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Operating Instructions: Diesel Engine 16 V 4000 E20
Operating Instructions: Diesel Engine 16 V 4000 E20
Diesel engine
16 V 4000 E20
M015241/03E
Printed in Germany
2011 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Commissioning Note
Important
Please complete and return the Commissioning Note card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support (war
ranty, spare parts, etc.).
Table of Contents
6 Troubleshooting
1 Safety
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
General conditions
Personnel and organizational requirements
Transport
Crankshaft transport locking device
Safety regulations for startup and operation
Explosion hazard when removing
inspection port cover on engine
Safety regulations for maintenance and
repair work
Fluids and lubricants, fire prevention and
environmental protection
Engine Barring with starting system
Conventions for safety instructions in the
text
7
8
9
10
12
13
14
17
19
20
2 General Information
2.1 Engine layout
2.2 Engine side and cylinder designations
2.3 Sensors and actuators Overview
21
25
26
3 Technical Data
3.1 16V 4000 E20 engine data
3.2 Firing order
28
32
7.1 Engine
64
67
34
35
36
37
38
39
40
67
69
71
71
72
74
75
75
76
80
81
82
88
89
92
81
82
83
88
89
90
91
92
93
94
96
5 Maintenance
64
66
33
41
44
7 Task Description
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3
months)
4.2 Putting the engine into operation after
scheduled out-of-service-period
4.3 Engine Start in manual mode
4.4 Operational checks
4.5 Engine Shutdown in manual mode
4.6 After stopping the engine
4.7 Plant Cleaning
6.1 Troubleshooting
6.2 DDEC alarms
93
94
95
100
100
101
103
103
104
105
106
108
109
122
123
124
127
128
124
126
127
128
130
110
110
111
112
113
116
8 Appendix A
8.1 Abbreviations
8.2 MTU contacts/service partners
131
134
117
117
118
118
119
9 Appendix B
9.1 Special Tools
9.2 Index
135
139
120
96
97
99
1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
Incorrect use
Operation, maintenance and repair by unqualified personnel
Modifications or conversions
Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the operating instructions and mainte
nance and repair specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta
tion.
Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and
transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person
nel must have read and understood the safety-relevant instructions.
This is especially important for personnel who work on the engine only on an occasional basis. These
persons shall receive repeated instruction.
Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.
Depending on the kind of work, use the necessary personal protective equipment.
1.3 Transport
Transport
Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.
Always use the lifting eyes on the engine when transporting an engine separately.
Only use transport and lifting devices approved by MTU.
Transport the engine/genset in the installation position only, maximum admissible inclination is 10.
Remove any loose parts on the genset.
Hoist the engine/genset slowly ensuring that lifting cables/chains do not touch the engine or any of its
component parts. Readjust lifting device as necessary.
Pay attention to the center of gravity of the engine/genset.
When specially wrapped in aluminum foil, suspend the engine/genset by the lifting eyes on the bearing
pedestal or transport by means of handling equipment (forklift truck) capable of bearing the load.
TIM-ID: 0000002618 - 005
Fit the crankshaft shipping lock on the engine and fit the engine mount locking devices prior to transport.
Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip
ping and tipping when driving up or down inclines and ramps.
Release the locknuts (6) on both sides of the flywheel housing, remove screws (5) and take off the two
locks (4).
Remove screws (2), washers (3), cover plate (8) with label (7) and plates (1).
Store the removed parts of the transport locking device carefully for possible reuse!
Secure the two plates (1) with screws (5) and nuts (6) together with cover plate (8) at the bores on
both sides of the flywheel housing. Tightening torque: 250 Nm + 25 Nm, lubricant: engine oil.
Screw nut (6) onto screws (5) up to the end of the thread.
Fit the locks (4) through the openings of plates (1) and fasten with the screws (5).
Tighten screws (5) in alternating steps on both sides. Tightening torque : 30 Nm + 3 Nm, lubricant: en
gine oil.
Screw on nuts (6) of both screws (5) at plates (1) and secure.
Mark the engine as "Fitted with transportation locking device".
Engine operation
The following conditions must be fulfilled before starting the engine:
Wear ear protection.
Ensure that the engine room is well ventilated.
Do not inhale engine exhaust gases.
Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
Protect battery terminals, battery-charger terminals and cables against accidental contact.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Safety instructions
Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion
due to oil vapors).
Note cooling time for components which are heated for installation or removal Risk of burning.
Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
Laser devices of classes 1, 2 or 3A.
Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Use only fluids and lubricants that have been tested and approved by MTU.
Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
not smoke.
Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.
Lead
When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
Adopt suitable measures to avoid the formation of lead dust.
Switch on extraction system.
Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
Pay special attention to the pressure level in the compressed air network and pressure vessel.
Assemblies and equipment to be connected must either be designed for this pressure, or, if the per
mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection.
Hose couplings and connections must be securely attached.
Wear goggles when blowing off components or blowing away chips.
Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before equipment or tool is to be replaced.
Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
Carry out leak test in accordance with the specifications.
Painting
When carrying out painting work outside the spray stands provided with fume extraction systems, en
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
No open flames.
No smoking.
Observe fire prevention regulations.
Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
Avoid body contact (eyes, hands).
Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
Make sure that working area is well ventilated.
Avoid all knocks and jars to the containers, fixtures or workpieces.
When working with acids and alkalis, wear protective goggles or face mask, gloves and protective
clothing.
If such solutions are spilled onto clothing, remove the affected clothing immediately.
Rinse injured parts of the body thoroughly with clean water.
Rinse eyes immediately with eyedrops or clean tap water.
1.
2.
3.
WARNING
CAUTION
Note:
This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
Read and familiarize yourself with all safety notices before starting up or repairing the product.
Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
1.
2.
2 General Information
2.1 Engine layout
Engine version with closed-circuit crankcase ventilation
5
6
7
8
9
Main PTO
Charge-air coolant outlet
Charge-air coolant inlet
Coolant pump, LT circuit
Coolant pump, HT circuit
1
2
3
4
5
6
7
4 Crankcase breather of
closed-circuit crankcase
ventilation (oil separator)
5 Exhaust outlet
1 Battery-charging genera
tor
2 Combustion-air inlet
3 Exhaust turbocharger
1 Crankcase breather, A
side
2 Crankcase breather, B
side
3 Crankcase breather
mounted on cylinder
head cover
4 Cylinder head cover
4000
Series
Application: E=Excavator
Application segment
Design index
16
3 KS = Driving end
4 Left engine side
3 Technical Data
3.1 16V 4000 E20 engine data
Explanation:
DL
BL
A
G
R
L
N
X
REFERENCE CONDITIONS
Engine model
16V 4000
Application group
5A
25
55
Barometric pressure
mbar
1000
100
POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders
16V 4000
rpm
1800
kW
1600
mbar
25
mbar
50
Exhaust backpressure
mbar
30
mbar
50
30
CONSUMPTION
Number of cylinders
16V 4000
g/kWh
194
% of B
0.3
Number of cylinders
16V 4000
Number of cylinders
16
degrees
90
Bore
mm
165
Stroke
mm
190
Cylinder displacement
liter
4.06
Total displacement
liter
65.0
16V 4000
bar ABS
2.7
410
16V 4000
92
95
97
40
bar
0.2
bar
2.2
77
85
Number of cylinders
16V 4000
65
55
15
40
32
44
16V 4000
88
93
bar
5.0
Number of cylinders
16V 4000
bar
6,0
bar
4.5
bar
4.0
bar
1.0
FUEL SYSTEM
Number of cylinders
16V 4000
bar
0.1
bar
1.5
bar
4.0
bar
6.0
bar
3.5
(H.P. pump)
Fuel pressure before injection pump, to
(H.P. pump)
Fuel pressure before injection pump, min.
(H.P. pump)
16V 4000
R
40
16V 4000
L
degrees
22.5
degrees
10
CAPACITIES
16V 4000
liter
210
Engine oil capacity, initial filling (standard oil system) (Option: max.
operating inclinations)
liter
520
Oil pan capacity, dipstick mark min. (standard oil system) (Option:
max. operating inclinations)
liter
360
Oil pan capacity, dipstick mark max. (standard oil system) (Option:
max. operating inclinations)
liter
460
16V 4000
R
kg
7490
Number of cylinders
db(A)
118
16V 4000
8V
A1-B4-A4-A2-B3-A3-B2-B1
12V
A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
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
Number of cylin
ders
4 Operation
4.1 Putting the engine into operation after extended out-ofservice periods (>3 months)
Preconditions
Engine is stopped and starting disabled.
MTU Fluids and Lubricants Specifications (A001061/..) are available.
Action
Engine
Valve gear
Fuel prefilter
Fuel system
Coolant circuit
If engine is out of service for more than one year, change engine coolant
( Page 104).
Change charge-air coolant ( Page 111).
Coolant circuit
DDEC
Coolant circuit
Startup
Item
Action
Coolant circuit
Coolant circuit
WARNING
Preparation
Item
Measure
Switch on.
If coolant temperature is
> 40 C (with coolant preheating unit, if applicable)
press start button.
Automatic starting sequence is executed
Engine speed display instrument indicates increasing speed
After the starting sequence is completed, engine is running at idle
speed.
Item
WARNING
Operational checks
Item
Action
Engine operation
HP pump
Fuel prefilter
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
Before stopping the engine, operate it at idle speed until operating temperatures decrease and
stable values are indicated.
Preparation
Item
Measure
Engine
Measure
Task
Coolant circuit
Switch OFF.
Part No.
Qty.
30390
WARNING
CAUTION
Note:
Compressed air
Risk of injury!
Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
Water jet.
Risk of injury and scalding!
Do not direct water jet at persons.
Wear protective clothing, gloves, and goggles / safety mask.
Excessive reaction time of cleaning agents on components.
Damage to component!
Observe manufacturer's instructions.
Wear protective clothing, gloves, and goggles / safety mask.
There is a risk of damaging sensors with compressed air.
Plant Cleaning
1.
2.
3.
4.
Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro
tection).
Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.
For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Carry out external cleaning as follows:
a) Remove coarse dirt.
b) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
c) Use the high-pressure jet to remove the loosened dirt.
d) During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m
must be observed. The temperature of the cleaning medium must not exceed 80 C.
5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task
Maintenance tasks
W0500
( Page 96)
W0501
( Page 36)
W0504
( Page 36)
W0505
( Page 108)
W0506
( Page 36)
W0507
( Page 36)
W0508
Check reading on differential pressure gage of fuel prefilter (if ( Page 36)
fitted)
W0525
( Page 119)
W1001
( Page 89)
W1002
( Page 76)
W1003
( Page 117)
W1006
( Page 82)
W1008
Replace engine oil filter at each oil change or when the time
limit (years) is reached, at the latest
( Page 100)
W1009
( Page 101)
W1011
( Page 67)
W1022
( Page 127)
W1044
( Page 74)
W1209
( Page 120)
W1697
W1698
( Page 116)
6 Troubleshooting
6.1 Troubleshooting
Engine does not turn when starter is actuated
Component
Cause
Action
Battery
Low or faulty
Starter
Engine cabling
Faulty
Engine/generator
control system
DDEC
Engine
Contact Service.
Cause
Action
Starter
Engine cabling
Faulty
Fuel system
DDEC
Faulty
Contact Service.
Cause
Action
Injector faulty
Engine cabling
Faulty
Fuel system
DDEC
Faulty
Contact Service.
Cause
Action
Fuel supply
Air supply
Component
Cause
Action
Injector faulty
Engine cabling
Faulty
Engine
Overloaded
Contact Service.
Cause
Action
Injector faulty
Speed sensor
Faulty
Contact Service.
Fuel system
DDEC
Faulty
Contact Service.
Cause
Action
Engine coolant
Intercooler
Contaminated
Contact Service.
Engine room
Cause
Action
Air supply
Intercooler
Contaminated
Contact Service.
Contact Service.
Cause
Action
Intercooler
Contact Service.
Component
Cause
Action
Air supply
Injector faulty
Engine
Overloaded
Contact Service.
Cause
Action
Engine oil
Contact Service.
Cause
Action
Engine
Fuel system
Water in fuel
Leaking
Contact Service.
Intercooler
Inactive codes:
is flashing:
is flashing:
Flashing phase 1
Flashing phase 2
Flashing phase 1
Flashing phase 2
There is a pause of 0.5 seconds between the flashing phases 1 and 2. When a fault code changes from
active to inactive, the pause is 3 seconds.
To terminate flash code indication, switch DIAGNOSTIC REQUEST and IGNITION switches off.
IGNITION is allowed to be switched on again only after 30 seconds.
This method does not allow exact fault diagnostics, since a flash code may indicate faults with several
causes.
The Diagnostic Data Reader (DDR) is intended to:
Read out alarms from the DDEC electronic system
Change parameters (limited extent)
The DDR provides the possibility to read out active and inactive fault codes via separate menus. Addi
tionally, the inactive fault codes stored in the DDEC can be deleted.
For detailed functional description, refer to the description of the DDR.
The DDR (Part No. 5355383601/77) consists of:
the Pro Link 9000 basic unit
the MPC Cartridge to integrate a PCMCIA card
a PCMCIA card
a connection cable
an additional adapter cable is required (Part No. J 38500 60A)
44 | Troubleshooting | M015241/03E 2011-12
Accessory equipment:
Printer (Part No. J-38699) for direct connection to the DDR
Spare paper (Part No. J-38480-5) for printer (5 rolls)
The following information will be available by reading out fault codes with the DDR.
Example:
33
MID:128
Engine
TURBO
BOOST
SENSOR
INPUT
VOLTAGE
HIGH
A1
PID:
102
FMI:3
Explanation:
33 Flash code
MID: 128 Indicates origin of alarm
TURBO-BOOST-SENSOR-INPUT-VOLTAGE-HIGH Fault text
further faults are present A= active, I= inactive
MID (Message Identification Character)
Indicates origin of alarm
MID 128 Master
MID 175 Receiver 1
MID 183 Receiver 2
PID (Parameter Identification Character)
To identify transmitted data: (e. g. engine speed, coolant temperature etc.)
PID 0-127 1 data byte
PID 128-191 2 data bytes
PID 192-253 variable
SID (Subsystem Identification Character)
Identifies the origin of alarms from subsystems, which can be replaced as a complete unit (e.g. injec
tors).
FMI (Failure Mode Identifier)
Identifies the type of fault.
FMI 0 Measured value exceeds the limit value (monitoring for TOO HIGH), example: Coolant tem
perature
FMI 1 Measured value does not reach the limit value (monitoring for TOO LOW), example: Lube oil
pressure
FMI 3 Signal path interrupted or signal is exceeds the permissible measuring range (sensor defect)
FMI 4 Signal path short circuit against (-) supply of sensor or signal does not reach permissible
measuring range (sensor defect)
Flash PID
code
SID
FMI
Description
Tasks
11
187
Contact Service.
11
187
Contact Service.
12
187
Contact Service.
Flash PID
code
13
111
SID
FMI
Description
Tasks
13
111
14
14
52
110
Temperature sensor/inter
cooler, input voltage too
high.
1. Check wiring.
1. Check wiring.
2. Contact Service.
2. Contact Service.
14
175
Contact Service.
15
52
Temperature sensor/inter
cooler, input voltage too
low.
1. Check wiring.
1. Check wiring.
15
110
2. Contact Service.
2. Contact Service.
15
175
Contact Service.
16
111
16
111
17
51
1. Check wiring.
1. Check wiring.
1. Check wiring.
17
17
72
354
3
3
2. Contact Service.
2. Contact Service.
2. Contact Service.
5. Contact Service.
Flash PID
code
18
18
18
21
22
23
51
72
FMI
Description
Tasks
1. Check wiring.
1. Check wiring.
1. Check wiring.
1. Check wiring.
1. Check wiring.
1. Check wiring.
1. Check wiring.
1. Check wiring.
1. Check wiring.
354
91
91
174
23
24
SID
3
65
174
24
4
65
25
2. Contact Service.
2. Contact Service.
2. Contact Service.
2. Contact Service.
2. Contact Service.
2. Contact Service.
2. Contact Service.
2. Contact Service.
26
25
11
26
61
11
1. Check wiring.
1. Check wiring.
1. Check wiring.
1. Check wiring.
1. Check wiring.
1. Check wiring.
1. Check wiring.
27
27
27
28
28
TIM-ID: 0000003162 - 001
2. Contact Service.
28
29
105
171
172
105
171
172
351
3
3
4
4
4
4
2. Contact Service.
2. Contact Service.
2. Contact Service.
2. Contact Service.
2. Contact Service.
2. Contact Service.
2. Contact Service.
Flash PID
code
29
SID
404
FMI
Description
Tasks
Temperature sensor / ex
haust turbocharger outlet,
input voltage too low (ver
sion 32.0 or later).
1. Check wiring.
2. Contact Service.
31
51
31
51
Contact Service.
31
51
Contact Service.
31
52
31
52
Contact Service.
31
52
Contact Service.
32
238
32
238
1. Check wiring.
2. Contact Service.
32
239
32
239
1. Check wiring.
2. Contact Service.
33
102
34
102
35
19
35
100
1. Check wiring.
36
19
36
100
1. Check wiring.
2. Contact Service.
37
18
37
94
2. Contact Service.
Flash PID
code
37
SID
95
FMI
Description
Tasks
1. Check wiring.
2. Contact Service.
38
18
38
94
38
95
1. Check wiring.
2. Contact Service.
39
146
Contact Service.
39
146
12
Contact Service.
39
146
Contact Service.
39
147
Contact Service.
39
147
11
Contact Service.
39
147
12
39
147
14
39
147
39
152
Contact Service.
2. Contact Service.
39
153
41
21
42
21
Contact Service.
Flash PID
code
43
SID
111
FMI
Description
Tasks
44
52
44
105
44
110
44
172
44
175
105
14
110
14
4. Contact Service.
45
19
45
100
46
168
Contact Service.
Flash PID
code
SID
FMI
Description
Tasks
46
214
Contact Service.
46
232
Contact Service.
47
18
Contact Service.
47
94
Contact Service.
47
102
Contact Service.
47
106
47
164
Contact Service.
48
18
48
94
4. Contact Service.
48
106
48
164
Contact Service.
48
351
Contact Service.
48
404
48
411
48
412
Contact Service.
48
154
Contact Service.
48
155
Contact Service.
49
351
3. Contact Service.
Flash PID
code
49
SID
404
FMI
Description
Tasks
404
14
Contact Service.
51
351
51
404
52
254
12
Contact Service.
53
253
Contact Service.
53
253
12
Contact Service.
53
253
13
Out of calibration.
Contact Service.
12
1. Check wiring.
84
2. Contact Service.
55
216
14
55
231
12
55
248
Contact Service.
55
248
Contact Service.
56
250
12
57
249
12
58
92
Contact Service.
61
xxx
62
26
62
26
54
Flash PID
code
SID
FMI
Description
Tasks
62
26
62
40
62
40
62
40
62
53
62
53
62
53
62
54
62
54
62
54
62
55
62
55
62
55
62
56
62
56
62
56
63
57
Contact Service.
63
57
Contact Service.
Flash PID
code
SID
FMI
Description
Tasks
63
57
63
57
Contact Service.
63
58
Contact Service.
63
58
Contact Service.
63
58
63
58
Contact Service.
63
59
Contact Service.
63
59
Contact Service.
63
59
63
59
Contact Service.
63
60
Contact Service.
63
60
Contact Service.
63
60
63
60
Contact Service.
64
103
Exhaust turbocharger
speed too high.
Contact Service.
64
103
Exhaust turbocharger
speed sensor, input signal
faulty (irregular period).
Contact Service.
65
51
65
51
65
51
65
51
65
107
65
107
66
99
66
99
Contact Service.
Flash PID
code
SID
FMI
Description
Tasks
66
76
Contact Service.
66
76
66
76
66
76
Contact Service.
67
20
Contact Service.
67
20
Contact Service.
67
106
Contact Service.
67
106
Contact Service.
67
109
Contact Service.
67
109
Contact Service.
68
230
68
230
71
xxx
72
84
Contact Service.
72
84
11
Contact Service.
72
65
Contact Service.
72
65
Contact Service.
73
107
2. Contact Service.
73
77
Contact Service.
73
77
Contact Service.
73
77
Contact Service.
Flash PID
code
SID
FMI
Description
Tasks
73
77
Contact Service.
73
77
Contact Service.
73
151
14
73
226
11
Contact Service.
73
227
Contact Service.
73
227
Contact Service.
73
227
74
70
Contact Service.
74
99
75
168
Contact Service.
75
214
Contact Service.
75
232
Contact Service.
76
121
Contact Service.
77
Contact Service.
77
19
77
20
Contact Service.
77
72
Contact Service.
77
72
Contact Service.
77
73
77
81
Contact Service.
77
81
Contact Service.
2. Contact Service.
Flash PID
code
SID
FMI
Description
Tasks
77
81
77
81
77
81
12
77
95
77
99
77
100
Contact Service.
77
102
Contact Service.
77
105
77
107
77
108
Contact Service.
77
108
Contact Service.
77
109
Contact Service.
77
110
Contact Service.
77
111
Contact Service.
2. Contact Service.
77
171
Contact Service.
77
171
Contact Service.
77
172
Contact Service.
77
174
Contact Service.
77
174
Contact Service.
77
175
Contact Service.
77
222
14
Contact Service.
77
251
10
77
251
13
77
252
10
77
252
13
Contact Service.
Contact Service.
SID
FMI
Description
Tasks
77
354
Contact Service.
77
354
Contact Service.
77
446
Contact Service.
11
77
151
78
86
14
81
98
Contact Service.
81
101
Contact Service.
81
153
Contact Service.
81
164
Contact Service.
81
173
Contact Service.
81
411
Contact Service.
81
412
Contact Service.
81
129
Contact Service.
81
130
Contact Service.
81
131
Contact Service.
81
132
Contact Service.
81
133
Contact Service.
Flash PID
code
Flash PID
code
SID
FMI
Description
Tasks
81
134
Contact Service.
81
135
Contact Service.
81
136
Contact Service.
81
137
Contact Service.
81
138
Contact Service.
81
139
Contact Service.
81
140
Contact Service.
81
141
Contact Service.
81
142
Contact Service.
81
143
Contact Service.
81
144
Contact Service.
81
154
Contact Service.
81
155
Contact Service.
81
277
Contact Service.
81
277
12
82
98
Contact Service.
82
101
Contact Service.
SID
FMI
Description
Tasks
82
153
Contact Service.
82
164
Contact Service.
82
173
Contact Service.
82
411
82
412
Contact Service.
82
129
Contact Service.
82
130
Contact Service.
82
131
Contact Service.
82
132
Contact Service.
82
133
Contact Service.
82
134
Contact Service.
82
135
Contact Service.
82
136
Contact Service.
82
137
Contact Service.
82
138
Contact Service.
82
139
Contact Service.
Flash PID
code
Flash PID
code
SID
FMI
Description
Tasks
82
140
Contact Service.
82
141
Contact Service.
82
142
Contact Service.
82
143
Contact Service.
82
144
Contact Service.
82
154
Contact Service.
82
155
Contact Service.
82
412
Contact Service.
82
412
12
83
73
Contact Service.
83
98
2. Contact Service.
83
101
Contact Service.
83
153
Contact Service.
83
173
Contact Service.
83
411
Contact Service.
83
412
Contact Service.
83
129
Contact Service.
83
130
Contact Service.
SID
FMI
Description
Tasks
83
131
Contact Service.
83
132
Contact Service.
83
133
Contact Service.
83
134
Contact Service.
83
135
Contact Service.
83
136
Contact Service.
83
137
Contact Service.
83
138
Contact Service.
83
139
Contact Service.
83
140
Contact Service.
83
141
Contact Service.
83
142
Contact Service.
83
143
Contact Service.
83
144
Contact Service.
84
98
2. Contact Service.
84
101
84
153
Contact Service.
Flash PID
code
Flash PID
code
SID
FMI
Description
Tasks
85
190
85
190
14
Contact Service.
86
73
Contact Service.
86
108
Contact Service.
87
73
Contact Service.
87
108
Contact Service.
88
20
Contact Service.
88
109
Contact Service.
89
95
Contact Service.
89
111
12
2. Contact Service.
7 Task Description
7.1 Engine
7.1.1
DANGER
Part No.
Qty.
Barring device
F6555766
Barring device
F6783293
Adapter
F6558528
Ratchet
F30006212
5.
3.
4.
5.
7.1.2
DANGER
2.
3.
Note:
4.
Note:
5.
6.
Part No.
Endoscope
Qty.
Y20097353
Preparatory steps
1.
2.
Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached
BDC.
Insert endoscope into cylinder liner through injector seat.
Measure
No action required
Final steps
Install injector ( Page 83).
Install cylinder head cover ( Page 80).
1.
2.
7.2.2
Measure
Light scoring
Minor dirt scores can occur during the assembly of a new engine (honing prod
ucts, particles, broken-off burrs). Removed cylinders clearly exhibit such scor
ing on the running surface under endoscope magnification. Cannot be felt with
the fingernail.
Findings not critical.
Single scores
Clearly visible scores caused by hard particles. They usually start in the TDC
area and cross through the honing pattern in the direction of stroke.
Findings not critical.
Scored area
These areas consist of scores of different lengths and depths next to one an
other. In most cases, they are found at the 6-o'clock and 12-o'clock positions
(inlet/exhaust) along the transverse engine axis.
Findings not critical.
Smoothened area
Smoothened areas are changes to the running surface but almost the whole
honing pattern is still visible. Smoothened areas appear brighter and more bril
liant than the surrounding running surface.
Findings not critical.
Polished area
Polished areas are on the running surface and show local removal of the hon
ing pattern. Grooves from the honing process are not visible any more.
New cylinder liners must be fitted in the following cases
Polished area:
covers more than 20% of the entire piston running surface,
covers more than 30 of the circumference and extends over more than 50%
of piston stroke,
is wider than 15 mm over the entire piston stroke.
Discoloration
This is caused by oxidation (surface discoloration through oil or fuel) and tem
perature differences around the liner. It appears rather darker within the honed
structure in contrast to the bright metallic running surface. The honing pattern
is undisturbed. Discolorations extend in stroke direction and may be interrupt
ed.
Black lines are a step towards heat discoloration. They are visible as a clear
discoloration from TDC to BDC in the running surface and the start of localized
damage to the honing pattern.
Cylinders with a number of black lines around the running surface have limited
service life and should be replaced.
M015241/03E 2011-12 | Task Description | 69
Findings
Measure
Discolorations (Heat)
These are caused by a disturbance in the liner / ring tribosystem. Usually they
run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring
and becoming more visible from the second TDC-ring onwards and less pro
nounced from TDC-ring 1. The honing pattern is usually no longer visible and
displays a clearly defined (straight) edge to the undisturbed surface. The dam
aged surface is usually discolored. The circumferential length varies.
Liners with heat discoloration starting in the TDC-ring 1 have to be replaced.
Seizures, Seizure
marks
The findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough in
vestigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid un
necessary disassembly work, it is recommended that another inspection be carried out after further oper
ation of the engine.
2.
7.3.2
Part No.
Qty.
F30510423
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
8.
9.
10.
11.
7.3.3
WARNING
CAUTION
Compressed air
Risk of injury!
Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
Excessive reaction time of cleaning agents on components.
Damage to component!
Observe manufacturer's instructions.
Wear protective clothing, gloves, and goggles / safety mask.
( Page 72)
1.
2.
3.
Part No.
Qty.
Engine oil
3.
7.4.2
Part No.
Qty.
Feeler gage
Y20010128
F30047446
F30039526
Engine oil
Preparatory steps
Remove cylinder head cover ( Page 80).
Install barring gear ( Page 64).
3.
1.
2.
2.
3.
4.
3.
4.
5.
6.
7.
Tighten locknut (1) to specified torque using a torque wrench holding adjusting screw (2) firmly in so do
ing.
Name
Size
Type
Nut
Lubricant
Value/Standard
(Engine oil)
90 Nm +9 Nm
Replace or rectify adjusting screws and/or locknuts which do not move freely.
Check valve clearance.
1.
2.
Final steps
Remove barring gear ( Page 64).
Install cylinder head cover ( Page 80).
1.
2.
7.4.3
Part No.
Qty.
1.
2.
3.
4.
WARNING
3.
Injector Replacement
Special tools, Material, Spare parts
Designation / Use
Injector
Part No.
Qty.
Replacing injector
Remove injector and install new injector ( Page 83).
7.6.2
Part No.
Qty.
F6790161
Milling cutter
F30452739
F30452578
0015384230
F30510423
F30047446
40477
X00058060
Engine oil
WARNING
CAUTION
CAUTION
Preparatory steps
Shut off fuel inlet to engine.
Remove cylinder head cover ( Page 80).
1.
2.
Removing injector
Note:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Installing injector
1.
2.
3.
4.
5.
6.
7.
8.
10.
Size
Thrust ring
Type
Lubricant
Tightening torque
Value/Standard
5 Nm to 10 Nm
11.
12.
Place hold-down clamp (1) in correct installation position. Tighten screw (2) with torque wrench to the
specified initial tightening torque.
Name
Size
Type
Lubricant
Value/Standard
Screw
M12
Preload torque
(Engine oil)
5 Nm to 10 Nm
13.
Fit O-rings (4) and (6) on high-pressure fuel line (5) and coat with grease.
14.
Tighten high-pressure fuel line (5) to the specified initial tightening torque.
Name
Size
HP line
15.
Type
Lubricant
Value/Standard
Preload torque
(Engine oil)
5 Nm to 10 Nm
Lubricant
Value/Standard
Size
Type
Screw
M12
Tightening torque
100 Nm + 10 Nm
9.
16.
Tighten union nut of connecting piece (limiting valve) to specified torque using a torque wrench.
Name
Size
Union nut
17.
Type
Lubricant
Tightening torque
Value/Standard
140 Nm + 10 Nm
Tighten union nut of connecting piece (injector) to specified torque using a torque wrench.
Name
Size
Union nut
Type
Lubricant
Tightening torque
Value/Standard
120 Nm +10 Nm
18.
19.
Insert cable terminals (arrows) underneath screws on injector and tighten screws to specified torque us
ing a torque wrench.
Name
Screw
Size
Type
Tightening torque
Lubricant
Value/Standard
1.5 Nm
Final steps
Install cylinder head cover ( Page 80).
Open up fuel inlet to engine.
1.
2.
Part No.
Qty.
B80144852
Diesel fuel
WARNING
4.
5.
6.
7.
8.
Part No.
Qty.
F30379104
5.
6.
7.8.2
Part No.
Qty.
Diesel fuel
WARNING
5.
6.
7.
8.
7.8.3
Part No.
Diesel fuel
Sealing ring
WARNING
Qty.
7.
WARNING
WARNING
Compressed air
Risk of injury!
Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
2.
1.
2.
3.
4.
1.
2.
7.11.2
Part No.
Ether cartridge
DANGER
Qty.
1.
2.
3.
4.
Note:
3.
4.
5.
1.
2.
3.
4.
5.
7.12.2
Part No.
Qty.
F30027337
Ratchet adapter
F30027341
Engine oil
Sealing ring
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Procedure without pump: Draining oil via drain plug(s) on oil pan
1.
2.
3.
2.
3.
4.
5.
Tighten drain plugs (2) and (3) with torque wrench to the specified torque.
Name
Size
Type
Screw
Lubricant
Value/Standard
(Engine oil)
100 Nm +10 Nm
3.
4.
5.
7.12.3
WARNING
WARNING
Part No.
Qty.
5605892099/00
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Engine noise above 85 dB (A).
Risk of damage to hearing!
Wear ear protectors.
4.
5.
Part No.
Qty.
F30379104
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Note:
3.
4.
5.
6.
7.
7.13.2
Part No.
Qty.
Filter wrench
F30379104
F30027336
Ratchet adapter
F30027339
50602
X00029933
WARNING
Sealing ring
Sealing ring
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Compressed air
Risk of injury!
Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
WARNING
Filter sleeve
1.
2.
3.
4.
19.
20.
21.
Install clamp (3) and tighten to specified torque using a torque wrench.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Name
Size
Clamp
22.
Type
Lubricant
Tightening torque
Value/Standard
6 Nm + 1 Nm
Size
Screw
Type
Tightening torque
Lubricant
Value/Standard
6 Nm + 1 Nm
WARNING
Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to
escape.
Continue to turn breather valve counterclockwise and remove.
Check coolant level (coolant must be visible at the lower edge of the cast-in eye).
7.14.2
Part No.
Qty.
Engine coolant
1.
2.
7.14.3
WARNING
Preparatory steps
1.
2.
5.
6.
7.
7.14.4
Part No.
Qty.
Engine coolant
WARNING
CAUTION
Preparatory steps
1.
2.
2.
3.
4.
5.
6.
7.
Alternatively: Fill in coolant in expansion tank until the coolant level at top edge of filler neck remains
constant.
Check proper condition of breather valve, clean sealing faces if required.
Set breather valve onto filler neck and close until first stop is reached.
Start engine ( Page 35).
After the engine has run at unloaded condition for 10 seconds, stop engine ( Page 37).
Turn breather valve counterclockwise and remove.
Check coolant level ( Page 103) and top up if required:
a) Repeat the steps from "Start engine" ( Step 4) until coolant is no longer needed to be topped up.
b) Check proper condition of breather valve, clean sealing faces if required.
c) Set breather valve onto filler neck and close it.
Final steps
1.
2.
Start the engine and operate it at unloaded condition for some minutes.
Check coolant level ( Page 103) and top up if required.
7.14.5
DANGER
WARNING
4.
7.14.6
WARNING
WARNING
Part No.
Qty.
5605892099/00
6.
WARNING
2.
Switch on engine control system and check display (coolant level is automatically monitored by engine
control system).
Top up coolant if necessary ( Page 113).
7.15.2
Part No.
Qty.
Charge-air coolant
1.
2.
7.15.3
Part No.
Qty.
6.
7.
8.
7.15.4
Part No.
Coolant
Sealing ring
WARNING
CAUTION
Qty.
Preparatory steps
1.
2.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Final steps
1.
2.
Start the engine and run it without load for some minutes.
Check coolant level ( Page 110) and top up coolant as required.
7.15.5
DANGER
WARNING
4.
Findings
Action
Drive belt A
Singular cracks
None
Drive belt
Drive belt B
Drive belt C
Chunking
Item
1.
2.
3.
7.17.2
WARNING
Compressed air
Risk of injury!
Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
Findings
Measure
Clean
None
Contaminated
Clean
Note:
1.
2.
7.17.3
WARNING
Part No.
Qty.
F30026582
Ratchet adapter
F30027340
Heavy object.
Risk of crushing!
Use appropriate lifting devices and appliances.
Removing battery-charging
generator
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
4.
Size
Type
Screw
M10x1.5
Tightening torque
Lubricant
Value/Standard
60 Nm +5 Nm
Size
Type
Screw
M10x1.5
Tightening torque
Lubricant
Value/Standard
42 Nm
5.
6.
7.17.4
WARNING
Part No.
Qty.
F30026582
Ratchet adapter
F30027340
Heavy object.
Risk of crushing!
Use appropriate lifting devices and appliances.
5.
6.
7.
8.
2.
3.
4.
5.
Size
Type
Screw
M10x1.5
Tightening torque
Lubricant
Value/Standard
60 Nm +5 Nm
Size
Type
Screw
M10x1.5
Tightening torque
Lubricant
Value/Standard
42 Nm
1.
Result:
7.17.5
WARNING
Part No.
Qty.
F30026582
Ratchet adapter
F30027340
3.
4.
5.
Size
Type
Screw
M10x1.5
Tightening torque
Lubricant
Value/Standard
60 Nm +5 Nm
Size
Type
Screw
M10x1.5
Tightening torque
Lubricant
Value/Standard
42 Nm
Part No.
Qty.
Y4345711
Preparatory steps
1.
2.
Result:
3.
Hold belt tension tester over belt drive until the measured value is indicated.
Initial operation with fan
36 Hz 5 Hz
49 Hz 5 Hz
44 Hz 5 Hz
3.
7.18.2
Part No.
Qty.
Preparatory steps
1.
2.
5.
Part No.
Qty.
Isopropyl alcohol
X00058037
6.
Close male connectors that are not plugged in with the protective cap supplied.
Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
Ensure that all sensor connectors are securely engaged.
Note:
7.
8.
Check securing screws of cable clamps on engine and tighten loose threaded connections.
Ensure that cables are fixed in their clamps and cannot swing freely.
Check that cable ties are firm, tighten loose cable ties.
Replace faulty cable ties.
Visually inspect the following electrical line components for damage:
connector housings;
contacts;
sockets;
cables and terminals;
plug-in contacts.
( Contact Service) if cable conductors are damaged.
Part No.
Qty.
Isopropyl alcohol
DANGER
3.
5.
7.20.2
5.
8 Appendix A
8.1 Abbreviations
Abbreviation
Meaning
Explanation
A/D
Analog/Digital
ADEC
AFRS
ANSI
ATL
Abgasturbolader
ATS
BR
Baureihe
Series
BV
Betriebsstoffvorschrift
CAN
CDC
CEL
Circuit
CLS
CPS
CTS
DDEC
DDL
Diagnostic lines
DDR
Diagnostic unit
DIN
DL
Default Lost
DOC
DPF
DT
Diagnostic Tool
Diagnostic unit
ECM
ECU
Engine governor
EDM
EEPROM
EFPA
Abbreviation
Meaning
EGR
EMU
ETK
Ersatzteilkatalog
EUI
FPS
FRS
FTS
FWCP
Control cabinet
GND
Ground
HD
Hochdruck
HI
High
HIHI
High High
HT
High Temperature
IDM
INJ
Injector
ISO
KGS
Kraftgegenseite
KS
Kraftseite
LED
LO
Low
LOLO
Low Low
LSG
N/A
Not Applicable
LP
Low Pressure
OEM
OI
Optimized Idle
OLS
OPS
OTS
OT
Oberer Totpunkt
PAN
Panel
Control panel
PIM
PWM
Modulated signal
P-xyz
Pressure-xyz
RL
Redundancy Lost
Explanation
Abbreviation
Meaning
Explanation
SAE
SD
Sensor Defect
SEL
SID
System Identifier
SRS
TDC cylinder 1
SS
Safety System
TBS
TCI
TCO
TD
Transmitter Deviation
TPS
TRS
T-xyz
Temperature-xyz
UT
Unterer Totpunkt
VNT
VSG
Variable-Speed Governor
VSS
WZK
Werkzeugkatalog
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you
- 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-online.com
9 Appendix B
9.1 Special Tools
Adapter
Part No.:
F6558528
Qty.:
Used in:
1
7.1.1 Engine Barring manually ( Page 64)
Barring device
Part No.:
F6555766
Qty.:
Used in:
1
7.1.1 Engine Barring manually ( Page 64)
Barring device
Part No.:
F6783293
Qty.:
Used in:
1
7.1.1 Engine Barring manually ( Page 64)
Endoscope
Part No.:
Y20097353
Qty.:
Used in:
Feeler gage
Part No.:
Y20010128
Qty.:
Used in:
1
7.4.2 Valve clearance Check and adjustment ( Page 76)
Filling device
Part No.:
B80144852
Qty.:
Used in:
1
7.7.1 Fuel system Venting ( Page 88)
Filter wrench
Part No.:
F30379104
Qty.:
Used in:
1
7.8.1 Fuel filter Replacement ( Page 89)
Qty.:
Used in:
1
7.13.1 Engine oil filter Replacement ( Page 100)
Qty.:
Used in:
1
7.13.2 Centrifugal oil filter Cleaning and filter sleeve replacement ( Page 101)
F6790161
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 83)
Milling cutter
Part No.:
F30452739
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 83)
5605892099/00
Qty.:
Used in:
1
7.12.3 Engine oil Sample extraction and analysis ( Page 99)
Qty.:
Used in:
1
7.14.6 Coolant Sample extraction and analysis ( Page 109)
Y4345711
Qty.:
Used in:
1
7.18.1 Fan drive belt Tension check / adjustment ( Page 124)
Ratchet
Part No.:
F30006212
Qty.:
Used in:
1
7.1.1 Engine Barring manually ( Page 64)
Ratchet adapter
Part No.:
F30027341
Qty.:
Used in:
1
7.12.2 Engine oil Change ( Page 97)
Part No.:
F30027339
Qty.:
Used in:
1
7.13.2 Centrifugal oil filter Cleaning and filter sleeve replacement ( Page 101)
Ratchet adapter
Part No.:
F30027340
Qty.:
Used in:
1
7.17.3 Battery-charging generator Removal and installation ( Page 120)
Qty.:
Used in:
1
7.17.4 Battery-charging generator drive Drive belt and belt tensioner replacement (
Page 122)
Qty.:
Used in:
1
7.17.5 Battery-charging generator drive Drive belt tension adjustment ( Page 123)
Ratchet adapter
F30452578
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 83)
F30039526
Qty.:
Used in:
1
7.4.2 Valve clearance Check and adjustment ( Page 76)
Qty.:
Used in:
1
4.7 Plant Cleaning ( Page 39)
F30510423
Qty.:
Used in:
1
7.3.2 Crankcase breather Filter element replacement ( Page 72)
F30047446
Qty.:
Used in:
1
7.4.2 Valve clearance Check and adjustment ( Page 76)
0015384230
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 83)
F30510423
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 83)
F30026582
Qty.:
Used in:
1
7.17.3 Battery-charging generator Removal and installation ( Page 120)
Qty.:
Used in:
1
7.17.4 Battery-charging generator drive Drive belt and belt tensioner replacement (
Page 122)
Qty.:
Used in:
1
7.17.5 Battery-charging generator drive Drive belt tension adjustment ( Page 123)
F30027337
Qty.:
Used in:
1
7.12.2 Engine oil Change ( Page 97)
F30027336
Qty.:
Used in:
1
7.13.2 Centrifugal oil filter Cleaning and filter sleeve replacement ( Page 101)
Qty.:
Used in:
1
7.6.2 Injector Removal and installation ( Page 83)
Part No.:
9.2 Index
16V 4000 E20 engine data28
A
Abbreviations131
After stopping the engine38
B
Battery-charging generator
Check 119
Battery-charging generator drive Drive belt and belt
tensioner replacement122
Battery-charging generator drive Drive belt tension ad
justment123
Battery-charging generator Condition check 118
Battery-charging generator Removal and installation
120
C
Centrifugal oil filter
Cleaning and filter sleeve replacement 101
Charge-air coolant
Change 111
Draining 112
Filling 113
Level check 110
Charge-air coolant level
Check 110
Charge-air coolant pump
Relief bore check 116
Cold start system with ether injection Check95
Contact persons134
Coolant
Sample extraction and analysis 109
Coolant - charge air
Level check 110
Coolant - charge-air
Change 111
Coolant level
Check 103
Crankcase breather
Oil separator check 71
Crankcase breather (open-circuit crankcase ventilation)
Filter element cleaning 74
Crankcase breather Filter element replacement72
Crankshaft transport locking device10
Cylinder head cover
Removal and installation 80
Cylinder liner
Endoscopic examination 67
D
DDEC alarms44
DDEC and connectors Cleaning128
DDEC Checking plug-in connections130
Drive belt
Condition check 117
E
Edge-type fuel filter Draining91
Engine
Barring manually 64
Shutdown in manual mode 37
Start in manual mode 35
Wiring check 127
Engine coolant
Change 104
Engine coolant pump
Relief bore check 108
Engine coolant Draining105
Engine coolant Filling 106
Engine layout21
Engine oil
Change 97
Sample extraction and analysis 99
Engine oil filter Replacement100
Engine oil level
Check 96
Engine side and cylinder
Designations 25
Engine wiring
Check 127
Engine Barring with starting system66
F
Fan drive
Drive belt replacement 126
Fan drive belt Tension check / adjustment 124
Fire prevention and environmental protection17
Firing order32
Fluids and lubricants17
Fuel filter
Replacement 89
Fuel prefilter - Draining90
Fuel system Venting88
G
General conditions7
H
HP pump
Relief bore check 81
I
Injector
Removal and installation 83
Replacement 82
Inspection port cover
Explosion hazard 13
Instructions and comments on endoscopic and visual ex
amination of cylinder liners69
Intercooler
Drain, coolant leakage 92
M
Maintenance and repair work
Safety regulations 14
MTU contact persons134
O
Operational checks 36
P
Personnel and organizational requirements8
Plant
Cleaning 39
Putting the engine into operation
Preparation after scheduled out-of-service-period
34
Putting the engine into operation after extended out-ofservice periods (>3 months)33
S
Safety instructions20
Sensors and actuators Overview26
Service indicator
Check 93
Service partners134
Starter
Condition check 94
Startup and operation
Safety regulations 12
T
Transport9
Troubleshooting41
V
Valve clearance
Adjustment 76
Check and adjustment 76
Valve gear
Lubrication 75
W
Wiring - engine
Check 127