flywheel interface DISC 21 Combustion air Exhaust gas Number of cylinders 16 Charge air pressure before cylinder BL R bar...

Страница 47: ...ty air temperature w o start aid w o preheating case A R C 10 Coolant preheating preheating temperature min R C 32 Firing speed from R rpm 80 Firing speed to R rpm 120 Capacities Number of cylinders 1...

Страница 48: ...Exhaust noise unsilenced BL sound power level LW ISO 6798 3 R dB A 130 Engine surface noise with attenuated intake noise filter BL sound power level LW ISO 6798 R dB A 126 M015710 04E 2012 09 Technic...

Страница 49: ...3 11 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 24 bar to 28 bar 64 Technical Data M015710 04E 2012 09 TIM ID 0000002820 001...

Страница 50: ...ing order 8V A1 B4 A4 A2 B3 A3 B2 B1 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 20 V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 M01...

Страница 51: ...r 12 V and 16 V engines Engine model Length A Width B Height C 12 V 4000 Gx3 approx 2520 mm approx 1660 mm approx 2160 mm 16 V 4000 Gx3 approx 2990 mm approx 1660 mm approx 2160 mm 66 Technical Data M...

Страница 52: ...e gauge Align adjustable pointer with position of pressure indicator Page 155 Coolant circuit If engine is out of service for more than one year change engine coolant Page 177 Change charge air coolan...

Страница 53: ...169 Cooling system Check engine coolant level Page 176 Check charge air coolant level Page 184 Cooling system Preheat coolant with preheating unit Fuel prefilter Drain Page 156 Monitoring equipment Ca...

Страница 54: ...g the engine Item Task Switchgear cabinet control panel etc depending on manufacturer If coolant temperature is 40 C with preheating equipment or 5 C without preheating equipment Press start button Au...

Страница 55: ...n a pushbutton is provided Bypassing the safety system Override Item Action Switchgear cabinet control panel etc depending on manufacturer Activate pushbutton for Override input of the ECU Certain shu...

Страница 56: ...abinet Actuate switch button for ECU override input Control cabinet Automatic starting procedure is performed any safety functions and alarms leading to engine shutdown are disregarded Tachometer indi...

Страница 57: ...ngine operation are required Check for abnormal running noises and vibration Fuel prefilter Check reading on differential pressure gauge to ensure that maximum permissible value is not exceeded Page 1...

Страница 58: ...breaker Item Task Engine After opening the generator breaker if provided allow to cool down off load for approx 5 minutes Preparing the pump drive diesel mechanical diesel electric Item Task Engine Al...

Страница 59: ...from LOP Item Task EMERGENCY STOP but ton Press Engine is stopped by switching off power supply to ECU Signalization e g by horn flashing lamp is released After emergency stop from LOP Item Task Switc...

Страница 60: ...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 M015710 04E 2012 09 Operation 75 T...

Страница 61: ...the engine room is not heated the coolant is not maintained at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and e...

Страница 62: ...cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental pro tection 2 Prior to putting the cleaning unit into operation read the Operating Instr...

Страница 63: ...fuel pre filter Page 72 W0534 Carry out test run minimum duration until steady state temperature is reached no less than 1 3 load monthly Page 133 W1001 Replace fuel filter or fuel filter element Page...

Страница 64: ...nu facturer s documentation Engine Governor Plug in connections are loose Check plug connections Page 197 Engine Running gear blocked engine cannot be barred manually Contact Service Engine turns but...

Страница 65: ...omponent Probable cause Task Engine coolant Incorrect coolant concentration Check MTU test kit Intercooler Contaminated Contact Service Engine room Air intake temperature too high Check fans and air s...

Страница 66: ...ocharg er cylinder head pis ton rings cylinder lin er Defective Contact Service Exhaust gas white Component Probable cause Task Engine Not at operating temperature Run engine to reach operating temper...

Страница 67: ...vice 005 HI T Charge Air ZKP Number 2 0121 931 Limit value 1 Cause Corrective action Charge air temperature too high 1 Reduce power 2 Check intercooler 006 SS T Charge Air ZKP Number 2 0121 932 Limit...

Страница 68: ...shutdown u Engine must not be started risk of engine failure contact Service 019 HI T Exhaust A ZKP Number 2 0126 931 Limit value 1 Cause Corrective action Exhaust gas temperature A side too high 1 Ch...

Страница 69: ...ause Corrective action Oil filter differential pressure too high u Replace oil filter Page 171 026 SS P Diff Lube Oil ZKP Number 2 0154 932 Limit value 2 Cause Corrective action Oil filter differentia...

Страница 70: ...igh 1 Automatic power reduction by engine control system 2 Check air filters Page 163 33 HI P Diff Fuel ZKP Number 20 114 931 Limit value 1 Cause Corrective action Fuel filter differential pressure to...

Страница 71: ...use Corrective action Cut in of turbocharger ETC 2 failed 1 Reduce power 2 Contact Service 044 LO Coolant Level Intercooler ZKP Number 2 0153 921 Limit value 1 Cause Corrective action Intercooler cool...

Страница 72: ...3 Cause Corrective action Coolant temperature too high low 1 Allow engine to cool down 2 Check engine coolant cooler clean if dirty 3 Contact Service 60 SS T Coolant L4 ZKP Number 20 120 934 Limit va...

Страница 73: ...ZKP Number 2 0102 922 Limit value 2 Cause Corrective action Fuel supply pressure too low Engine stop 1 Check fuel lines for leakage 2 Clean fuel prefilter Page 154 3 Flush fuel prefilter Page 157 4 R...

Страница 74: ...ng or HP fuel control block wiring faulty u Contact Service 083 LO P Fuel Common Rail ZKP Number 2 0104 921 Cause Corrective action Rail pressure set value Speed sensitive fuel limiter reduction Sucti...

Страница 75: ...P Number 2 1090 923 Cause Corrective action Starter speed was not attained Termination of starting sequence Starter rotates too slowly or does not rotate at all u Contact Service 093 SS T Preheat ZKP...

Страница 76: ...vice 118 LO ECU Power Supply Voltage ZKP Number 2 0140 921 Limit value 1 Cause Corrective action Supply voltage too low 1 Check ECU supply voltage 2 Contact Service 119 LOLO ECU Power Supply Voltage Z...

Страница 77: ...ion Alarm is triggered if the mean value of the power has exceeded the maximum value stipulated by PR1 1088 001 within the last 24 hours u Reduce power 142 AL MCR exceeded 1 hour ZKP Number 1 1088 006...

Страница 78: ...d u Contact Service 182 AL CAN Wrong Parameters ZKP Number 2 0500 682 Cause Corrective action Incorrect parameter values entered in data record u Contact Service 183 AL CAN No PU Data ZKP Number 2 050...

Страница 79: ...ause Corrective action CAN controller 2 is in Bus Off status automatic changeover to CAN 1 Short circuit massive interference or Baud rate incompatibility 1 Check CAN bus for short circuit rectify sho...

Страница 80: ...ling B9 replace as necessary Error cleared after restarting the engine 204 SD Level Lube Oil ZKP Number 1 8004 602 Cause Corrective action Lube oil level sensor defective short circuit or wire break u...

Страница 81: ...sary Error cleared after restarting the engine 212 SD P Coolant ZKP Number 1 8004 564 Cause Corrective action Coolant pressure sensor faulty short circuit or wire break u Check sensor and cabling B16...

Страница 82: ...abling B3 replace as necessary Error cleared after restarting the engine 220 SD Level Coolant Water ZKP Number 1 8004 584 Cause Corrective action Coolant level sensor faulty short circuit or wire brea...

Страница 83: ...sensor and cabling B5 3 replace as necessary 229 AL Stop Camshaft Sensor Defect ZKP Number 1 8004 562 Cause Corrective action Engine stop due to camshaft sensor fault and a previous crankshaft sensor...

Страница 84: ...ination with the alarm SD P Fuel before Filter or SD P Fuel after Filter u Check for additional message 240 SD P Fuel ZKP Number 1 8004 565 Cause Corrective action Fuel pressure sensor faulty short ci...

Страница 85: ...reak 1 Check cabling 2 Check speed demand 268 SD Spinning Value ZKP Number 28 006 591 Cause Corrective action Analog wheel slip signal faulty short circuit or wire break u Check sensor and cabling rep...

Страница 86: ...ective action Time of flight measuring fault of injector Time of flight measured value extremely low or extremely high u Replace injector concerned if the fault message appears frequently Page 146 304...

Страница 87: ...ctive action Time of flight measuring fault of injector Time of flight measured value extremely low or extremely high u Replace injector concerned if the fault message appears frequently Page 146 309...

Страница 88: ...ective action Time of flight measuring fault of injector Time of flight measured value extremely low or extremely high u Replace injector concerned if the fault message appears frequently Page 146 314...

Страница 89: ...ctive action Time of flight measuring fault of injector Time of flight measured value extremely low or extremely high u Replace injector concerned if the fault message appears frequently Page 146 319...

Страница 90: ...der A4 ZKP Number 1 8004 523 Cause Corrective action Short circuit in injector cabling to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 325 AL Wiring Cylinder A5 ZKP Number 1 8004...

Страница 91: ...nder B1 ZKP Number 1 8004 530 Cause Corrective action Short circuit in injector cabling to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 332 AL Wiring Cylinder B2 ZKP Number 1 800...

Страница 92: ...er B8 ZKP Number 1 8004 537 Cause Corrective action Short circuit in injector cabling to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 339 AL Wiring Cylinder B9 ZKP Number 1 8004...

Страница 93: ...linder A5 ZKP Number 1 8004 544 Cause Corrective action Open circuit in injector wiring to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 346 AL Open Load Cylinder A6 ZKP Number 1...

Страница 94: ...linder B2 ZKP Number 1 8004 551 Cause Corrective action Open circuit in injector wiring to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 353 AL Open Load Cylinder B3 ZKP Number 1...

Страница 95: ...Contact Service 359 AL Open Load Cylinder B9 ZKP Number 1 8004 558 Cause Corrective action Open circuit in injector wiring to cylinder Result Misfiring 1 Check solenoid valve 2 Contact Service 360 AL...

Страница 96: ...fault If bit 1 1020 021 power stage failure Stop engine is set engine is additionally stopped in this case 1 Short circuit of injector connection of one or more injectors to ground 2 Short circuit of...

Страница 97: ...1 TOP 1 u Check cabling to plant 382 AL Wiring TOP 2 ZKP Number 2 8006 639 Cause Corrective action Short circuit or wire break on transistor output plant side 2 TOP 2 u Check cabling to plant 383 AL W...

Страница 98: ...nt temperature reading too high Engine stop 1 Check cabling and sensor 2 Contact Service 394 LO P Lube Oil Red ZKP Number 2 0112 921 Limit value 1 Cause Corrective action Redundant lube oil pressure r...

Страница 99: ...target device input 3 Contact Service 402 AL Open Load Digital Input 3 ZKP Number 2 8006 627 Cause Corrective action Line disruption on digital input 3 Cabling faulty or no resistance over switch 1 Ch...

Страница 100: ...uption on digital input 8 Cabling faulty or no resistance over switch 1 Check cabling 2 Check target device input 3 Contact Service 408 AL Open Load Emerg Stop Input ESI ZKP Number 2 8006 633 Cause Co...

Страница 101: ...el Prefilter ZKP Number 2 0156 931 Limit value 1 Cause Corrective action Water level in fuel prefilter too high u Drain water Page 156 415 LO P Coolant Intercooler ZKP Number 2 0107 921 Limit value 1...

Страница 102: ...se Corrective action Input signal of Aux 1 has exceeded not attained limit value 1 depending on configuration u Determine cause of limit value violation and rectify fault 421 AL L2 Aux 1 ZKP Number 2...

Страница 103: ...e Engine ZKP Number 20 173 932 Limit value 2 Cause Corrective action Coolant temperature too high u Check coolant circuit 440 AL L1 P Aux 1 ZKP Number 2 0110 921 Limit value 1 Cause Corrective action...

Страница 104: ...harge Air ZKP Number 2 0103 932 Limit value 2 Cause Corrective action Charge air pressure too high u Contact Service 450 SD Idle End Torque Input ZKP Number 2 8006 592 Cause Corrective action Input si...

Страница 105: ...configuration u Determine cause of limit value violation and rectify fault 460 HI T Exhaust EMU ZKP Number 2 8006 652 Limit value 1 Cause Corrective action EMU exhaust gas temperature value too high 1...

Страница 106: ...ture faulty u Replace Engine Control Unit 469 SD AUX 1 ZKP Number 1 8004 590 Cause Corrective action Analog input signal for Aux 1 faulty short circuit or wire break u Check signal transmitter and cab...

Страница 107: ...ircuit on channel FO 1 Check cabling 2 Contact Service 475 AL CR Trigger Engine Stop ZKP Number 1 8010 009 Cause Corrective action Tripped by crash recorder triggering due to engine shutdown u Determi...

Страница 108: ...rt circuit or wire break u Check sensor and cabling B4 23 replace as necessary 483 SD T Exhaust D ZKP Number 18 004 597 Cause Corrective action Exhaust temperature sensor on A side faulty short circui...

Страница 109: ...tive action Speed of second secondary turbocharger too high u Reduce power 489 SS ETC3 Overspeed ZKP Number 23 014 932 Limit value 2 Cause Corrective action Speed of second secondary turbocharger too...

Страница 110: ...arter 501 AL Wiring POM Starter 2 ZKP Number 14 500 901 Cause Corrective action A cabling fault in connection of starter 2 of CPM has been detected This may be due to a missing consumer wire break or...

Страница 111: ...14 500 908 Cause Corrective action POM sends a different ID number than expected u Check POM wiring harness 510 AL Override applied ZKP Number 27 002 010 Cause Corrective action Override was activated...

Страница 112: ...oolant temperature value from three sources is too high u Reduce power 524 SS Engine Overspeed Mid Val ZKP Number 20 480 089 Limit value 2 Cause Corrective action Average engine overspeed value from t...

Страница 113: ...circuit 530 SS P Lube Oil Red2 ZKP Number 20 480 295 Limit value 2 Cause Corrective action Second redundant lube oil pressure too high u Check oil level top up as necessary 543 AL Multiple FDH Slaves...

Страница 114: ...restart engine 551 SS Engine Overspeed Camshaft ZKP Number 22 510 933 Limit value 2 Cause Corrective action Camshaft overspeed 1 Acknowledge alarm 2 Attempt to restart engine 555 AL Call MTU Field Se...

Страница 115: ...l Pan ZKP Number 20 137 921 Limit value 1 Cause Corrective action L1 T Lube Oil Pan has violated limit value 1 u 579 AL MD Forced Idle ZKP Number 21 063 511 Cause Corrective action MD forced idle dema...

Страница 116: ...y Danger to life Before barring the engine ensure that nobody is in the danger zone Engine Barring manually 1 Remove guard plate 2 Engage barring device 2 with ring gear 3 and install on flywheel hous...

Страница 117: ...moved from the engine Engine Barring with starting system 1 Release latch of connector X4 2 Remove connector from engine governor 3 Bar engine in unloaded condition Press START button 4 Let the cranks...

Страница 118: ...nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine Test run 1 Start engine Page 69 2 Perform test run not below 1 3 load and at least...

Страница 119: ...First signs of marks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are no...

Страница 120: ...Final steps 1 Install injector Page 147 2 Install cylinder head cover Page 144 M015710 04E 2012 09 Task Description 135 TIM ID 0000000015 014...

Страница 121: ...Smoothened areas appear brighter and more brilliant than the surrounding running surface Findings not critical Bright area Bright areas are on the running surface and show local removal of the honing...

Страница 122: ...ion starting in TDC ring 1 have to be replaced Seizure marks scuff ing Irregular circumference lengths and depths Can be caused either by the piston skirt or the piston crown Material deposits on the...

Страница 123: ...ion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing oil separator el...

Страница 124: ...phragm 3 on housing 1 5 Install new seal 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4 to the specified torque Name Size Type Lubricant Value Standard Screw...

Страница 125: ...re parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 144 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Страница 126: ...Y20010128 1 Torque wrench 60 320 Nm F30047446 1 Ring socket 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 144 2 Install barring device Page 131 Note The OT mark if f...

Страница 127: ...k valve clearance 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 ov...

Страница 128: ...with torque wrench to the specified tightening torque holding the adjusting screw 2 to prevent it from turning Name Size Type Lubricant Value Standard Locknut M16 x 1 5 Tightening torque Engine oil 9...

Страница 129: ...head covers 1 prior to removal 2 Remove screws 3 4 with washers 2 5 3 Take off cylinder head cover 1 with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean mounting surface 2 Check...

Страница 130: ...ors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke CAUTION Fuel system high pressure pump not filled with engine oil Damage to...

Страница 131: ...or Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 147 146 Task Description M...

Страница 132: ...rench 60 320 Nm F30452768 1 Assembly paste Optimoly Paste White T 40477 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 1 Engine oil O ring Spare Parts Catalog WARNING Fuels are combustible Risk of...

Страница 133: ...cylinder head 7 Remove injector with installation removal tool 8 Remove installation removal tool 9 Remove sealing ring 4 from injector or use a self made hook to take it out of the cylin der head 10...

Страница 134: ...nstallation position of seal ing ring 4 Fit new O rings 3 included in the scope of supply of the injector O ring 2 and damp ing ring 1 onto the injector and coat with grease 5 Remove oil carbon from s...

Страница 135: ...torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque 100 Nm 10 Nm 14 Tighten adapter 3 with torque wrench to the specified tightening t...

Страница 136: ...ew Tightening torque 40 Nm 5 Nm 19 Fit cable connector onto injector Note Failure to reset drift compensation CDC will void the emissions certification 20 Reset drift compensation CDC with Dia Sys E53...

Страница 137: ...trical sparks and ignition sources Do not smoke Venting LP fuel system 1 Open vent plug 1 2 Unlock fuel priming pump 2 screw out handle by turning it counterclockwise 3 Operate the pump with the handl...

Страница 138: ...osion Avoid open flames electrical sparks and ignition sources Do not smoke Fuel filter Replacement 1 Remove easy change filter using the filter wrench 2 Clean sealing surface on filter head 3 Slightl...

Страница 139: ...ff fuel supply 2 Remove nuts from filter head 3 Take off filter housing and drain fuel into appropriate container 4 Remove filter element securing nut and re move filter element by pulling it downward...

Страница 140: ...n installing the new filter element align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gauge 1 2 Check differential pressure Checking differential pressure of fuel prefilter 1...

Страница 141: ...drained 1 Left filter cut in 2 Right filter cut in 2 Open threaded vent plug 5 of filter to be drained 3 Unlock drain valve 6 by pressing toggle and open it 4 Drain water and contaminants from filter...

Страница 142: ...e Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine noise...

Страница 143: ...alve 6 Fuel prefilter Topping up with fuel 1 Stop engine Page 73 and disable engine start 2 Remove screws for cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new gasket in cov...

Страница 144: ...Diesel fuel Filter element Spare Parts Catalog Gasket Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smok...

Страница 145: ...2 7 Remove spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring housing 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and s...

Страница 146: ...ercooler Checking condensate drain for coolant discharge and obstructions 1 With the engine running verify that air emerges from the condensate drain bore s at driving end left and right engine side I...

Страница 147: ...terial Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Air filter Replacement 1 Remove air filter and install new one Page 164 2 Reset signal ring of service indicator Page 165...

Страница 148: ...Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Air filter Check 1 Check entire circumference of air filter for damage 2 Fit new air filter if damaged Page 164 M015710 04E 2012...

Страница 149: ...1 Release clamp 2 2 Remove air filter 1 and clamp 2 from connecting flange of intake housing 3 3 Verify that there are no objects in the con necting flange of the intake housing 3 and clean it 4 Place...

Страница 150: ...disabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 162 2 After installation of new filter press reset button 1 Result Eng...

Страница 151: ...g the engine make sure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Air starter Manual operation 1 Press pushbutton for manual sta...

Страница 152: ...l to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Version without semirotary hand pump Drain the engine o...

Страница 153: ...ce engine oil filter Page 171 5 Install drain plug s with new sealing ring 6 Tighten drain 2 and 3 with torque wrench to specified tightening torque Name Size Type Lubricant Value Standard Screw M26 x...

Страница 154: ...ack to the oil pan 3 The oil level must reach mark 1 or exceed mark 1 by up to 2 cm 4 Top up with oil to mark 1 as necessary Page 167 5 Insert oil dipstick into guide tube up to the stop Checking oil...

Страница 155: ...ar protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine oil Sample...

Страница 156: ...ng gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Unscrew engine oil filter with filter wrench 2 Clean sealing face on connecting piece...

Страница 157: ...oning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear pro...

Страница 158: ...dings Action Strainer Metallic residues Clean Monitor engine operation Check strainer daily Contact Service Strainer Damaged Fit new part Square section ring Damaged Fit new part O ring Damaged Fit ne...

Страница 159: ...talog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clo...

Страница 160: ...r base 10 with sealing ring 9 14 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the outer wall 15 Check sealing ring 5 fit new one if neces sary 16 Mount rotor cover 4...

Страница 161: ...first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check engine coolant level coolant must be visible at the bottom edge of the filler neck s cast...

Страница 162: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant Change 1 Drain engine coolant Page 178 2 Fill with engine coolant Page 179 M015710 04E 2012 09 Task Description...

Страница 163: ...eather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Draw off separated corrosion...

Страница 164: ...lding Let the engine cool down Wear protective clothing gloves and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant...

Страница 165: ...alve and close it 9 Start engine Page 69 10 After 10 seconds of running the engine without load shut down the engine Page 73 11 Turn breather valve of coolant expansion tank counterclockwise until the...

Страница 166: ...e engine Page 73 8 Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 9 Turn breather valve counterclockwise and remove 10 Check coolant l...

Страница 167: ...ne coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Shut down engine Page 73 and disable engine start observe general safety instruc tions Maintenance and Repair 3 C...

Страница 168: ...r protective clothing gloves and goggles safety mask WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine coolant Sample extraction and analysis 1 With the engine ru...

Страница 169: ...on tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visible at marking plate 4...

Страница 170: ...pecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 186 2 Fill with charge air coolant Page 187 M015710 04E 2012 09 Task Des...

Страница 171: ...urn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 3 Continue to turn breather valve counter clockwise and remove 4 Draw off separated corr...

Страница 172: ...calding Let the engine cool down Wear protective clothing gloves and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coola...

Страница 173: ...ose 9 Start engine Page 69 10 After 10 seconds of running the engine without load shut down the engine Page 73 11 Turn breather valve of coolant expansion tank counterclockwise until the first stop an...

Страница 174: ...the engine Page 73 8 Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 9 Turn breather valve counterclockwise and remove 10 Check coolan...

Страница 175: ...ge air coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Shut down engine Page 73 and disable engine start observe general safety instruc tions Maintenance and Repair...

Страница 176: ...led Guard is removed Drive belt Condition check Item Findings Action Drive belt A Singular cracks None Drive belt Belt is oily shows signs of over heating Replace Page 193 Drive belt B Cracks on entir...

Страница 177: ...er 2 Slacken screws 1 and 2 by half a turn Result Belt tensioner moves against the drive belt and tensions it 3 Tighten screw 2 with torque wrench to the specified tightening torque Name Size Type Lub...

Страница 178: ...Tighten screw 3 5 Remove the used drive belt 6 Fit new drive belt 7 Slacken screw 3 by half a turn Result Belt tensioner moves against the drive belt and tensions it 8 Tighten screw 3 to specified tig...

Страница 179: ...gine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service 194 Task Description M015...

Страница 180: ...nnot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contac...

Страница 181: ...Cleaning 1 Remove coarse dirt from housing surface with isopropyl alcohol 2 Remove dirt from connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace ill...

Страница 182: ...ways use test connectors to enter the connectors Never use test leads for this purpose Otherwise the contacts could be bent Checking plug in connections on engine governor 1 Check all plug in connecti...

Страница 183: ...it from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 2 3 Undo latches 3 of the connectors 4 Remove all connectors 5 Remove screws 1 6 Take off Engine Control Unit Inst...

Страница 184: ...as soon as possible 2nd function Read out fault codes CKT Circuit CLS Coolant level sensor CPS Coolant pressure sensor CTS Coolant temperature sensor DDEC Detroit Diesel Electronic Controls Engine con...

Страница 185: ...d in accordance with DIN ISO 1204 KS Kraftseite Engine driving end in accordance with DIN ISO 1204 LED Light Emitting Diode LO Low Alarm Measured value lower than 1st minimum limit value LOLO Low Low...

Страница 186: ...air pressure TCI Turbo Compressor Inlet TCO Turbo Compressor Outlet TD Transmitter Deviation Alarm Deviation in transmitter values TPS Throttle Position Sensor TRS Timing Reference Sensor T xyz Tempe...

Страница 187: ...u either during operation for preventive maintenance corrective work in case of malfunction or changed operating conditions or for spare parts supply Your contact at Headquarters Service support mtu o...

Страница 188: ...Page 131 Feeler gauge Part No Y20010128 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 141 Filter wrench Part No F30379104 Qty Used in 1 7 8 1 Fuel filter Replacement Page 153 Qty Used...

Страница 189: ...ge 147 MTU test kit Part No 5605892099 00 Qty Used in 1 7 13 3 Engine oil Sample extraction and analysis Page 170 Qty Used in 1 7 15 6 Engine coolant Sample extraction and analysis Page 183 Ratchet ad...

Страница 190: ...6212 Qty Used in 1 7 1 1 Engine Barring manually Page 131 Rigid endoscope Part No Y20097353 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 134 Ring socket 24 mm Part No F30039526 Qty U...

Страница 191: ...in 1 7 6 2 Injector Removal and installation Page 147 Torque wrench 10 60 Nm Part No F30510423 Qty Used in 1 1 4 Crankshaft transport locking device Page 8 Torque wrench 10 60 Nm Part No F30452769 Qt...

Страница 192: ...t diaphragm check and replacement Page 138 Qty Used in 1 7 14 3 Centrifugal oil filter Cleaning and filter sleeve replacement Page 174 Torque wrench 60 320 Nm Part No F30047446 Qty Used in 1 7 4 2 Val...

Страница 193: ...Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 7 6 2 Injector Removal and installation Page 147 208 Appendix B M015710 04E 2012 09 DCL ID 0000007500 002...

Страница 194: ...64 Replacement 162 Air filter Check 163 Air starter Manual operation 166 Auxiliary materials 16 B Battery charging generator Drive belt replacement 193 Drive belt tension adjustment 192 C Centrifugal...

Страница 195: ...Explosion hazard 12 Intercooler Checking condensate drain for coolant discharge 161 Checking condensate drain for obstructions 161 M Main dimensions 66 Maintenance task reference table QL1 78 Maintena...

Страница 196: ...V Valve clearance Adjustment 141 Check 141 Valve gear Lubrication 140 W Wiring engine Check 195 M015710 04E 2012 09 Appendix B 211 DCL ID 0000007500 002...

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