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Manual Mantenimiento MTU

Manual Mantenimiento MTU

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Technical Documentation

Diesel Engine 12 V 4000 G23, G43 12 V 4000 G63, G83 16 V 4000 G23, G43 16 V 4000 G63, G83 Operating Instructions M015710/01E

Printed in Germany © 2007 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, microfilming 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.

Wichtig – Important – Importante
Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen GmbH zurücksenden. Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten LogistikSupport (Gewährleistung, Ersatzteile etc.). 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 (warranty, spare parts, etc.). Veuillez séparer la carte “Signalisation de mise en service“ et la renvoyer à la MTU Friedrichshafen GmbH. Les informations contenues dans la signalisation de mise en service constituent la base pour l'assistance en exploitation contractuelle (garantie, rechanges, etc.). Rogamos separen la tarjeta “Aviso de puesta en servicio“ y la devuelvan rellenada a MTU Friedrichshafen GmbH. Las informaciones respecto al aviso de puesta en servicio constituyen la base para el soporte logístico contractual (garantía, piezas de repuesto, etc.). Ritagliare “Avviso di messa in servizio“ e rispedirlo debitamente compilato alla MTU Friedrichshafen GmbH. Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.). É gentileza cortar o cartão "Participação da colocação em serviço", preenché-lo e devolvé-lo a MTU Friedrichshafen. Os dados referentes à colocação em serviço representam a base para o suporte logístico (garantia, peças sobressalentes, etc.) estabelecido contratualmente.

Postcard MTU Friedrichshafen GmbH Department MST 88040 Friedrichshafen GERMANY

: No.: N° de commande: N° de pedido: N. commessa: No.: MTU works order No. do pedido: Inbetriebnahmedatum: Date put into operation: Mise en service le: Fecha de puesta en servicio: Messa in servizio il: Data da colocação em serviço: Schiffstyp / Schiffshersteller: Vessel/type/class / Shipyard: Type du bateau / Constructeur: Tipo de buque / Constructor: Tipo di barca / Costruttore Tipo de embarcação/estaleiro naval: Inbetriebnahmemeldung Commissioning Note Notice de mise en service Aviso de puesta en servicio Avviso di messa in servizio Participação da colocação em serviço .: o No du moteur: N de motor: Motore N. do motor: Motortyp: Engine model: Type du moteur: Tipo de motor: Motore tipo: Tipo do motor: Eingebaut in: Installation site: Lieu de montage: Lugar de montaje: Installato: Incorporado em: Endabnehmer/Anschrift: End user`s address: Adresse du client final: Dirección del cliente final: Indirizzo del cliente finale: Usuário final/endereço: Bemerkung: Remarks: Remarques: Observaciones: Commento: Observações: Auftragsnr.Bitte in Blockschrift ausfüllen! Please use block capitals! Prière de remplir en lettres capitales! ¡A rellenar en letras de imprenta! Scrivere in stampatello! Favor preencher com letras de forma! Motornr.: Engine No.

. . . . ...... .. . .. . . . .. . .. .... . . . .. . Main Engine Dimensions ....... 1.. .. . . .. . . . .. ... . . .. . .. ... . . .. . .. . . . . 05 05 06 07 08 11 13 15 15 15 17 17 18 18 19 19 20 20 21 21 26 31 36 41 46 51 55 55 56 57 58 59 60 Personnel and organizational requirements Transport . .... . . . .. .. . . .... . . ... .. .. . optimized fuel consumption . 2.. . . . ... . .. . .. . .. .... . .. . .. . . . .5 2... 3.. . . . . ... . . . . .. . .. . . .. . . . . . .. . . .. .... . . . . . ... . . . ... . .. . . . . .3 Engine data 12/16V 4000 Gx3: Standby operation 3D. ... . variable 3B. . .. . . . . . . . . . . . . . ... .. . . . .. .. .. .. .. ... . .. .... .. ... ... .. . .. 2... . . .. ... . .. .. . . ... . . . . ...... . .. . .. .4 2. . . variable 3B. 2. Stopping the engine in manual mode M015710/01E 07-02 © MTU . . ... ... .. . . . . .. . . .. . . ... . . .. . . . .. .... .. . . . . . .. . .3 2. .. . . . ..... .. . .. . .... . . . . .. . . ... . .. . . .. . .. . .4 1.... .6. .. . .. .... . ..5 3.. . . ..1 3... .. . .. . .. . . . . . .. . . .. optimized exhaust emissions (TA-Luft) . . . . . .. . ... . .... . ...... . . .. .. . .. .6. ..... . . .. .. . . . .. fire prevention and environmental protection Standards for warning notices in the publication . . . . . . ... . . . . . .. .. .. . .. . . . . . . . . . ... .6..2... .. . . .4 12V 4000 Gx3 engine data: Continuous operation. ... . . . . .5 1.. . . .. . .. . . .. . . . . .. . ..1 2. .. . . . .. . .. .. . 2.. . . . . . . . . . optimized exhaust emissions (EPA stage 2) .... . .1 12V 4000 Gx3 engine data: Standby operation 3D. . . . . . . . . . . . . . 2. .. . . . . . . ... .1 Engine side and cylinder designations .. . . . ... ... . . . .. . . . . .. . . .. . . . . . . . . . . optimized fuel consumption . .. . .. .. . . ... . . . . .... .. . . . . .. .... . . . . . . .. . . . . . .. .. . . .6. . . ....... . . . .. . . ... .. . . . . . . .. . . . . ... . ........ Putting the engine into operation after scheduled out-of-service-period Starting the engine in manual mode Emergency start (override mode) Operational checks ..6. . . ..6 Engine Layout . .1 1. ..Table of Contents 01 1 Safety . ... .. .. . .. .... . . . ... .. .. .. .. optimized exhaust emission (EPA stage 2) .... . . . ... . .. . .. ..1.. ... ... .. .4 3.. . 3 Operation . . . . . . . . .. . . .. .... . ... ... . . . . . .. ... . . . . . .. . . . .. .. . ... . . ... .. ... .... ... . .. Final Compression Pressure . . . . . . .. .. . .. . . .. .. optimized fuel consumption . . .. 2. . . . . . . .. . . . . ... . .. . .. .. . .. . . . . . . ... .. . .. . .. . . . . . . ..3. . .. . . . . . . . . ... Firing Order . ... . . .. 2. .. . . ... . . . ... .. .6 General conditions . . . . . . ..... .. . .. . . .. . . .. . .5. . . .... .. . . .. . . ... .. . ..1 Engine layout .. .. .. .. .. . . . .. .. . . . . . . .... .. . . ..... . ...... . .5 16V 4000 Gx3 engine data: Continuous operation.. . .2 1. . . ... . . ... ..... .. . . . . ... . ...2 16V 4000 Gx3 engine data: Standby operation 3D. . . . . ..... . .. . . .. . .2 2. .. . . .. .. . .... . .. . .. . . ...... .. . . . .. . . . .... . . .. . . . .. . 2. .. . . .. . ... .. . . .6. 2. . . . ....... .. . . . ..... . ... . .. . . . . .2 3.. . . .. . . . ...6.. . ... . 2. .. .. .. .. .. . . . . . 2 Product Summary ...... .. . . ..... . .. ... . . . 2. .. . optimized fuel consumption . . . .. . . . . . . . .. ... .. . . .. .. . . ... variable 3B... . .. .. . ... . ... . . Technical Data ... . . ........ Engine Side and Cylinder Designations ... . .. .. .. variable 3B.. ..1 Engine – Main dimensions .. . . . . . .. . . .. .3 1. . .. . . . . Auxiliary materials. .... . . . . .. .. . ..7 12V 4000 Gx3 engine data: Continuous operation. .. . . . . . . .... .. .... . .. .. . . . .. . . . .. . . ... . . .. . .. . .4.. . 2. . . .. . .. . . . . . .. . . . . . . . . . . . .. Safety requirements when working on the engine . .6 12/16 V 4000 Gx3 engine data: Continuous operation.. .. .3 3... . .. .. . . .. .. . .. . . . . . .. .. . . . ...1 Firing order .. . .. .. . .. . .. .. . . 2.... .6 Putting the engine into operation after extended out-of-service-periods (>3 months) . . . .. . . . .1 Final compression pressure . . . .. ... . . . .. . . . . . . . . . . .. ... . . .. ...

.. . . . . . . . ... diaphragm check and replacement . .. . . Engine – Barring with starting system ... .. . .... .. . .. .. . . ... . . . . . .. .. .. . . . .. . . . .. .. . . . . . . . . . ........ .. ... . 6... . .. . . . .. ... . . . ... . . . . .. .3. . . ..... . .. . . . . After stopping the engine – putting the engine out of service . . .. . . .. . . ... .. . . .. . ... .. . .. ..2 Injector – Removal and Installation ... ... . .... . . . .3 . .. .... ... .. . . .. . . . .. .2. . . . .1.. .. Crankcase Breather . . . . . . . . .... ... ... .. .. . .... . .. .. .. . . . . . .. ... . .. . . .02 Table of Contents 3. . . ... . . . .. . . . . . .. . . . . . . . .. . . . .. ... . . . .1.. . ... . . . . . .. . . .. . . . ..... . . .. .. . . . . .. . .. ... .7 6.. . .. . . . . .. . . .. . . . . . General. . ... .. . .. . ... . . . . . . . .. .. . ..1 Engine 6. ... .. . . . . .. . . . .. . . . . . . . 6. . . . . . . . . Air Filter . . . .. . . .... . .... . . . . .. . .... . . . . Valve Drive . ...8... . . . . .. . ... . .. . . .. . . . . .. . .. .. .. . . .... . . .. . . . Left Side ...2 Valve clearance – Check and adjustment ... .. .. . . ..2 Fuel prefilter cleaning . .. . . ... 6. . . . . 6.. .1 Crankcase breather – Oil separator replacement. . . . .. ..1 5. ... .. . . . . . . .. . .. .. . . . .. . . ... . .. .. . . . . . .. . . .. . . . . .7... . . . . . . . ..Fault messages 6 Task Description . . ... . ... . . ........ . . .. . . . . .. . .. .. ... . . .2. . . .... . . . . . .. . . . . . . . ... .. . ... . .7 3.. . . . . . .. .... ..4 6.. . ... . .. 6. . .. .. .. . .. . Fuel System . . . . . ... . .. .. . .. . . . 61 62 63 65 65 66 68 71 71 74 95 95 95 96 97 98 98 100 102 102 104 104 105 108 109 109 110 114 114 115 115 116 117 118 120 122 124 124 125 After stopping the engine – engine remains ready for operation .. .9 4 Emergency stop . .. . . . . .. . . .5.. . . ... .. . . .. .. ..4 Fuel prefilter – draining . .2 Cylinder Liner . . . .. . . . ... . . . . . ..2 Instructions and comments on endoscopic and visual examination of cylinder liners .. . .4.. . .. . .. . Engine test run . Maintenance schedule matrix Maintenance tasks . .... . . .... . . ... .. . . .. . .. .. .. .. . . . . . .. . .. ... . . . .. . . .. . . .. . ..... . . . .. . . . . ..1 Fuel filter – Replacement . . .. ... .. ... . . . . .. .. . . . . . .. .. . . .. ... ... ... . ....1 6. . . .. . ..1 Injector – Replacement . ... . . . . ... . . . . . . . ... . . ..8 6. . . Fuel Filter .. . . . . . . . . . .. . . .6. .. .... . . . . . . .. . .. . . . . . . .9 M015710/01E 07-02 © MTU .. . .. .. . .. .. . . .. .. .7. . . . .. . .. . . . . . .. . . .. . .. 6... . .6 Fuel prefilter – filter element replacement . .. .. . . 6. . ... . . .. 5 Troubleshooting 5. . . . . . ... .. .. . Engine – Barring manually .. . .. . .... .. . . .. . . . .. . .. .. .. .7. . . . 6... . . ...1 Fuel system – Venting . .. .. .3 Cylinder head cover – Remove and install . .. ..4.. .. . . . .. .1 4. .. ... . .. ..2 4..... . . . 6. . Charge-air Cooling. . .. . Injector . 6.. . .. .... . . . . 6. . .. . ... . .. . .7.. . . . . . . .. ... . .. 6. .. .. . .... ... .3 Fuel prefilter – differential pressure check and adjustment of gauge . . . .. ..7. . .4. . .. . .. . . ..... ... . . .. ... . . . . . .. .. ... . . ... . .. . . . . .. . . . ..... . . . ... .. . . . . . . . . . . .. . . .. . .. . ... .. . ... . ... ... .. . . . .. . . . . Maintenance 4.. .. ... ... . . . . . ... 6. . .. . . . . . . . . . . .. . .. ... . .. .. .. .. .. ... . . . . . .. .. . . .. . . .. ..8 3. .. . .. . .. . . . . . .... . .. ... . . . . . . . . . .... . . . . . .. . .. .. . . . . .. . . . .3 Preface . Troubleshooting Engine governor ADEC (ECU 7) for Series 4000 genset engines . . . . . . .3 6. . .. . . . . .. . .6 6. . . .. . ... ... . . . . .. . . ... . . .. . . . . .1 Intercooler – Checking condensate drains for coolant discharge and obstructions . . . . . . . . . .. . . ... . . . . . . . . . . . . . . . ..5... . . . .2 6.. . .... .. . . . . . .. .. .7. .. . . .1 Valve gear – Lubrication . ... . . . . . ..... . . . . .... ... . .. . 6.. . . . .. . . . . .. ..... . . ... . . .. . .. .. . .. . ... . . . . . .... 6. . . . . .. .... . . .... . . .. .. . .. . . . . . . . .. .. . ... . . .. . .. .... .. . . .. . . .. . .. . . .. . . . ... . . . ... . .. . . .. .. . . . . . . .5 Fuel prefilter – flushing . . .2 .. . . .... . . . . . . . . . . . . 6. . . . .. . . . 6. . . . . .. . .1.. . . .. .. . . .. . . . 6.5 6.... . . . .. . . . . .... . . .... .. .. .1 Cylinder liner – Endoscopic examination . . . ... ... .. 6.. . . .. . . . . . ... .. . . .. . .

. . . . . . . . . . . . Oil Filtration/Cooling . . . . . .12. . ... . . . . . . .. . . . . . . . . . . . . . . .. . . .. .. . . . . .. .. . . . . . . . 6. . . . . .. . . . . . . .13 6.. . . . . . . . .. .2 Engine oil – Level check . . . . . . .17 6.. . . . . . .. . .. .. . . . . 6. . . .1 Air starter – manual operation . . . . .. . . . . . . . . . . .. . . . . . . . . . . .17. . . . ... . . .. . .. . . . .3 Engine coolant – Draining . . . . . . .. . . . . . . . . . .5 Charge-air coolant pump – Relief bore check . .. .. .. . .. . LT Circuit . ... .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . .. ... . .12. 6. . . . . . ... . . . . . . .. . .. . . . .. . .. .. . . . 6. . . . . . . . . . . . .. .1 Engine coolant – Change . . . . . . . . . . .. . . Staring Equipment . . . . 6. . . . . . . . . . . . .. .. . . .2 Battery-charging generator drive – Drive belt replacement . .. . . . . . . . . . . . . . .14. . . . . . . .. . .. . . . . .. .. . . . HT Circuit . . . . . .. . . . . . . . .15. . . .. .. . .. . . . . . .. . .. . . . .. . . . . . . . Rubber sleeves between air intake elbow and turbocharger – Replacement . .. . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . 6. .. . . . . . . . .. . ... . . . . . . .. . . . . . . . .2 Charge-air coolant – Filling . . . . . . . . . . . . .. .. . . 6. . .. .. .. . . . . . . . . . . . . . . . . . . .10. . . . . . .16 6. . . . . . . . . . .. . . . 6. . . . .. . . . ... . . . .. . . . . .. . .3 6. . . . .18. . . . . . . . .. . . . . .. . ... ... 125 126 127 128 129 129 130 130 131 132 132 134 135 136 136 137 139 139 140 142 143 144 145 146 146 147 149 150 151 152 152 153 153 154 155 155 156 156 157 159 159 167 167 Air Intake .6 Engine coolant – Sample extraction and analysis . . . . . . . . . .. . . . .. . . . . . . 6. . . . . . . .. . . . .. . .. .. . . . . . . . . . . 6. .. . .. . ... . . . . . . . ... . . . . .. . . . . . . . .. . ..1 . . Lube-oil System. Cabling. .. . . . . . . . . . . . . .. . . . .1 Charge-air coolant change . . .. .. . . .. . . . .. .9. . . . . . .. . . . . . . . . .9.5 Engine coolant pump – Relief bore check . . .. ... . . . . . . . . . .. . .. . ... . . . . .. . . . . . . . . . . . . .. M015710/01E 07-02 © MTU . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . General for Engine / Gearbox / Plant . . . . 6. . .. . . . . .. . . . .Table of Contents 03 6. . . .. ... . .. . . ...12. .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . .2 ECU – Checking plug-in connections . . . . .. . . . . . . . .14. . . . . .. . . . . . . .. . . . . . . . . . . . . .. Lube-oil Circuit .. . .. .. . . . . .1 Special tools . . . . . . .. . . . . . . . . .. . . . . . . . . . .. .. . . . . . . .. . . . . . .. . . . . . . . ... . . . . . . . .15. . . . . . .. . . . . . . .. .. .. . . . .. . .15.. . . . . . . .. . .. . . .. . . . . . . General.. . . . . .1 Service indicator – Signal ring position check . . . .. .4 Engine coolant level – Check . . . . . .. .1 6. . . Manufacturer’s documentation . .. . .15 6. . 6. . . . .19 7 Special Tools . .. . . . . . .. . . . . . . . . . . . . . . .4 Charge-air coolant level check . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . .18 6. . ..15. . . . . . . ... . .2 6. . . . . . . . . . . . . . . . . . . . . . . . . . .14.. . . . .19.11. . . . . . .. . . . . . . . .1 Battery-charging generator drive – Drive belt tension adjustment .. . .. .. .. . . . . . . . . . . .1 Engine oil filter – Replacement . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . .. .. . . .. . . . . . . . . . . .11.. . . .. . . . . . . .2 Engine coolant – Filling . . .16.19. . . .. . . . . .. . . . . . . . .13. . .1 Engine oil – Change . . . . . . .. . . . . . . 6. . . . . . . . Cooling Circuit. . . . .3 Charge-air coolant – Draining . . . .. . . . . .. . .9.. . . . 6. . . . . . . . 6. ..9. . .15. . .1 Engine wiring – Check .. . . . . . . . . . . . . .. . . . .13. . . . . . .. . 6. . .2 Centrifugal oil filter – Cleaning and filter-sleeve replacement .14. . .. Belt Drive .. . . . . . . . . . . . . . . . . . . . . 6. . . . . . . . . . . .. Battery-charging Generator . .2 Starter – Condition check .. . . . . . . . . . . . Accessories for Engine Governor (Electronic) / Control System . .1 ECU and connectors – Cleaning . . . . . . . . . . .. . . . . . . . . . Air filter – Check .. . . . . .. . . . . . . . .. .. . .. . 6. . . . . . .. . . . .. . . . . . . . ... . . . . . . . . . . . . . . . . .14 6. .12 6.. . .. .. . . . . . .3 Engine oil – Sample extraction and analysis . . . . . . . 6. . . . . . . . . . 6. . . . . . . .. ... . .. . . . . . . . .. ... . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . .1 Drive belt – Condition check .. . 6. . . . .. . . Air filter removal and installation . . 7.. .10 6. 8 Annex 8. . . . . . . . .. . . . . . ... . .. . . . . .4 6. . . . . . .14. . .. .. . . . . . . . .. . . .. . . . . . . . . 6.. . . . ..14.. . 6.. . . . . . . . . . . . . . . .17. . . . . .. 6.11 Air filter replacement . .. . . 6. . .... . . . . . . . . . 6. .

.. ... ..... . . ........ ... ... . . . .. . . . .. . .... ...... .. 168 169 173 . ....... ... ........... ..... .3 8.. ....... .. ... .... Abbreviations Index ..... ..4 MTU contact person/service partner .2 8.... . ..... .... .... .04 Table of Contents 8.. .... .................... M015710/01E 07-02 © MTU ....... ........ ..... . .

Correct use also includes observation of and compliance with the maintenance specifications. no liability nor warranty claims vis-à-vis the engine manufacturer will be accepted. Modifications or Conversions Modifications made by the customer to the engine may affect safety. Any other use is considered improper use. M015710/01E 07-02 © MTU . persons and property may be at risk in the event of: • Incorrect use • Operation. maintenance and repair by unqualified personnel • Modifications or conversions • Non-compliance with the Safety Instructions Correct use The engine is intended exclusively for the application specified in the contract or defined at the time of delivery. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. the applicable country-specific legislation and other compulsory regulations regarding accident prevention must be observed. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. This engine is a state-of-the art product and conforms with all applicable specifications and regulations.1 Safety General conditions General In addition to the instructions in this publication. The responsibility is borne by the user alone. The manufacturer will accept no liability for any resultant damage. Nevertheless. In the event of any damage caused by the use of other spare parts.Safety 05 1 1.

protective goggles. It must be kept at hand near the engine and accessible at any time to all personnel involved in operation. Do not wear jewelry (e. Responsibilities of the operating. maintenance and repair personnel must be specified. The personnel must be instructed on engine operation and repair by means of this publication.06 Safety 1. repair or transportation. This is especially important for personnel who work on the engine only on an occasional basis. maintenance. chains etc.2 Personnel and organizational requirements Personnel Work on the engine must only be carried out by properly qualified and instructed personnel. Working clothes and protective equipment Wear proper work clothing for all work. Work clothing must be tight fitting so that it does not catch on rotating or projecting components. and in particular the safety instructions must be explained.). Depending on the kind of work. apron. maintenance. use additional protective equipment. e. The specified legal minimum age must be observed. helmet. gloves. M015710/01E 07-02 © MTU . repair or transportation. Organization This publication must be issued to all personnel involved in operation.g. Such personnel must be given instructions repeatedly. rings.g.

In the case of special packaging with aluminum foil. Take note of the engine center of gravity. it is imperative to install transportation locking devices for crankshaft and engine mounts. Prior to transporting the engine. unless expressively authorized by MTU on a case-to-case basis to do so. Secure the engine against tilting during transportation. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Setting the engine down after transport Place the engine only on an even. suspend the engine on the lifting eyes of the transport pallet or transport with equipment for heavy loads (forklift truck). Use only the transport and lifting equipment approved by MTU. Never place an engine on the oil pan.3 Transport Engine transport Lift the engine only with the lifting eyes provided. The engine must be especially secured against slipping or tilting when going up or down inclines and ramps.Safety 07 1. firm surface. M015710/01E 07-02 © MTU .

Use only proper. Before putting the device or the system into operation. Always support by suitable means which conform with the applicable regulations before commencing maintenance or repair work.4 Safety requirements when working on the engine Safety precautions when putting the equipment into operation Prior to initial operation. Inhalation of poisonous exhaust gases is a health hazard. check that all protective devices/safety guards have been installed and that all tools and loose parts have been removed from the engine. After completing work on the engine. Disconnect the battery when electrical starters are fitted. Inadequate protection of electrical components can lead to electric shocks and serious injuries. Take care not to damage fuel lines during maintenance and repair work. The operator must carry out the individual operations according to the documentation. never release coolant. Do not work on engines or components which are only held by lifting equipment or crane. violation of limit values and warning or alarm messages. Post the "Do Not Start" sign in the operating room or affix it to the controlling device! Persons not involved must keep clear. Always seal connections with caps or covers if a line is removed or opened. calibrated tools. Lock-out/tag-out the engine to preclude undesired starting. compressed-air or hydraulic lines. Never carry out maintenance and repair work with the engine running unless expressly instructed to do so. Ensure that the engine room is well ventilated. always ensure • that all maintenance and repair work is completed • that all loose components have been removed from rotating parts • that nobody is standing in the danger zone of moving engine components. Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury.g. always wear ear protectors. Safety requirements for operators Procedures for cases of emergency must be practised regularly. emergency engine stop. Immediately after putting the device or system into operation. Before barring the engine. make sure that nobody is standing in the danger zone. use the correct tightening torque and ensure that all retainers and dampers are installed correctly. When the engine is running. Before starting work. During operation. carry out emergency operations e.P. Have maintenance and repair work carried out by qualified and authorized personnel only. Engine operation When the engine is running. Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent. The operator must know the consequences of each operation to be carried out. Maintenance and repair Strict adherence to the maintenance and repair schedule is an essential safety factor. generator terminals or cables. The operator must be familiar with the controls and displays. lines which are to be opened. oil. Keep fuel injection lines and connections clean. the displays and monitoring units must be permanently observed with regard to present operating status. M015710/01E 07-02 © MTU . do not touch battery terminals. make sure that all control and display instruments as well as the signaling and alarm systems work properly. Never bend a fuel line and do not install bent lines. The exhaust pipework must be free of leaks and discharge the gases to atmosphere. To tighten the connections when installing the lines. Close the main valve on the compressed-air system and vent the compressed air line when air starters are fitted. Exhaust gases from combustion engines are poisonous. The following steps must be taken if a malfunction of the system is recognized or reported by the system: • notify the supervisory personnel in charge • analyze the message • if required. During engine operation. fuel. Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools required. the product must have been installed correctly and approved according to MTU specifications.08 Safety 1. relieve pressure in systems and H.

• For hydraulic installation. slings. 10 kg and 30 kg. Before starting work. Never use the engine as a ground connection. Lifting eyes must not be unevenly loaded. depending on age and sex. If components (e. always use suitable ladders and work platforms. are sufficiently strong and that hooks are correctly positioned. Do not touch elastomeric seals if they have carbonized or resinous appearance. Wear protective gloves! Take care with hot fluids in lines.g. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system. For a hydraulic installation/removal tool with central expansion pressure supply. The max. After completion of maintenance and repair work. Never route the welding lead over or near the wiring harnesses of MTU systems. ensure that the engine room is adequately ventilated. hooks. permissible push-on pressure specified for the equipment must not be exceeded. ensure that nobody is standing in the immediate vicinity of the component to be installed/removed. make sure that no loose objects are in/on the engine plant. screw on the tool with the piston retracted. When working high on the engine. Make sure components are placed on stable surfaces. It is not necessary to remove the connector and the connections when carrying out welding operation on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire is disconnected from the negative and positive poles on the battery. screw spindle into shaft end until correct sealing is achieved. The resulting acid leads to serious burning if it contacts the skin. Welding work Never carry out welding work on the engine or engine-mounted units. When changing the engine oil or working on the fuel system. The material decomposes when exposed to fire or temperatures exceeding 300 °C. In order to prevent back injuries when lifting heavy components adults. screw on the tool with the piston extended. pipes and chambers ⇒ Risk of injury! Note cooling period for components which are heated for installation or removal ⇒ Risk of injury! Never touch hot parts of the compressor and exhaust system ⇒ Risk of burning! Take special care when removing ventilation or plugs from engine. exhaust manifold) are to be welded. close vent plugs). "Viton" sealing rings) are stable under normal operating conditions. Elastomers (e. they must be removed from the engine. are tested and authorized. except when necessary for design reasons during installation. collect fluids in a suitable container. as the liquids can still be hot. In order to avoid discharge of highly pressurized liquids. there is the risk that the component to be installed/removed may be suddenly released from the pressure connection. pump until bubble-free air emerges. This prevents the welding current passing through the engine resulting in burnt/scorched bearings. Hydrogen fluoride vapors are released in this case. sliding surfaces and tooth flanks which may lead to bearing seizure and/or other material damage. Hydraulic installation and removal Only the hydraulic installation and removal equipment specified in the work schedule and in the assembly instructions must be used. Observe special cleanness when conducting maintenance and repair work on the engine plant. • For hydraulic removal. hold a cloth over the screw or plug. Do not place fuel or oil lines near hot components. therefore: • Use lifting gear or seek assistance. should only lift weights between max. The H. As long as the system is under pressure.P. open vent plugs. During hydraulic installation and removal. M015710/01E 07-02 © MTU .g.g. the pumps and the lines at the relevant points for the system to be used (e. • Ensure that all chains. ⇒ Risk of injury! When draining. Do not attempt to bend or apply force to lines. Take special care when draining hot fluids. mop up any spilt fluids or wipe or soak them with a suitable bonding agent. It is even more dangerous if the engine has recently been shut down.Safety 09 Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other components to avoid contact with them. lines for hydraulic installation and removal are tested with 3800 bar. The welding unit ground connection must not be more than 60 cm from the weld point. pay attention to the following: • Vent the hydraulic installation/removal tool. etc.

M015710/01E 07-02 © MTU . Do not secure wiring to fluid-carrying lines. during maintenance and / or repair work. i. use cable clamps to properly support the wires. Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery body. On completion of all repair work. De-energize the appropriate areas prior to working on assemblies. Working on electrical/electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so. Do not allow battery acids to come in contact with skin or clothing. always wear special laser-protection goggles. Laser equipment must be fitted with the protective devices necessary for safe operation according to type and application. On completion of the maintenance and repair work. Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is not damaged by contact with sharp objects.10 Safety Before use.e. Operation of electrical equipment When operating electrical equipment. Separate testing of the repaired component without system integration is insufficient. Noncompliance with the warning instructions given for this equipment may result in serious injury or damage to property. a maximum output of 5 mW. which have maximum output in the visible wavelength range (400 to 700 nm). For conducting light-beam procedures and measurement work. thermal and optomechanical effects of the laser can cause damage. particularly protected against moisture. The main danger is irreparable damage to the eyes. the component and system must be subjected to a function check. only the following laser devices must be used: • Laser devices of classes 1. and in which the beam axis and surface are designed to prevent any risk to the eyes. no cable binders must be used as. certain components of this equipment are live. check battery polarity. the tools must be checked at regular intervals (crack test). concentrated radiation by the effect of stimulated emission in the range of visible light or in the infrared or ultraviolet spectral range. Working with laser equipment When working with laser equipment. Before connecting the cable to the battery. 2 or 3A. Wear protective goggles. The photochemical. by rubbing against other component or by a hot surface. Spare parts shall be properly stored prior to replacement. i. Do not place tools on the battery. Defective electronic components and assemblies must be suitably packed when dispatched for repair. For this purpose. Avoid sparks and naked flames. • Laser devices of class 3B. Laser equipment can generate extremely intensive. any cables which have become loose must be correctly connected and secured.e. the binders can be removed but not installed a second time. If wires are installed beside mechanical components and there is a risk of chafing. Gases released from the battery are explosive. particularly protected against moisture and impact and wrapped in antistatic foil if necessary. Any measures requiring a power supply are expressly defined as such at the appropriate place in the manual.

Safety

11

1.5

Auxiliary materials, fire prevention and environmental protection

Fire prevention Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying around on the engine. Do not store combustible materials near the engine. Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a noncombustible fluid. When starting the engine with a foreign power source, connect the ground lead last and remove it first. To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead of the engine or to the ground terminal of the starter. Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use. Noise Noise can lead to an increased risk of accident if acoustic signals, warning shouts or sounds indicating danger are drowned. At all workplaces with a sound pressure level over 85 dB (A), always wear ear protectors (protective wadding, plugs or capsules). Environmental protection Dispose of used fluids, lubricants, materials and filters in accordance with local regulations. Manipulation of the injection control system can influence the engine performance and exhaust emissions. As a result, compliance with environmental regulations may no longer be guaranteed. Only fuels of the specified quality required to achieve emission limits must be used. In Germany, the VAwS (= regulations governing the use of materials that may affect water quality) is applicable, which means work must only be carried out by authorized specialist companies (MTU is such a company). Auxiliary materials Use only fluids and lubricants that have been tested and approved by MTU. Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions applicable to the product. Take care when handling hot, chilled or caustic materials. When using inflammable materials, avoid sparks, flames and do not smoke. Lead • When working with lead or lead-containing pastes, avoid direct contact to the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust! • Switch on fume extraction system. • After coming into contact with lead or lead-containing materials, wash hands! Acids and alkaline solutions • When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing. • Immediately remove clothing wetted by acids and alkalis! • Rinse injuries with plenty of water! • Rinse eyes immediately with eyedrops or clean tap water. Paints • When painting anywhere other than in spray booths equipped with extractors, ensure good ventilation. Make sure that adjacent work areas are not affected. • No naked flames! • No smoking. • Observe fire prevention regulations! • Wear masks providing protection against paint and solvent fumes. Liquid nitrogen • Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. • Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and loss of tissue. • Wear protective clothing, including gloves, closed shoes and protective goggles!

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12

Safety

• Ensure that the room is well ventilated. Nitrogen concentration exceeding 88% of breathing air leads to suffocation. • Avoid all knocks and jars to the containers, fixtures or workpieces. Compressed air Compressed air is air compressed at excess pressure and is stored in vessels from which it can be extracted. The pressure at which the air is kept can be read off at pressure gauges which must be connected to the compressed air vessels and the compressed air lines. When working with compressed air, safety precautions must be constantly observed: • Pay special attention to the pressure level in the compressed air network and pressure vessel! • Devices and equipment connected must either be designed for this pressure or, if the permitted pressure for the connected elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose coupling and connections must be securely attached! • Always wear protective goggles when blowing off tools or chips! • The snout of the air nozzle should be provided with a protective disc (e.g. rubber disc), which prevents air-borne particles being deflected and thereby prevents injury to eyes. • First shut off compressed air lines before compressed air equipment is disconnected from the supply line or before equipment or tools are exchanged! • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of containers, carries the 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 shattering! • Do not use compressed air to clean contaminated clothing whilst it is being worn. Used oil Used oil may contain health-threatening combustion residues. Rub barrier cream into hands! Wash hands after contact with used oil.

M015710/01E

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© MTU

Safety

13

1.6

Standards for warning notices in the publication
DANGER In the event of immediate danger. Consequences: Death or serious injury. • Preventive measures In the event of possibly dangerous situations. Consequences: Death or serious injury. • Preventive measures In the event of dangerous situations. Consequences: Slight injury or material damage. • Preventive measures

WARNING

CAUTION

Note: This Publication contains especially emphasized safety instructions in accordance with the American standard ANSI Z535, which begin with one of the above signal words according to the degree of danger: Warning notices 1. Read and become acquainted with all cautions and symbols before operating or repairing this product. 2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!

M015710/01E

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© MTU

14 Safety M015710/01E 07-02 © MTU .

Product Summary 15 2 2. general electrical systems M015710/01E 07-02 © MTU .1. driving end and free end (coupling) 500 Monitoring and control systems.1 2.1 Product Summary Engine Layout Engine layout Illustration is also valid for 12V 4000 Gx3 engines 010 020 030 040 050 070 080 100 110 120 Crankcase and attachments Gear train Running gear Cylinder head Valve gear Fuel system (high pressure) Fuel system (low pressure) Exhaust turbocharger Intercooler Air intake / air supply 140 170 180 200 210 230 250 Exhaust system Starting equipment Lube oil system Coolant system Power supply Mounting / support PTO systems.

16 Product Summary Engine model designation Key to the engine model designations 12/16V 4000 Gx3 12/16 V 4000 G x 3 Number of cylinders Cylinder arrangement: Vee configuration Series Application Application segment (2. 8) Design index M015710/01E 07-02 © MTU . 6. 4.

The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). starting with No.2 2.1 Engine Side and Cylinder Designations Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS).Product Summary 17 2. 1 at the driving end.2. 1. The cylinders of each bank are numbered consecutively. The numbering of engine components is also from the driving end. 1 KGS = Free end 2 Right side 3 KS = Driving end 4 Left side M015710/01E 07-02 © MTU . starting with No.

2520 mm approx.1 Main Engine Dimensions Engine – Main dimensions Engine – Main dimensions Illustration is also valid for 12/16V engines Length (A) 12V Length (A) 16V Width (B) 12/16V Height (C) 12/16V approx. 2160 mm M015710/01E 07-02 © MTU . 2990 mm approx.3.18 Product Summary 2.3 2. 1660 mm approx.

4 2.4.Product Summary 19 2.1 Firing Order Firing order Firing order 12V 16 V 20V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 M015710/01E 07-02 © MTU .

1 Final Compression Pressure Final compression pressure Final compression pressure Final compression pressure at 120 rpm 24 bar to 28 bar M015710/01E 07-02 © MTU .20 Product Summary 2.5.5 2.

value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value. A L A L mbar mbar mbar mbar 12 15 50 30 85 12 15 50 30 85 12 15 50 30 85 12 15 50 30 85 M015710/01E 07-02 © MTU .6 2. value: Continuous power BL Ref. up to which the engine can be operated. N Not yet defined value . max. optimized fuel consumption Explanation: DL Ref.6. max. of power settings).Product Summary 21 2. without change (e. Exhaust pressure Exhaust pressure.g.1 Technical Data 12V 4000 Gx3 engine data: Standby operation 3D.Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group Intake air temperature Charge-air coolant temperature Raw water inlet temperature Barometric pressure Site altitude above sea level °C °C °C mbar m 12V 4000 G23 3D 25 55 1000 100 12V 4000 G43 3D 25 55 1000 100 12V 4000 G63 3D 25 55 1000 100 12V 4000 G83 3D 25 55 1000 100 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046) Number of cylinders Rated engine speed Fuel stop power ISO 3046 A A rpm kW 12 1500 1575 12 1800 1736 12 1500 1750 12 1800 1910 GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) Intake air depression.

22

Product Summary

MODEL RELATED DATA (basic design) Number of cylinders Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) Exhaust piping, non-cooled Working method: four-cycle, diesel, single-acting Combustion method: Direct fuel injection Cooling system: conditioned water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V angle Bore Stroke Displacement per cylinder Total displacement Compression ratio Cylinder heads: single-cylinder Cylinder liners: Wet, replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before cylinder, BL R bar abs 12 2.9 12 3.2 12 3.2 12 3.4 SAE DISC Degrees mm mm liters liters 12 X X X X X X 12 90 170 210 4.77 57.2 16.5 X X 2 2 00 21 12 X X X X X X 12 90 170 210 4.77 57.2 16.5 X X 2 2 00 21 12 X X X X X X 12 90 170 210 4.77 57.2 16.5 X X 2 2 00 21 12 X X X X X X 12 90 170 210 4.77 57.2 16.5 X X 2 2 00 21

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Product Summary

23

COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling equipment) Coolant temperature after engine, alarm Coolant temperature after engine, shutdown Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from Lube-oil operating temperature before engine, to Lube oil temperature before engine, alarm Lube oil temperature before engine, shutdown Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil pressure before engine, alarm Lube oil pressure before engine, shutdown R R R L R R R L °C °C °C °C bar bar bar bar 12 88 98 99 101 5.0 7.0 --12 88 98 99 101 5.0 7.0 --12 88 98 99 101 5.0 7.0 --12 88 98 99 101 5.0 7.0 --A L L °C % bar 12 55 50 0.7 12 55 50 0.7 12 55 50 0.7 12 55 50 0.7 A R L L L °C °C °C % bar 12 100 102 104 50 0.7 12 100 102 104 50 0.7 12 100 102 104 50 0.7 12 100 102 104 50 0.7

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© MTU

24

Product Summary

FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min. (when engine is starting) Fuel pressure at engine supply connection, max. (when engine is starting) GENERAL OPERATING DATA Number of cylinders Cold start capability: Air temperature (w/o start aid, w/o preheating) - (case A) Coolant preheating, preheating temperature (min.) Firing speed, from Firing speed, to CAPACITIES Number of cylinders Engine coolant capacity, engine side (without cooling equipment) Charge-air coolant, engine side Total engine oil capacity at initial filling (standard oil system) (Option: max. operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, dry (basic engine configuration acc. to scope of supply specification) R kg 12 6200* 12 6200* 12 6200* 12 6200* R R R liters liters liters 12 160 40 260 12 160 40 260 12 160 40 260 12 160 40 260 R R R R °C °C rpm rpm 12 10 32 80 120 12 10 32 80 120 12 10 32 80 120 12 10 32 80 120 L L bar bar 12 -0.1 1.5 12 -0.1 1.5 12 -0.1 1.5 12 -0.1 1.5

R

liters

L

liters

160

160

160

160

L

liters

200

200

200

200

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ISO 6798) Engine surface noise with attenuated intake noise (filter). BL.Product Summary 25 ACOUSTICS Number of cylinders Exhaust noise. (sound power level LW. BL (sound power level LW. ISO 6798) R R dB(A) dB(A) 12 125 121 12 127 123 12 126 122 12 129 124 M015710/01E 07-02 © MTU . unsilenced.

without change (e. Exhaust pressure Exhaust pressure. max. up to which the engine can be operated.2 16V 4000 Gx3 engine data: Standby operation 3D.6. of power settings). N Not yet defined value . value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value. A L A L mbar mbar mbar mbar 16 15 50 30 85 16 15 50 30 85 16 15 50 30 85 16 15 50 30 85 M015710/01E 07-02 © MTU . value: Continuous power BL Ref. optimized fuel consumption Explanation: DL Ref.Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group Intake air temperature Charge-air coolant temperature Raw water inlet temperature Barometric pressure Site altitude above sea level °C °C °C mbar m 16 V 4000 G23 3D 25 55 1000 100 16 V 4000 G43 3D 25 55 1000 100 16 V 4000 G63 3D 25 55 1000 100 16 V 4000 G83 3D 25 55 1000 100 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046) Number of cylinders Rated engine speed Fuel stop power ISO 3046 A A rpm kW 16 1500 1965 16 1800 2280 16 1500 2185 16 1800 2500 GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) Intake air depression. max.26 Product Summary 2.g.

77 76.5 X X 2 2 00 21 16 X X X X X X 16 90 170 210 4.w.5 X X 2 2 00 21 16 X X X X X X 16 90 170 210 4.3 SAE DISC Degrees mm mm liters liters 16 X X X X X X 16 90 170 210 4. (facing driving end) Number of cylinders Cylinder arrangement: V angle Bore Stroke Displacement per cylinder Total displacement Compression ratio Cylinder heads: single-cylinder Cylinder liners: Wet.3 16.3 16.5 X X 2 2 00 21 16 X X X X X X 16 90 170 210 4.8 16 3.1 16 3. diesel.77 76.Product Summary 27 MODEL RELATED DATA (basic design) Number of cylinders Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) Exhaust piping.3 16. replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before cylinder.5 X X 2 2 00 21 M015710/01E 07-02 © MTU .c. single-acting Combustion method: Direct fuel injection Cooling system: conditioned water Direction of rotation: c.77 76.3 16. non-cooled Working method: four-cycle.1 16 3.77 76. BL R bar abs 16 2.

7 6.5 --16 88 94 97 99 4. shutdown Coolant antifreeze content. max. from Lube oil operating pressure before engine. shutdown Lube oil operating pressure before engine.7 16 100 102 104 50 0.28 Product Summary COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling equipment) Coolant temperature after engine.7 A R L L L °C °C °C % bar 16 100 102 104 50 0. max.7 16 100 102 104 50 0. alarm Lube oil temperature before engine. max.5 --A L L °C % bar 16 55 50 0. alarm Lube oil pressure before engine. to Lube oil temperature before engine. Pressure loss in off-engine cooling system. to Lube oil pressure before engine. alarm Coolant temperature after engine.7 16 55 50 0.7 M015710/01E 07-02 © MTU . from Lube-oil operating temperature before engine.5 --16 88 95 97 99 4.7 6.7 16 55 50 0.7 16 100 102 104 50 0. max. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine. Pressure loss in off-engine cooling system. COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content. shutdown R R R L R R R L °C °C °C °C bar bar bar bar 16 89 95 97 99 4.5 --16 88 94 97 99 4.2 5.7 16 55 50 0.2 5.

Product Summary

29

FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection, min. (when engine is starting) Fuel pressure at engine supply connection, max. (when engine is starting) GENERAL OPERATING DATA Number of cylinders Cold start capability: Air temperature (w/o start aid, w/o preheating) - (case A) Coolant preheating, preheating temperature (min.) Firing speed, from Firing speed, to CAPACITIES Number of cylinders Engine coolant capacity, engine side (without cooling equipment) Charge-air coolant, engine side Total engine oil capacity at initial filling (standard oil system) (Option: max. operating inclinations) Oil change quantity, max. (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. operating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, dry (basic engine configuration acc. to scope of supply specification) R kg 16 7700 16 7700 16 7700 16 7700 R R R liters liters liters 16 260 50 300 16 260 50 300 16 260 50 300 16 260 50 300 R R R R °C °C rpm rpm 16 10 32 80 120 16 10 32 80 120 16 10 32 80 120 16 10 32 80 120 L L bar bar 16 -0.1 1.5 16 -0.1 1.5 16 -0.1 1.5 16 -0.1 1.5

R

liters

240

240

240

240

L

liters

210

210

210

210

L

liters

240

240

240

240

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Product Summary

ACOUSTICS Number of cylinders Exhaust noise, unsilenced, BL, (sound power level LW, ISO 6798) Engine surface noise with attenuated intake noise (filter), BL (sound power level LW, ISO 6798) R R dB(A) dB(A) 16 126 128 16 129 125 16 128 125 16 130 126

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Product Summary

31

2.6.3

Engine data 12/16V 4000 Gx3: Standby operation 3D, optimized exhaust emissions (EPA stage 2)

Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group Intake air temperature Charge-air coolant temperature Raw water inlet temperature Barometric pressure Site altitude above sea level °C °C °C mbar m 12V 4000 G43 3D 25 45 1000 100 12V 4000 G83 3D 25 45 1000 100 16 V 4000 G43 3D 25 45 1000 100 16 V 4000 G83 3D 25 45 1000 100

POWER-RELATED DATA (performance refers to net brake power as per ISO 3046) Number of cylinders Rated engine speed Fuel stop power ISO 3046 A A rpm kW 12 1800 1736 12 1800 1910 16 1800 2280 16 1800 2500

GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) Intake air depression, max. Exhaust pressure Exhaust pressure, max. A L A L mbar mbar mbar mbar 12 15 50 30 85 12 15 50 30 85 16 15 50 30 85 16 15 50 30 85

M015710/01E

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© MTU

5 X X 2 2 00 21 M015710/01E 07-02 © MTU .w.c.77 57.3 16.2 16.3 16.77 76.5 X X 2 2 00 21 12 X X X X X X 12 90 170 210 4. BL R bar abs 12 3.77 57. non-cooled Working method: four-cycle.32 Product Summary MODEL RELATED DATA (basic design) Number of cylinders Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) Exhaust piping. replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before cylinder.2 16.3 SAE DISC Degrees mm mm liters liters 12 X X X X X X 12 90 170 210 4. (facing driving end) Number of cylinders Cylinder arrangement: V angle Bore Stroke Displacement per cylinder Total displacement Compression ratio Cylinder heads: single-cylinder Cylinder liners: Wet.5 X X 2 2 00 21 16 X X X X X X 16 90 170 210 4. single-acting Combustion method: Direct fuel injection Cooling system: conditioned water Direction of rotation: c.77 76.5 X X 2 2 00 21 16 X X X X X X 16 90 170 210 4.2 12 3.2 16 3.3 16 3. diesel.

to Lube oil temperature before engine.5 --16 88 94 97 99 4. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine.7 A R L L L °C °C °C % bar 12 100 102 104 50 0. max. shutdown R R R L R R R L °C °C °C °C bar bar bar bar 12 88 98 99 101 5. alarm Coolant temperature after engine. max. COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content. from Lube oil operating pressure before engine. Pressure loss in off-engine cooling system. to Lube oil pressure before engine. max.7 6.7 16 100 102 104 50 0.7 12 45 50 0.7 12 100 102 104 50 0.Product Summary 33 COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling equipment) Coolant temperature after engine.0 --12 88 98 99 101 5. alarm Lube oil temperature before engine.7 16 100 102 104 50 0. from Lube-oil operating temperature before engine. shutdown Lube oil operating pressure before engine. alarm Lube oil pressure before engine. Pressure loss in off-engine cooling system. shutdown Coolant antifreeze content.7 M015710/01E 07-02 © MTU .7 16 45 50 0.0 7.5 --A L L °C % bar 12 45 50 0.7 16 45 50 0.7 6.0 --16 88 94 97 99 4.0 7. max.

(case A) Coolant preheating.1 1. engine side (without cooling equipment) Charge-air coolant. preheating temperature (min. (standard oil system) (Option: max. min. operating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. max.5 12 -0. to scope of supply specification) R kg 12 6200* 12 6200* 16 7700 16 7700 R R R liters liters liters 12 160 40 260 12 160 40 260 16 260 50 300 16 260 50 300 R R R R °C °C rpm rpm 12 10 32 80 120 12 10 32 80 120 16 10 32 80 120 16 10 32 80 120 L L bar bar 12 -0. w/o preheating) . operating inclinations) Oil change quantity. to CAPACITIES Number of cylinders Engine coolant capacity. operating inclinations) Oil pan capacity at dipstick mark "min. operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight.1 1.5 16 -0.5 R liters 240 240 L liters 160 160 210 210 L liters 200 200 240 240 M015710/01E 07-02 © MTU . max. (when engine is starting) Fuel pressure at engine supply connection.34 Product Summary FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection.1 1. dry (basic engine configuration acc. from Firing speed. engine side Total engine oil capacity at initial filling (standard oil system) (Option: max." (standard oil system) (Option: max. (when engine is starting) GENERAL OPERATING DATA Number of cylinders Cold start capability: Air temperature (w/o start aid.5 16 -0.) Firing speed.1 1.

(sound power level LW. ISO 6798) R R dB(A) dB(A) 12 127 123 12 129 124 16 129 125 16 130 126 M015710/01E 07-02 © MTU . ISO 6798) Engine surface noise with attenuated intake noise (filter). BL.Product Summary 35 ACOUSTICS Number of cylinders Exhaust noise. unsilenced. BL (sound power level LW.

A L A L mbar mbar mbar mbar 12 15 50 30 85 12 15 50 30 85 12 15 50 30 85 12 15 50 30 85 M015710/01E 07-02 © MTU . optimized fuel consumption Explanation: DL Ref. variable 3B.Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group Intake air temperature Charge-air coolant temperature Raw water inlet temperature Barometric pressure Site altitude above sea level °C °C °C mbar m 12V 4000 G23 3B 25 55 1000 100 12V 4000 G43 3B 25 55 1000 100 12V 4000 G63 3B 25 55 1000 100 12V 4000 G83 3B 25 55 1000 100 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046) Number of cylinders Rated engine speed Continuous power ISO 3046 (10% overload capability) (design power DIN 6280. value: Continuous power BL Ref. ISO 8528) A A rpm kW 12 1500 1420 12 1800 1520 12 1500 1575 12 1800 1736 GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) Intake air depression.6. max. max. of power settings). Exhaust pressure Exhaust pressure. up to which the engine can be operated. N Not yet defined value . without change (e.36 Product Summary 2.g.4 12V 4000 Gx3 engine data: Continuous operation. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value.

5 X X 2 2 00 21 12 X X X X X X 12 90 170 210 4.2 16.9 12 3.5 X X 2 2 00 21 12 X X X X X X 12 90 170 210 4.5 X X 2 2 00 21 12 X X X X X X 12 90 170 210 4.Product Summary 37 MODEL RELATED DATA (basic design) Number of cylinders Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) Exhaust piping.6 12 2.2 SAE DISC Degrees mm mm liters liters 12 X X X X X X 12 90 170 210 4.77 57. replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before cylinder .9 12 2.2 16.2 16.77 57. single-acting Combustion method: Direct fuel injection Cooling system: conditioned water Direction of rotation: c.77 57.5 X X 2 2 00 21 M015710/01E 07-02 © MTU .c. (facing driving end) Number of cylinders Cylinder arrangement: V angle Bore Stroke Displacement per cylinder Total displacement Compression ratio Cylinder heads: single-cylinder Cylinder liners: Wet. non-cooled Working method: four-cycle.DL R bar abs 12 2. diesel.w.2 16.77 57.

0 7.7 M015710/01E 07-02 © MTU .0 6.7 12 100 102 104 50 0.7 12 100 102 104 50 0. to Lube oil pressure before engine.0 --12 88 98 99 101 5.7 12 100 102 104 50 0.7 12 55 50 0.0 7.7 12 55 50 0. Pressure loss in off-engine cooling system.0 --A L L °C % bar 12 55 50 0.38 Product Summary COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling equipment) Coolant temperature after engine. max. shutdown Lube oil operating pressure before engine. Pressure loss in off-engine cooling system. from Lube oil operating pressure before engine. max. to Lube oil temperature before engine. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine. max. shutdown R R R L R R R L °C °C °C °C bar bar bar bar 12 88 98 99 101 5.7 12 55 50 0.0 7. alarm Lube oil pressure before engine.0 --12 88 98 99 101 5. from Lube-oil operating temperature before engine. COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content. alarm Lube oil temperature before engine. alarm Coolant temperature after engine.0 --12 88 98 99 101 5. shutdown Coolant antifreeze content. max.7 A R L L L °C °C °C % bar 12 100 102 104 50 0.

(case A) Coolant preheating.5 R liters L liters 160 160 160 160 L liters 200 200 200 200 M015710/01E 07-02 © MTU . to CAPACITIES Number of cylinders Engine coolant capacity. operating inclinations) Oil pan capacity at dipstick mark "min. operating inclinations) Oil pan capacity at dipstick mark "max. max.1 1. to scope of supply specification) R kg 12 6200* 12 6200* 12 6200* 12 6200* R R R liters liters liters 12 160 40 260 12 160 40 260 12 160 40 260 12 160 40 260 R R R R °C °C rpm rpm 12 10 32 80 120 12 10 32 80 120 12 10 32 80 120 12 10 32 80 120 L L bar bar 12 -0.5 12 -0. operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight. (when engine is starting) Fuel pressure at engine supply connection. operating inclinations) Oil change quantity.5 12 -0.1 1. engine side (without cooling equipment) Charge-air coolant.5 12 -0. engine side Total engine oil capacity at initial filling (standard oil system) (Option: max. (standard oil system) (Option: max. min.) Firing speed." (standard oil system) (Option: max. preheating temperature (min.1 1. dry (basic engine configuration acc." (standard oil system) (Option: max.Product Summary 39 FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection. (when engine is starting) GENERAL OPERATING DATA Number of cylinders Cold start capability: Air temperature (w/o start aid. from Firing speed. w/o preheating) . max.1 1.

ISO 6798) R R dB(A) dB(A) 12 124 120 12 125 122 12 125 121 12 127 123 M015710/01E 07-02 © MTU .DL (sound power level LW. unsilenced .40 Product Summary ACOUSTICS Number of cylinders Exhaust noise. DL (sound power level LW. ISO 6798) Engine surface noise with attenuated intake noise (filter).

variable 3B. A L A L mbar mbar mbar mbar 16 15 50 30 85 16 15 50 30 85 16 15 50 30 85 16 15 50 30 85 M015710/01E 07-02 © MTU . of power settings).6. optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. max. up to which the engine can be operated. N Not yet defined value .Product Summary 41 2. without change (e.Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group Intake air temperature Charge-air coolant temperature Raw water inlet temperature Barometric pressure Site altitude above sea level °C °C °C mbar m 16 V 4000 G23 3B 25 55 1000 100 16 V 4000 G43 3B 25 55 1000 100 16 V 4000 G63 3B 25 55 1000 100 16 V 4000 G83 3B 25 55 1000 100 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046) Number of cylinders Rated engine speed Continuous power ISO 3046 (10% overload capability) (design power DIN 6280. ISO 8528) A A rpm kW 16 1500 1798 16 1800 2020 16 1500 1965 16 1800 2280 GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) Intake air depression. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value. max. Exhaust pressure Exhaust pressure.5 16V 4000 Gx3 engine data: Continuous operation.g.

w.8 16 3. single-acting Combustion method: Direct fuel injection Cooling system: conditioned water Direction of rotation: c.42 Product Summary MODEL RELATED DATA (basic design) Number of cylinders Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) Exhaust piping.1 SAE DISC Degrees mm mm liters liters 16 X X X X X X 16 90 170 210 4.77 76.3 16.6 16 2.3 16.3 16.77 76.DL R bar abs 16 2.c.5 X X 2 2 00 21 M015710/01E 07-02 © MTU .77 76. replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before cylinder .9 16 2. (facing driving end) Number of cylinders Cylinder arrangement: V angle Bore Stroke Displacement per cylinder Total displacement Compression ratio Cylinder heads: single-cylinder Cylinder liners: Wet.5 X X 2 2 00 21 16 X X X X X X 16 90 170 210 4.5 X X 2 2 00 21 16 X X X X X X 16 90 170 210 4.5 X X 2 2 00 21 16 X X X X X X 16 90 170 210 4. non-cooled Working method: four-cycle.3 16.77 76. diesel.

Pressure loss in off-engine cooling system. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine. max. from Lube-oil operating temperature before engine. max. COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content. shutdown R R R L R R R L °C °C °C °C bar bar bar bar 16 89 95 97 99 4. Pressure loss in off-engine cooling system. max.7 16 55 50 0.7 16 100 102 104 50 0. to Lube oil pressure before engine.7 6. alarm Coolant temperature after engine.7 16 100 102 104 50 0. alarm Lube oil temperature before engine.7 M015710/01E 07-02 © MTU .Product Summary 43 COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling equipment) Coolant temperature after engine. to Lube oil temperature before engine.5 --16 88 95 97 99 4.5 --16 90 96 97 99 4.7 16 100 102 104 50 0.7 6.7 16 55 50 0. alarm Lube oil pressure before engine.2 5. shutdown Lube oil operating pressure before engine. max.7 16 55 50 0. from Lube oil operating pressure before engine. shutdown Coolant antifreeze content.5 --16 89 95 97 99 4.7 A R L L L °C °C °C % bar 16 100 102 104 50 0.2 5.5 --A L L °C % bar 16 55 50 0.

(case A) Coolant preheating. from Firing speed. max. w/o preheating) . dry (basic engine configuration acc. to scope of supply specification) R kg 16 7700 16 7700 16 7700 16 7700 R R R liters liters liters 16 260 50 300 16 260 50 300 16 260 50 300 16 260 50 300 R R R R °C °C rpm rpm 16 10 32 80 120 16 10 32 80 120 16 10 32 80 120 16 10 32 80 120 L L bar bar 16 -0. (when engine is starting) Fuel pressure at engine supply connection.44 Product Summary FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection. preheating temperature (min. operating inclinations) Oil change quantity. (standard oil system) (Option: max. min.) Firing speed.5 16 -0." (standard oil system) (Option: max. engine side (without cooling equipment) Charge-air coolant. operating inclinations) Oil pan capacity at dipstick mark "max. max. operating inclinations) Oil pan capacity at dipstick mark "min.5 R liters 240 240 240 240 L liters 210 210 210 210 L liters 240 240 240 240 M015710/01E 07-02 © MTU .1 1.1 1.5 16 -0. (when engine is starting) GENERAL OPERATING DATA Number of cylinders Cold start capability: Air temperature (w/o start aid.1 1." (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight. to CAPACITIES Number of cylinders Engine coolant capacity.1 1. engine side Total engine oil capacity at initial filling (standard oil system) (Option: max.5 16 -0.

DL (sound power level LW. ISO 6798) R R dB(A) dB(A) 16 125 126 16 127 125 16 126 128 16 129 125 M015710/01E 07-02 © MTU . unsilenced .Product Summary 45 ACOUSTICS Number of cylinders Exhaust noise. ISO 6798) Engine surface noise with attenuated intake noise (filter).DL (sound power level LW.

N Not yet defined value . Exhaust pressure Exhaust pressure. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value.g. ISO 8528) A A rpm kW 12 1800 1520 12 1800 1736 16 1800 2020 16 1800 2280 GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) Intake air depression.Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group Intake air temperature Charge-air coolant temperature Raw water inlet temperature Barometric pressure Site altitude above sea level °C °C °C mbar m 12V 4000 G43 3B 25 45 1000 100 12V 4000 G83 3B 25 45 1000 100 16 V 4000 G43 3B 25 45 1000 100 16 V 4000 G83 3B 25 45 1000 100 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046) Number of cylinders Rated engine speed Continuous power ISO 3046 (10% overload capability) (design power DIN 6280. max. of power settings). A L A L mbar mbar mbar mbar 12 15 50 30 85 12 15 50 30 85 16 15 50 30 85 16 15 50 30 85 M015710/01E 07-02 © MTU . optimized exhaust emission (EPA stage 2) Explanation: DL Ref.6 12/16 V 4000 Gx3 engine data: Continuous operation. value: Continuous power BL Ref. up to which the engine can be operated. max.6. without change (e. variable 3B.46 Product Summary 2.

2 16.0 16 3.77 76.3 16.3 16.5 X X 2 2 00 21 12 X X X X X X 12 90 170 210 4.2 SAE DISC Degrees mm mm liters liters 12 X X X X X X 12 90 170 210 4. replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before cylinder .Product Summary 47 MODEL RELATED DATA (basic design) Number of cylinders Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) Exhaust piping. (facing driving end) Number of cylinders Cylinder arrangement: V angle Bore Stroke Displacement per cylinder Total displacement Compression ratio Cylinder heads: single-cylinder Cylinder liners: Wet.DL R bar abs 12 3. diesel.c.77 57. single-acting Combustion method: Direct fuel injection Cooling system: conditioned water Direction of rotation: c.5 X X 2 2 00 21 M015710/01E 07-02 © MTU .0 12 3. non-cooled Working method: four-cycle.5 X X 2 2 00 21 16 X X X X X X 16 90 170 210 4.5 X X 2 2 00 21 16 X X X X X X 16 90 170 210 4.2 16.w.1 16 3.77 76.77 57.

7 12 45 50 0.7 16 45 50 0. Pressure loss in off-engine cooling system. Pressure loss in off-engine cooling system. max.7 16 45 50 0.0 --12 88 98 99 101 5.0 7.0 --16 90 96 97 99 4. max.7 16 100 102 104 50 0. COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content. alarm Coolant temperature after engine. alarm Lube oil temperature before engine. shutdown Coolant antifreeze content.7 6. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine.7 A R L L L °C °C °C % bar 12 100 102 104 50 0.48 Product Summary COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling equipment) Coolant temperature after engine.5 --16 88 94 97 99 4. to Lube oil temperature before engine. shutdown Lube oil operating pressure before engine.5 --A L L °C % bar 12 45 50 0. from Lube-oil operating temperature before engine.7 12 100 102 104 50 0. max. to Lube oil pressure before engine. from Lube oil operating pressure before engine. max. shutdown R R R L R R R L °C °C °C °C bar bar bar bar 12 88 98 99 101 5.7 M015710/01E 07-02 © MTU . alarm Lube oil pressure before engine.7 16 100 102 104 50 0.7 6.0 7.

preheating temperature (min. operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight. operating inclinations) Oil change quantity. from Firing speed. operating inclinations) Oil pan capacity at dipstick mark "min. max. to scope of supply specification) R kg 12 6200* 12 6200* 16 7700 16 7700 R R R liters liters liters 12 160 40 260 12 160 40 260 16 260 50 300 16 260 50 300 R R R R °C °C rpm rpm 12 10 32 80 120 12 10 32 80 120 16 10 32 80 120 16 10 32 80 120 L L bar bar 12 -0.5 R liters 240 240 L liters 160 160 210 210 L liters 200 200 240 240 M015710/01E 07-02 © MTU .Product Summary 49 FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection.1 1. engine side Total engine oil capacity at initial filling (standard oil system) (Option: max.1 1.5 12 -0. (standard oil system) (Option: max." (standard oil system) (Option: max. (when engine is starting) GENERAL OPERATING DATA Number of cylinders Cold start capability: Air temperature (w/o start aid. to CAPACITIES Number of cylinders Engine coolant capacity.5 16 -0. engine side (without cooling equipment) Charge-air coolant. (when engine is starting) Fuel pressure at engine supply connection.(case A) Coolant preheating. dry (basic engine configuration acc. operating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. min. w/o preheating) .1 1. max.) Firing speed.1 1.5 16 -0.

unsilenced . ISO 6798) Engine surface noise with attenuated intake noise (filter).50 Product Summary ACOUSTICS Number of cylinders Exhaust noise. ISO 6798) R R dB(A) dB(A) 12 125 122 12 127 123 16 127 125 16 129 125 M015710/01E 07-02 © MTU .DL (sound power level LW. DL (sound power level LW.

max.6. without change (e. up to which the engine can be operated. ISO 8528) GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) Intake air depression.g. Exhaust pressure Exhaust pressure. of power settings).7 12V 4000 Gx3 engine data: Continuous operation. optimized exhaust emissions (TA-Luft) Explanation: DL Ref. value: Continuous power BL Ref. variable 3B. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value.Product Summary 51 2. A L A L mbar mbar mbar mbar 12 15 50 30 85 12 15 50 30 85 A A rpm kW 12 1500 1420 12 1500 1575 M015710/01E 07-02 © MTU . N Not yet defined value .Not applicable X Applicable REFERENCE CONDITIONS Engine model Application group Intake air temperature Charge-air coolant temperature Raw water inlet temperature Barometric pressure Site altitude above sea level °C °C °C mbar m 12V 4000 G23 3B 25 55 1000 100 12V 4000 G63 3B 25 55 1000 100 POWER-RELATED DATA (performance refers to net brake power as per ISO 3046) Number of cylinders Rated engine speed Continuous power ISO 3046 (10% overload capability) (design power DIN 6280. max.

5 SAE DISC Degrees mm mm liters liters 12 X X X X X X 12 90 170 210 4.7 R bar abs 12 3. non-cooled Working method: four-cycle. A R L L L °C °C °C % bar 12 100 102 104 50 0. alarm Coolant temperature after engine.77 57. single-acting Combustion method: Direct fuel injection Cooling system: conditioned water Direction of rotation: c.2 16. shutdown Coolant antifreeze content.2 12 3.2 16. Pressure loss in off-engine cooling system. max.c.7 12 100 102 104 50 0.5 X X 2 2 00 21 12 X X X X X X 12 90 170 210 4. replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before cylinder .DL COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling equipment) Coolant temperature after engine.w.77 57.5 X X 2 2 00 21 M015710/01E 07-02 © MTU . (facing driving end) Number of cylinders Cylinder arrangement: V angle Bore Stroke Displacement per cylinder Total displacement Compression ratio Cylinder heads: single-cylinder Cylinder liners: Wet. max. diesel.52 Product Summary MODEL RELATED DATA (basic design) Number of cylinders Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) Exhaust piping.

1 1.Product Summary 53 COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content. to R R R R °C °C rpm rpm 12 10 32 80 120 12 10 32 80 120 L L bar bar 12 -0. Pressure loss in off-engine cooling system. min. from Lube-oil operating temperature before engine. from Lube oil operating pressure before engine. alarm Lube oil temperature before engine. (when engine is starting) GENERAL OPERATING DATA Number of cylinders Cold start capability: Air temperature (w/o start aid. shutdown FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connection.) Firing speed. alarm Lube oil pressure before engine.7 12 55 50 0. max. preheating temperature (min.1 1. to Lube oil temperature before engine. LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before engine.5 R R R L R R R L °C °C °C °C bar bar bar bar 12 88 98 99 101 5. shutdown Lube oil operating pressure before engine. max. w/o preheating) (case A) Coolant preheating. max.0 --A L L °C % bar 12 55 50 0.0 7.7 M015710/01E 07-02 © MTU . (when engine is starting) Fuel pressure at engine supply connection.0 7. to Lube oil pressure before engine.5 12 -0.0 --12 88 98 99 101 5. from Firing speed.

54 Product Summary CAPACITIES Number of cylinders Engine coolant capacity. unsilenced . DL (sound power level LW. ISO 6798) Engine surface noise with attenuated intake noise (filter). operating inclinations) Oil pan capacity at dipstick mark "min. operating inclinations) Oil pan capacity at dipstick mark "max. max.DL (sound power level LW. engine side (without cooling equipment) Charge-air coolant. to scope of supply specification) ACOUSTICS Number of cylinders Exhaust noise. operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight. operating inclinations) Oil change quantity. (standard oil system) (Option: max." (standard oil system) (Option: max." (standard oil system) (Option: max. dry (basic engine configuration acc. ISO 6798) R R dB(A) dB(A) 12 126 122 12 127 122 R kg 12 6200* 12 6200* R R R R L L liters liters liters liters liters liters 160 200 160 200 12 160 40 260 12 160 40 260 M015710/01E 07-02 © MTU . engine side Total engine oil capacity at initial filling (standard oil system) (Option: max.

1 Operation Putting the engine into operation after extended out-of-service-periods (>3 months) Preconditions • Engine is stopped and starting disabled.) are available. Align adjustable pointer with position of pressure indicator (→ Page 117). Check charge-air coolant level (→ Page 150).g. Coolant circuit Coolant circuit ECU Monitoring equipment Engine/generator control system M015710/01E 07-02 © MTU .Operation 55 3 3. Select operating mode. Preheat coolant with preheating unit. e. Change charge-air coolant (→ Page 146). Lubricate valve gear every ≥ 6 months (→ Page 104). Check engine coolant level (→ Page 143).). Putting the engine into operation after extended out-of-service-periods (>3 months) Item Engine Valve gear Lube oil system Fuel prefilter Fuel prefilter. MANUAL OPERATION. Prime (→ Page 122). If engine is out of service for more than one year. • MTU Fluids and Lubricants Specifications (A001061/. Switch ON. change engine coolant (→ Page 139). pressure gauge Coolant circuit Task Depreserve (→MTU Fluids and Lubricants Specifications A001061/. Carry out lamp test (see manufacturer’s documentation). Check engine oil level (→ Page 134).. Check plug-in connections (→ Page 157). AUTOMATIC OPERATION..

Select operating mode. AUTOMATIC OPERATION. e. MANUAL OPERATION. Carry out lamp test (see manufacturer’s documentation). M015710/01E 07-02 © MTU . Check engine coolant level (→ Page 143).g. Check charge-air coolant level (→ Page 150). Preheat coolant with preheating unit. Drain (→ Page 118).56 Operation 3.2 Putting the engine into operation after scheduled out-of-service-period Preconditions • Engine is stopped and starting disabled. Switch ON. Putting the engine into operation Item Lube oil system Cooling system Cooling system Fuel prefilter Monitoring equipment Engine/generator control system Task Check oil level (→ Page 134).

without preheating pump). Run engine at 10 to 15 % of rated power to reach operating temperature. • External start interlock is not activated. control panel etc. Connecting the generator to network. ensure that nobody is in the danger zone. or • > 5 °C (50 Hz generator. DANGER WARNING Preparation Item Task Change to manual mode. Apply full load only after engine has reached operating temperature (coolant temperature approx. Risk of serious injury — danger to life! • Before barring or starting the engine. • Tachometer indicates increasing crankshaft speed. Switch ON. Engine noise above 85 dB (A). control panel etc. running the engine to reach operating temperature Item Switching cabinet. 75 °C). (depending on manufacturer) Engine Task Close the generator circuit breaker. (depending on manufacturer) Task If coolant temperature is • > 40 °C (with preheating pump). • After the starting procedure is completed. without preheating pump): Press start button. Unguarded rotating and moving engine components.Operation 57 3.3 Starting the engine in manual mode Preconditions • Generator is not connected to network. Operating mode selector switch (if provided) Preheating pump (if provided) Starting the engine Item Switching cabinet. or • > 10 °C (60 Hz generator. • Automatic starting procedure is performed. Risk of damage to hearing! • Wear ear protectors. engine is running at rated speed. M015710/01E 07-02 © MTU .

Serious damage to plant! • Initiate emergency start only in emergency situations. • Automatic starting procedure is performed.4 Emergency start (override mode) CAUTION Safety functions and engine shutdown alarms will be disregarded. control panel etc. (depending on manufacturer) Switching cabinet. control panel etc. (depending on manufacturer) Task Actuate switch/button for override input of ECU. • Tachometer indicates increasing crankshaft speed. Task Change to manual mode. Connecting the generator to network Item Switching cabinet. • After the starting procedure is completed. engine is running at rated speed. All safety functions are deactivated and engine shutdown alarms disregarded. Run at rated power. control panel etc. (depending on manufacturer) Engine Task If generator is not connected to network: Close the generator circuit breaker. Press start button. Preparation Item Operating mode selector switch (if provided) Emergency start Item Switching cabinet. M015710/01E 07-02 © MTU .58 Operation 3.

pressures). Always fill compressed-air tank to max. Engine at nominal speed Task Check displayed operational data (speed. pressure drop must not exceed 1 bar. temperature. Check signal ring position of service indicator (→ Page 129). Replace air filter (→ Page 125). If maximum exhaust temperatures are within the limit.Operation 59 3. Check drain for coolant discharge and obstruction (→ Page 124). Check operating pressure on pressure gauge. Check relief bore (→ Page 144). Check exhaust color (→ Page 71). Risk of serious injury – danger to life! • Take special care when working on a running engine.5 Operational checks DANGER Unguarded rotating and moving engine components. restricted engine operation is not required). pressure. Check engine/system and lines for leak-tightness. Drain condensate from compressed-air tank. Fuel prefilter Exhaust system Intercooler Air filters Engine coolant pump Charge-air coolant pump Compressed-air system (if applicable) M015710/01E 07-02 © MTU . Check relief bore (→ Page 151). Check if suction-side pressure indicated at the fuel prefilter pressure gauge is within the limit (→ Page 117). Check for abnormal running noises and vibration. if the signal ring is completely visible in the service indicator control window. Engine noise above 85 dB (A). WARNING Operational checks Item Control and display panels Engine under load. perform maintenance work on lines showing leakage while motor is turned off (exhaust manifolds and turbocharger turbine housing may be glowing with heat. Risk of damage to hearing! • Wear ear protectors.

• Automatic stopping procedure is performed. After stopping the engine Item Cooling pump Task Operate for approx.6 Stopping the engine in manual mode Preconditions • Generator is not connected to network. Stopping the engine when it is running at full load causes extreme stress to the engine. operate it at idle speed until operating temperatures decrease and stable values are indicated. M015710/01E 07-02 © MTU . allow the engine to cool down by running it idle for approx. (depending on manufacturer) Task Press stop button. Risk of overheating. damage to components! • Before stopping the engine. 5 minutes after engine stop.60 Operation 3. CAUTION Preparation Item Engine Task After the generator circuit breaker has been opened. Stopping the engine Item Switching cabinet. • Engine is running in manual mode. • Engine is stopped. control panel etc. 5 minutes.

• Engine is stopped by switching off power supply to ECU. • Signalization (e. control panel etc. Emergency stop from LOP Item EMERGENCY STOP button Task Press.7 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating.Operation 61 3. After emergency stop from LOP Item Switching cabinet. flashing lamp) is released. (depending on manufacturer) Task Press button for alarm acknowledgement. M015710/01E 07-02 © MTU . damage to components! • Initiate emergency stop only in emergency situations.g. by horn. • Audible and visual signalization stops.

After stopping the engine Item Engine/generator control system M015710/01E 07-02 © MTU . MANUAL OPERATION.g.8 After stopping the engine – engine remains ready for operation Task Select operating mode. e.62 Operation 3. AUTOMATIC OPERATION.

• antifreeze concentration is 50% and engine-room temperature is below -40°C.. After stopping the engine Item Cooling system Task Drain engine coolant (→ Page 142). carry out preservation (→MTU Fluids and Lubricants Specification A001061/.) is available. Drain charge-air coolant (→ Page 149) if: • freezing temperatures are expected and the engine is to remain out of service for an extended period and coolant has no antifreeze additive. Switch OFF.Operation 63 3. If the engine is to remain out of service for more than 1 week.. • the antifreeze concentration is insufficient for the engine-room temperature.).9 After stopping the engine – putting the engine out of service Preconditions • MTU Fluids and Lubricants Specification (A001061/. • the coolant is not maintained at a suitable temperature. • the engine room is not heated. seal the engine’s air and exhaust sides. Engine/generator control system Air intake and exhaust system M015710/01E 07-02 © MTU . If the engine is to remain out of service for more than 1 month.

64 Operation M015710/01E 07-02 © MTU .

QL4: Maintenance work which requires complete disassembly of the engine. • Fuel prefilter: The maintenance interval depends on how dirty the fuel is. Only use fluids and lubricants which meet MTU specifications or are approved by the component manufacturer concerned. The relevant manufacturer’s instructions apply with respect to the maintenance of any components which do not appear in this maintenance schedule. Never treat them with organic detergents. A001061/. Application group 3B 3D Continuous operation. • Battery: Battery maintenance depends on use and ambient conditions. Wipe with a dry cloth only. The maintenance schedule matrix normally finishes with extended component maintenance. Publication No. the operator/customer must perform the following additional maintenance work: • Protect components made of rubber or synthetic material from oil.1 Maintenance Preface MTU maintenance concept The maintenance system for MTU products is based on a preventive maintenance concept. Preventive maintenance instructions Specifications for fluids and lubricants. maintenance work is to be continued at the intervals indicated. They are therefore not listed in the maintenance schedule (exception: deviations from the Fluids and Lubricants Specifications). Preventive maintenance facilitates advance planning and ensures a high level of equipment availability. The various Qualification Levels QL1 to QL4 reflect the levels of training offered in MTU courses and the contents of the tool kits required: QL1: Operational monitoring and maintenance which can be carried out during a break in operation without disassembling the engine. The battery manufacturer’s instructions must be obeyed. guideline values for their maintenance and change intervals and lists of recommended fluids and lubricants are contained in the MTU Fluids and Lubricants Specifications A001061 and in the fluids and lubricants specifications produced by the component manufacturers. can be ignored. Out-of-service periods If the engine is to remain out of service for more than 1 month. The "Task" numbers stated in the list of jobs to be done/action to be taken indicate the relevant maintenance item. The time intervals at which the maintenance work is to be carried out and the relevant checks and tasks involved are average values based on operational experience and are therefore to be regarded as guidelines only. The maintenance schedule is based on the load profile / load factor specified below. The paper inserts in fuel prefilters must be replaced every 2 years at the latest (Task 9998). They serve as a reference for the scope of parts needed and also appear on the labels of the corresponding spare parts. QL2: Exchange of components (corrective only). Items that are listed in this maintenance schedule but that do not refer to the respective engine model. variable Standby operation M015710/01E 07-02 © MTU . carry out engine preservation procedures in accordance with the MTU Fluids and Lubricants Specifications. QL3: Maintenance work which requires partial disassembly of the engine. Maintenance personnel charged with carrying out maintenance work must be appropriately qualified depending on the complexity of the task concerned.Maintenance 65 4 4. Following this. Amongst other items. Special operating conditions and technical requirements may require additional maintenance work and/or modifications of the maintenance intervals.

500 X Daily 2 2 2 2 3 4 5 18 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Engine oil filter Engine operation Centrifugal oil filter Valve gear Fuel filter Belt drive Air filter Fuel injector Cylinder chambers Rubber sleeves Crankcase breather Exhaust turbocharger Component maintenance Fuel delivery pump Cylinder head Extended component maintenance M015710/01E 07-02 500 © MTU .000 1.66 Maintenance 4.000 operating hours Limit years Item Operating hours [hrs] 10.500 3.000 3.000 8.500 2.000 4.500 X 9.500 7.500 4.500 6.000 X X X X X 9.000 2.500 8.2 Maintenance schedule matrix Maintenance schedule matrix for application group 3B.000 X X X X X X X X X X X X 1.000 7.000 5.000 6. 0-10.500 5.

000 3.000 X X X X X X X X X X X X X Daily 2 2 2 2 3 6 4 18 X X X X X X X X X X X X X X X X X X X X X X X X Engine oil filter Engine operation Centrifugal oil filter Valve gear Fuel filter Belt drive Air filter Rubber sleeves Fuel injector Cylinder chambers Crankcase breather Exhaust turbocharger Component maintenance Cylinder head Extended component maintenance M015710/01E 07-02 500 © MTU .500 2.000 1.000 X X X X 5.500 4.000 operating hours Limit years Item Operating hours [hrs] 1.000 2. 0-6.000 4.500 5.Maintenance 67 Maintenance schedule matrix for application group 3C.500 X 6.500 3.

Replace exhaust turbocharger (→Maintenance Manual). Prior to maintenance work. Check rocker arms and valve bridge for wear (→Maintenance Manual) visually inspect swing followers and camshaft running faces with endoscope through pushrod bore (→Maintenance Manual). Clean air system (→Maintenance Manual). clean out and replace filter sleeve (→ Page 137). or when the interval (years) is reached. Check engine coolant thermostat and replace thermostat insert (→Maintenance Manual). replace if necessary (→ Page 152). Drain water and contaminants from fuel prefilter (if fitted) (→ Page 59). Check intercooler drain (if fitted) (→ Page 59). Replace air filter (→ Page 125). Check charge-air coolant thermostat and replace thermostat insert (→Maintenance Manual). Replace all rubber sleeves (→ Page 128) and DM125150921A.3 Qualification QL1 QL1 [h] Maintenance tasks Interval [a] Engine oil filter Engine operation Replace oil filter when changing engine oil. Perform endoscopic examination (→ Page 98). Check drive belt condition and tension. Check valve clearance (→ Page 105). Check engine visually for leaks and general condition (→ Page 59). Check for abnormal running noise. Crankcase breather: Replace filter or filter element (→ Page 102). Replace fuel injectors (→ Page 109). Clean intercooler and check for leaks (→Maintenance Manual). Check centrifugal oil filter for wear (if fitted) (→ Maintenance Manual). drain coolant and flush coolant circuits. exhaust gas color and vibrations (→ Page 59). Replace fuel filter or fuel filter element (→ Page 115). Replace fuel HP sensor (→Maintenance Manual). Overhaul engine coolant preheating (if fitted) (→Maintenance Manual). W2002 W2003 W2004 W2006 W2007 W2008 W2009 M015710/01E 07-02 © MTU . at the latest (→ Page 136). Check signal ring position of service indicator (→ Page 59). Check reading on differential pressure gauge of fuel prefilter (if fitted) (→ Page 59). Check water pump(s) relief bores (→ Page 59). W1008 W0500 W0501 W0502 W0503 W0505 W0506 W0507 W0508 W1009 W1001 W1002 W1241 W1005 W1006 W1011 W1250 W1046 W1041 W2000 W2001 Item Maintenance tasks Task QL1 QL1 QL1 QL1 QL1 QL1 QL1 QL1 QL1 QL3 QL3 Centrifugal oil filter Fuel filter Valve gear Belt drive Air filter Fuel injector Cylinder chambers Rubber sleeves Crankcase breather Exhaust turbocharger Component maintenance Centrifugal oil filter (if fitted): Check layer thickness of the oil residue.68 Maintenance 4. adjust belt tension (→ Page 153). Check engine oil level (→ Page 59).

QL3 QL3 QL4 Fuel delivery pump Cylinder head Extended component maintenance Replace fuel delivery pump (→Maintenance Manual). Replace piston rings (→Workshop Manual). Replace sealing materials of all disassembled components. Replace all elastomer parts and seals. W2010 W2070 W2062 W2110 W1051 W1134 W3000 W3001 W3002 W3003 W3004 W3005 W3006 W3007 W3042 M015710/01E 07-02 © MTU . to assembly Instructions. Inspect engine components acc. Disassemble engine completely. Replace cylinder liners (→Workshop Manual). Replace high-pressure fuel pump (→Workshop Manual). Overhaul cylinder heads (→Maintenance Manual). Replace auxiliary PTO antifriction bearing (→Workshop Manual). Replace crankshaft bearings (→Workshop Manual). Overhaul engine coolant pump (→Maintenance Manual).Maintenance 69 Qualification Interval [h] [a] Item Maintenance tasks Task Overhaul starter (→Maintenance Manual). Overhaul charge-air coolant pump (→Maintenance Manual). Replace conrod bearings (→Workshop Manual). Overhaul battery-charging generator (→Workshop Manual). repair or replace as necessary (→Workshop Manual).

70 Maintenance M015710/01E 07-02 © MTU .

Check plug-in connections (→ Page 157). Check (→ Page 155). Probable Cause Poor rotation by starter: Battery low or defective Defective Not vented Defective Task Charge or replace battery (see manufacturer’s documentation). Check (→ Page 155). Contact Service. Vent fuel system (→ Page 114).1 Troubleshooting Troubleshooting Probable Cause Low or defective Cable connections defective Task Charge or replace (see manufacturer’s documentation). Perform visual inspection (see manufacturer’s documentation). Check (→ Page 155). M015710/01E 07-02 © MTU .Troubleshooting 71 5 5. contact Service. Contact Service. Check if cable connections are properly secured. Check if cable connections are properly secured (see manufacturer’s documentation). Engine does not turn when starter is actuated Component Battery Starter Engine wiring Engine/generator control system ECU Engine Engine wiring or starter defective Defective Secure seating of assemblies or connectors not provided Plug-in connections are loose Running gear blocked (engine cannot be barred manually) Engine turns but does not fire Component Starter Engine wiring Fuel system ECU Engine fires unevenly Component Fuel injection equipment Engine wiring Fuel system ECU Probable Cause Injector defective Defective Not vented Defective Task Replace (→ Page 109). Vent fuel system (→ Page 114). Contact Service.

major coolant discharge Task Contact Service. M015710/01E 07-02 © MTU . Probable Cause Air filter clogged Contaminated Defective Task Check signal ring position of service indicator (→ Page 129). Check fans and air supply / ventilation ducts. Replace (→ Page 109). Replace (→ Page 115). Vent fuel system (→ Page 114). Check (→ Page 155). Contact Service. Contact Service. Contact Service. Probable Cause Incorrect coolant concentration Contaminated Air-intake temperature too high Task Check (MTU test kit). Air filter clogged Injector defective Defective Overloaded Task Replace (→ Page 122). Contact Service.72 Troubleshooting Engine does not reach nominal speed Component Fuel supply Probable Cause Fuel prefilter clogged Fuel filter clogged Air supply Fuel injection equipment Engine wiring Engine Engine speed not steady Component Fuel injection equipment Speed sensor Fuel system ECU Probable Cause Injector defective Defective Not vented Defective Task Replace (→ Page 109). Contact Service. Check signal ring position of service indicator (→ Page 129). Charge-air temperature too high Component Engine coolant Intercooler Engine room Charge air pressure too low Component Air supply Intercooler Exhaust turbocharger Coolant leaks on intercooler Component Intercooler Probable Cause Leaking. Contact Service.

Drain fuel prefilter (→ Page 118). cylinder liner Exhaust gas white Component Engine Fuel system Intercooler Probable Cause Not at operating temperature Water in fuel Leaking Task Run engine to reach operating temperature. Contact Service. Check fuel system on fuel prefilter. M015710/01E 07-02 © MTU . cylinder head. Replace (→ Page 102). Replace (→ Page 109). Contact Service. Probable Cause Air filter clogged Injector defective Overloaded Task Check signal ring position of service indicator (→ Page 129). Defective Task Drain engine oil (→ Page 132). Contact Service.Troubleshooting 73 Exhaust gas black Component Air supply Fuel injection equipment Engine Exhaust gas blue Component Engine oil Probable Cause Too much oil in engine Oil separator of crankcase breather contaminated Exhaust turbocharger. piston rings.

0122. Preliminary warning: Lube oil pressure too low. Engine stop. Engine stop. Check intercooler.0122. The fault code (1) comprises 3 digits.0121. 2.0100. Preliminary warning: Coolant pressure in intercooler too low.0124.0124. Engine stop. 2. Reduce power.931 Related parameter No.931 005 HI T-Charge Air 006 SS T-Charge Air 2. Contact Service to have sensors/actuators tested and replaced as necessary if troubleshooting as described in the table below proves unsuccessful.74 Troubleshooting 5.2 Engine governor ADEC (ECU 7) for Series 4000 genset engines . 2. Main warning: Fuel temperature too high. Reduce power. Reduce power. Preliminary warning: Charge-air temperature too high Main warning: Charge-air temperature too high. 2. The table below lists possible fault codes: Fault code No. 2. top up as necessary (→ Page 134).Fault messages The fault code numbers are generated by the Engine Control Unit and transmitted to the following display. Reduce power. Task Contact Service. Main warning: Charge-air coolant temperature too high.0121. 2. Fault messages may also be caused by faulty sensors/actuators. 1. 003 004 Designation HI T-Fuel SS T-Fuel Meaning Preliminary warning: Fuel temperature too high.932 Contact Service. 1.921 M015710/01E 07-02 © MTU . Check intercooler.932 009 010 AL L1 T-Coolant Intercooler AL L2 T-Coolant Intercooler LO P-Lube Oil 2.931 2.932 015 Check oil level.

Contact Service. Check cabling (→ Page 155). 2.931 020 SS T-Exhaust A Main warning: Exhaust temperature (A-side) too high. Alarm configuration limit value 2.0126.932 M015710/01E 07-02 © MTU .912 025 HI P-Diff.931 026 HI P-Diff. 1. 1.0154. Contact Service.0127. Check fuel system. 1. Check coolant level in expansion tank (→ Page 143). Preliminary warning: Oil filter differential pressure too high. Lube Oil 2. 1. 016 Designation SS P-Lube Oil Meaning Main warning: Lube oil pressure too low. Alarm configuration limit value 1.0126. Check cabling (→ Page 155). reduced fuel injection.0152. Related parameter No. 2.0152.931 022 SS T-Exhaust B Main warning: Exhaust temperature (B-side) too high. Preliminary warning: Leak-off fuel level too high. Engine stop. 2. Alarm configuration limit value 1. 2. Acknowledge alarm.0151. 2.0100. 2. 2. 2. Attempt to restart engine. Preliminary warning: Oil filter differential pressure too high. Contact Service. Alarm configuration limit value 1.931 Replace oil filter (→ Page 136). Coolant level too low.0154. Contact Service. Idle speed of ETC 2 too high. 1. Contact Service. top up as necessary (→ Page 134). Contact Service.921 024 SS Coolant Level 2. Lube Oil 027 HI Leak Fuel Level 029 030 HI ETC 2 idle speed SS Engine Speed 1. Engine will be shut down. Check oil level. 2.932 021 HI T-Exhaust B 2.932 023 LO Coolant Level 2. 2. Task 1. Engine overspeed. Alarm configuration limit value 2.8004. Check cabling (→ Page 155). 2. Alarm configuration limit value 1. 2.206 2.932 Replace oil filter (→ Page 136). Preliminary warning: Exhaust temperature (B-side) too high.Troubleshooting 75 Fault code No. Check coolant level in expansion tank (→ Page 143). 1. 2. Check cabling (→ Page 155). Coolant level too low.922 019 HI T-Exhaust A Preliminary warning: Exhaust temperature (A-side) too high.0127. Engine stop.2510. Attempt to restart engine (→ Page 57).

2. Reduce power. Check coolant level (→ Page 143). Engine stop. Task Contact Service. 2. Main warning: Coolant pressure too low.0106. 1. Reduce power. Preliminary warning: Coolant pressure too low.922 063 HI P-Crankcase Preliminary warning: Crankcase pressure too high.0153. 2. preliminary warning: speed of primary turbocharger too high.931 032 SS ETC 1 overspeed 1.931 M015710/01E 07-02 © MTU . Reduce power.3012. 1. Automatic engine shutdown.931 037 SS ETC 2 overspeed 2.0125. Engine stop or reduced fuel injection. Reduce power.76 Troubleshooting Fault code No.921 051 052 2. Related parameter No. 031 Designation HI ETC 1 overspeed Meaning Alarm configuration limit value 1. Contact Service. 2.932 036 HI ETC 2 overspeed Alarm configuration limit value 1. 2. 2. Reduce power. Contact Service.0101.921 2. Contact Service. 2. Fuel limitation to a fixed value. 1.8004. Check engine oil level (→ Page 134).8004. 2. Alarm configuration limit value 2.205 039 AL ETC 2 cut-in failure 1. Check air filters. Reduce power. Replace oil separator element (→ Page 102).3013. Synchronization error between ETCs 1 and 2. Check coolant circuit.3013.931 2. 1. 2. Alarm configuration limit value 2. Main warning: Lube oil temperature too high. 2.912 038 AL ETC Synchro Fault 1. preliminary warning: speed of secondary turbocharger too high. (→ Page 126).3011. Automatic power reduction by engine control system. Check coolant level (→ Page 150). Preliminary warning: Lube oil temperature too high. 1. 2. 1. 2. 1. Speed of primary turbocharger too high.0101. Intercooler coolant level too low. Contact Service. Reduce power. Main warning: speed of secondary turbocharger too high.932 057 058 LO P-Coolant SS P-Coolant 2. 2.204 044 L1 Coolant Level Intercooler HI T-Lube Oil SS T-Lube Oil Alarm configuration limit value 1.0125. ETC2 failed to cut in.

Allow engine to cool down. Related parameter No. Check coolant cooler. Engine stop. 3. 2. 2.921 066 SS P-Fuel Main warning: fuel supply pressure too low. 3. Fuel prefilter .932 065 LO P-Fuel Preliminary warning: Coolant fuel supply pressure too low. Reduce power.0120. 4. 1.0120. 2. Restart engine (→ Page 57). 5. 1. Main warning: Coolant temperature too high.Troubleshooting 77 Fault code No. Flush fuel prefilter (→ Page 120). 2. M015710/01E 07-02 © MTU . Task 1.931 2. Clean fuel prefilter (→ Page 116). 2.8004.Flushing (→ Page 120). Engine stop. Contact Service. Replace oil separator element (→ Page 102). 2. 2. 1. air in system). Clean fuel prefilter (→ Page 116). Engine stop. clean if necessary. HP system leaky.922 067 068 HI T-Coolant SS T-Coolant Preliminary warning: Coolant temperature too high. 4. 4. Check fuel lines for leaks. Replace fuel filter (→ Page 115). 1.932 081 AL Rail Leakage Pressure gradient in rail is too low during starting or too high during stopping. Alarm configuration limit value 2. 2. 064 Designation SS P-Crankcase Meaning Main warning: Crankcase pressure too high. Replace filter element of fuel prefilter (→ Page 122). Check fuel lines for leaks. Replace filter element of fuel prefilter (→ Page 122).0106.0102.0102. 3. Replace fuel filter (→ Page 115).046 Contact Service. Contact Service. 5.

030 2. Alarm configuration limit value 1.931 Contact Service.920 1. Alarm configuration limit value 1. coolant temperature too low for engine start.931 Reduce power.2500. 1.1090. Rail pressure <reference value. Check oil priming system.0104. Suction restrictor of HP fuel control block faulty or leakage in HP fuel system. Task Related parameter No.0128. Preliminary warning: Recirculation temperature too high.624 1. start of injection readjusted towards late. 2. Alarm configuration. Alarm configuration.1090. Contact Service.1090. Runup speed was not attained. coolant temperature too low for engine start.1090. DBR fuel limitation. Alarm configuration limit value.921 094 LO T-Preheat 095 102 104 118 AL Prelubrication Fault AL Consumption Meter Faulty AL Eng Hours Counter Defect LO ECU Supply Voltage M015710/01E 07-02 © MTU . Idling speed was not attained. 2.1090.932 2. Alarm configuration limit value. Termination of starting sequence. Contact Service. 2. Contact Service.1090.0140.925 085 HI T-Recirculation 086 089 090 091 092 HI T-Recirculation AL Stalling Engine SS No Idling Speed SS No Runup Speed SS No Starter Speed Contact Service. 2. 2. Suction restrictor of HP fuel block jamming or HP fuel control block wiring faulty. Alarm configuration limit value.8004. 2.78 Troubleshooting Fault code No. Alarm configuration limit value 2. Preliminary warning: Supply voltage too low.921 Check preheater. Consumption meter faulty.8004.623 Contact Service. engine start interlock active.921 083 LO P-Fuel (Common Rail) Contact Service. 2. Starter speed was not attained. DBR fuel limitation. Check ECU supply voltage. Starter rotates too slowly or does not rotate at all. Engine speed too low. Hourmeter faulty.922 093 SS T-Preheat Check preheater.923 2. Preheating temperature too low. Alarm configuration limit value. 082 Designation HI P-Fuel (Common Rail) Meaning Rail pressure > reference value.0128. 2. Main warning: Recirculation temperature too high.924 Contact Service. Alarm configuration. Oil priming failure. Reduce power. 2. Main warning: preheating temperature too low.0104. Check for additional messages. 2.

Preliminary warning: Supply voltage too high. automatic engine shutdown. Alarm configuration limit value 1. Supply voltage A/D converter too low. 142 BANK1 ECU DEFECT Replace ECU. 2. Power output stage for control of the solenoid valves on bank 2 is faulty. Main warning: Supply voltage too high. M015710/01E 07-02 © MTU .922 120 HI ECU Supply Voltage 2. Contact Service. Internal voltage (-15 VDC) faulty.921 134 15V POS ECU DEFECT Replace ECU. Contact Service. 2. Reduce power.932 122 HI T-ECU 2. automatic engine shutdown. ECU DEFECT Supply voltage of temperature sensors faulty.Troubleshooting 79 Fault code No.0140. 1. Power output stage for control of the solenoid valves on bank 1 is faulty. Replace ECU. Contact Service. Supply voltage A/D converter too low. automatic engine shutdown. 2. 144 145 146 147 148 BANK2 ECU DEFECT 15V_GOOD ECU DEFECT L1 AD-TEST1 SUPPLY AD-TEST1 ECU DEFECT L1 AD-TEST2 SUPPLY Replace ECU. Main warning: Supply voltage too low. Task 1. 119 Designation LOLO ECU Supply Voltage Meaning Alarm configuration limit value 2. Contact Service. 139 L1 TE BUFFER TEST Supply voltage of temperature sensors faulty. 2. Check ECU supply voltage. 2. Improve engine room ventilation. Engine does not start.0140. Power supply faulty. Replace ECU. Alarm configuration limit value 2. Preliminary warning: Temperature in ECU too high. 3. Alarm configuration limit value 1. Replace ECU. 1. 3. Internal voltage (-15 VDC) missing. Replace ECU. 136 15V NEG ECU DEFECT Contact Service.931 121 HIHI ECU Supply Voltage 2. automatic engine shutdown. Replace ECU. 140 TE BUF. 1. Electronic fault. Check ECU supply voltage. Replace ECU. Related parameter No. 1. Contact Service. Check ECU supply voltage. 2. 2.0132. Check sensors. 1. Check sensors. Engine does not start.0140.

A programming error occurred when attempting to copy a received PU data module into the Flash module.0500. Task Replace ECU. 149 150 151 176 Designation AD-TEST2 ECU DEFECT L1 AD-TEST3 SUPPLY AD-TEST3 ECU DEFECT AL LifeData Not Avail Meaning Internal electronic fault. No (appropriate) LifeData backup system available. Alarm configuration. Alarm configuration.680 Contact Service.686 186 AL CAN1 Bus Off M015710/01E 07-02 © MTU .0500. Replace ECU.4000. improve as necessary. 2.0500. automatic engine shutdown. Alarm configuration.004 Contact Service. Contact Service.684 184 AL CAN PU-Data Flash Error Contact Service. 2. Alarm configuration. 2. 2. This error message is generated if a CRC is faulty during a data upload to ADEC (indicated for each indiv.0500. Incorrect parameter values entered in data record. Replace ECU. A CAN mode has been selected in which communication with the PU data module is initialized. Connection to one node on CAN bus 1 failed. 3. Alarm configuration. Connection to one node on CAN bus 2 failed. Alarm configuration. ECU reset after expiration of time-out period. Alarm configuration. However.4000. the required PU data module is not available or not valid. module). Internal electronic fault. Internal electronic fault. automatic engine shutdown.0500. 2.0500. Alarm configuration.683 180 AL CAN1 Node Lost 181 AL CAN2 Node Lost 182 AL CAN Wrong Parameters AL CAN No PU-Data 183 Contact Service. Check shielding.80 Troubleshooting Fault code No. 1. 2. CAN controller 1 is in "Bus-Off" status. 2.682 Contact Service. Inspect CAN bus for short circuit and rectify short circuit as necessary. Related parameter No.006 177 AL LifeData restore incomplete Contact Service. 2.681 Contact Service. automatic engine shutdown. 2.

Fuel temperature sensor faulty. short circuit or wire break. EMU parameter are not supported. Inspect CAN bus for short circuit and rectify short circuit as necessary. improve as necessary. 1. CAN controller 2 has signalled a warning. 3. 2. 3. massive interference or Baud rate incompatibility.Troubleshooting 81 Fault code No. 2. replace as necessary. Automatic changeover to CAN 1.688 189 AL CAN2 Error Passive Alarm configuration. Check shielding.572 203 SD T-Charge Air SD alarm configuration.571 M015710/01E 07-02 © MTU . Check shielding. 2.8004. CAN controller 1 has signalled a warning. 2. improve as necessary.0500.0500. 2. improve as necessary. Error cleared after restarting the engine. short circuit or wire break.570 202 SD T-Fuel 1. Check shielding. Coolant temperature sensor faulty. Contact Service. replace as necessary.8004.0500.0500. replace as necessary. 1.689 190 201 AL EMU Parameter Not Supported SD T-Coolant Alarm configuration. Charge-air temperature sensor faulty. 187 Designation AL CAN1 Error Passive Meaning Alarm configuration. Contact Service. Check sensor and cabling (B6). Task 1. CAN controller 2 is in "Bus-Off" status. 2.687 188 AL CAN2 Bus Off Alarm configuration. Contact Service. Check sensor and cabling (B33). Check sensor and cabling (B9). short circuit or wire break.8004. Inspect CAN bus for short circuit and rectify short circuit as necessary.690 1. Contact Service. SD alarm configuration. Short circuit. Error cleared after restarting the engine. Inspect CAN bus for short circuit and rectify short circuit as necessary. Related parameter No. 3. Error cleared after restarting the engine. 1. SD alarm configuration. 2.

Check sensor and cabling (B43). Check sensor and cabling (B4. Lube oil pressure sensor faulty. Check sensor and cabling (B50). Crankcase pressure sensor faulty. short circuit or wire break. short circuit or wire break. SD alarm configuration.8004. short circuit or wire break.576 206 SD T-Exhaust B 1. Related parameter No.22). Intercooler coolant temperature sensor faulty.8004. replace as necessary.569 214 SD P-CrankCase 1. Error cleared after restarting the engine. SD alarm configuration. replace as necessary. Error cleared after restarting the engine. Charge-air pressure sensor faulty. Check sensor and cabling (B10). Exhaust temperature sensor on A-side faulty. replace as necessary. Check sensor and cabling (B5).8004. Error cleared after restarting the engine. replace as necessary. Error cleared after restarting the engine. SD alarm configuration. Check sensor and cabling (B16).577 208 SD P-Charge Air 1.8004. Error cleared after restarting the engine.566 211 SD P-Lube Oil 1. SD alarm configuration. Check sensor and cabling (B48). short circuit or wire break. Error cleared after restarting the engine. Intercooler coolant pressure sensor faulty.8004.21). SD alarm configuration. short circuit or wire break.568 215 SD P-HD 1. short circuit or wire break. Task Check sensor and cabling (B26). 204 Designation SD T-Coolant Intercooler Meaning SD alarm configuration. replace as necessary.564 213 SD P-Coolant Intercooler 1. Exhaust temperature sensor on B-side faulty. short circuit or wire break.567 M015710/01E 07-02 © MTU .563 212 SD P-Coolant SD alarm configuration. Check sensor and cabling (B4. short circuit or wire break. SD alarm configuration. SD alarm configuration.574 205 SD T-Exhaust A 1. replace as necessary.82 Troubleshooting Fault code No. 1.8004. replace as necessary.8004. Error cleared after restarting the engine. replace as necessary. Error cleared after restarting the engine. short circuit or wire break. Error cleared after restarting the engine.8004. replace as necessary. Rail pressure sensor faulty. HP regulator in emergency mode. Coolant pressure sensor faulty.8004. 1.

8004. SD alarm configuration.Troubleshooting 83 Fault code No.8004. replace as necessary. SD alarm configuration. Error cleared after restarting the engine.8004.8004. Check sensor and cabling (B5. 1. replace as necessary. Error cleared after restarting the engine. Error cleared after restarting the engine. replace as necessary.8004.498 M015710/01E 07-02 © MTU . Check sensor and cabling (F57). Sensor for intercooler coolant level faulty.585 222 SD Leak-Fuel Level 1. Related parameter No.584 221 SD Dif Lube Oil SD alarm configuration. short circuit or wire break. Check sensor and cabling (F46). short circuit or wire break.582 223 SD Level Coolant Intercooler 1. Check sensor and cabling (B13). Crankshaft sensor faulty.8004.583 227 SD P-Oil bef. replace as necessary.562 230 SD crankshaft 1. Task Check sensor and cabling (B7). Lube oil pressure differential sensor faulty.620 229 AL Stop Camshaft Sensor Defect 1. Check sensor and cabling (F25). 216 Designation SD T-Lube Oil Meaning SD alarm configuration.575 219 SD T-Intake Air SD alarm configuration. Check connector and cabling to sensor B1.8004. replace as necessary. replace as necessary. Engine stop due to camshaft sensor fault (and a prior crankshaft sensor fault in the same operating cycle). Intake air temperature sensor faulty. SD alarm configuration. replace as necessary. Check sensor and cabling (B3). replace as necessary. Coolant level sensor faulty. Error cleared after restarting the engine. short circuit or wire break. short circuit or wire break. Leak-off fuel level sensor faulty.8004. short circuit or wire break. replace as necessary. short circuit or wire break. Error cleared after restarting the engine. 1. Lube oil temperature sensor faulty. 1. Sensor for lube oil pressure before filter faulty. Error cleared after restarting the engine.573 220 SD Coolant Level SD alarm configuration. Check sensor and cabling (F33). Alarm configuration. Filter 1. Error cleared after restarting the engine. Error cleared after restarting the engine. short circuit or wire break. Error cleared after restarting the engine. 1. short circuit or wire break.3).8004. SD alarm configuration.

replace as necessary.128 233 SD ETC Speed 2 1. 1.1). replace as necessary. SD alarm configuration. Error cleared after restarting the engine.2). Internal ECU fault.8006.3011. short circuit or wire break. short circuit or wire break.3011.581 242 SD T-Coolant Redundant SD alarm configuration. Camshaft sensor faulty. Check sensor and cabling (B34).Analog filt 2. Check sensor and cabling (B44. Check sensor and cabling (B49). replace as necessary.8006. Analog speed demand faulty. Check cabling. Fuel pressure sensor faulty. SD alarm configuration.499 232 SD ETC Speed 1 SD alarm configuration. Speed sensor of secondary turbocharger faulty. short circuit or wire break. Speed sensor of primary turbocharger faulty. Electronics faulty. replace as necessary.8004. Redundant lube oil pressure sensor faulty. 1. Check speed demand signal.8004.621 245 SD ECU Supply Voltage 2. SD alarm configuration. Check cabling 2. short circuit or wire break. Task Check sensor and cabling (B1). Recirculation sensor faulty. SD alarm configuration.129 240 SD P-Fuel 1. Error cleared after restarting the engine. short circuit or wire break.8004. Filtered analog signal of load pulse missing. SD alarm configuration.84 Troubleshooting Fault code No. Error cleared after restarting the engine. Check sensor and cabling. Error cleared after restarting the engine. short circuit or wire break.8006.8004.586 266 SD Speed Demand 269 SD Loadp. 1. 2. Check sensor and cabling (B44.588 M015710/01E 07-02 © MTU .8004.589 Replace ECU. 1. 231 Designation SD camshaft Meaning SD alarm configuration. 1. Check sensor and cabling.565 241 SD T-Recirculation SD alarm configuration. replace as necessary. short circuit or wire break. short circuit or wire break.622 244 SD Oil Press Redundant 1. Error cleared after restarting the engine. SD alarm configuration. replace as necessary. Related parameter No. short circuit or wire break. Redundant coolant pressure sensor faulty. replace as necessary. replace as necessary. Error cleared after restarting the engine. Error cleared after restarting the engine. Error cleared after restarting the engine.

2.504 1.512 1. Time-of-flight measuring fault of injector: Time-of flight measured value extremely low or extremely high.518 1.8004.8004.8004.8004.8004.514 1.8004.8004.Troubleshooting 85 Fault code No.506 1.8004. 1. Task 1.510 1.505 1.8004.8004. Check cabling 2.507 1.8004.500 1.516 1.8006.8004.8004. Frequency input faulty.508 1.8004.503 1.519 M015710/01E 07-02 © MTU .8004.8004.515 1. Related parameter No. Contact Service.509 1.511 1. short circuit or wire break.513 1.501 1.590 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 AL Timing Cylinder A1 AL Timing Cylinder A2 AL Timing Cylinder A3 AL Timing Cylinder A4 AL Timing Cylinder A5 AL Timing Cylinder A6 AL Timing Cylinder A7 AL Timing Cylinder A8 AL Timing Cylinder A9 AL Timing Cylinder A10 AL Timing Cylinder B1 AL Timing Cylinder B2 AL Timing Cylinder B3 AL Timing Cylinder B4 AL Timing Cylinder B5 AL Timing Cylinder B6 AL Timing Cylinder B7 AL Timing Cylinder B8 AL Timing Cylinder B9 AL Timing Cylinder B10 Alarm configuration. Replace injector concerned if the fault message appears frequently (→ Page 109).502 1.517 1.8004. 3.8004. 270 Designation SD Frequency Input Meaning SD alarm configuration. Check setpoint speed transmitter.8004.8004.

536 1.525 1.532 1.535 1.530 1.8004.8004.538 1.524 1.8004.86 Troubleshooting Fault code No.8004. 2.8004.522 1.8004.8004. 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 Designation AL Wiring Cylinder A1 AL Wiring Cylinder A2 AL Wiring Cylinder A3 AL Wiring Cylinder A4 AL Wiring Cylinder A5 AL Wiring Cylinder A6 AL Wiring Cylinder A7 AL Wiring Cylinder A8 AL Wiring Cylinder A9 AL Wiring Cylinder A10 AL Wiring Cylinder B1 AL Wiring Cylinder B2 AL Wiring Cylinder B3 AL Wiring Cylinder B4 AL Wiring Cylinder B5 AL Wiring Cylinder B6 AL Wiring Cylinder B7 AL Wiring Cylinder B8 AL Wiring Cylinder B9 AL Wiring Cylinder B10 Meaning Alarm configuration. Related parameter No.537 1.8004.520 1.528 1. Contact Service.531 1.539 M015710/01E 07-02 © MTU .529 1.8004.8004.8004.526 1.8004. Task 1.533 1.8004.527 1.8004.8004.534 1. Cabling fault in injector cabling to cylinder. Check solenoid valve.8004. 1. Result: Misfiring.8004.521 1.8004.8004.8004.523 1.

2. Contact Service.558 1.557 1.556 1.8004.555 1. 1.8004.545 1. Related parameter No.549 1.8004.8004.546 1.543 1.8004. Result: Misfiring.559 M015710/01E 07-02 © MTU .541 1.8004.540 1. Disruption fault in injector cabling to cylinder. Task 1.8004.544 1.8004.552 1.551 1. 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 Designation AL Open Load Cylinder A1 AL Open Load Cylinder A2 AL Open Load Cylinder A3 AL Open Load Cylinder A4 AL Open Load Cylinder A5 AL Open Load Cylinder A6 AL Open Load Cylinder A7 AL Open Load Cylinder A8 AL Open Load Cylinder A9 AL Open Load Cylinder A10 AL Open Load Cylinder B1 AL Open Load Cylinder B2 AL Open Load Cylinder B3 AL Open Load Cylinder B4 AL Open Load Cylinder B5 AL Open Load Cylinder B6 AL Open Load Cylinder B7 AL Open Load Cylinder B8 AL Open Load Cylinder B9 AL Open Load Cylinder B10 Meaning Alarm configuration.Troubleshooting 87 Fault code No.8004.8004.554 1.8004.550 1.553 1. Check solenoid valve.8004.8004.8004.8004.8004.547 1.542 1.548 1.8004.8004.8004.8004.

repair as necessary.1020. Short circuit or wire break on transistor output 3 (TO 3). Short circuit or wire break on transistor output 4 (TO 4).636 374 AL Wiring TO 4 - 1. Related parameter No. 2.8004. Short circuit of positive connection of one or more injectors to ground 2. plant-side 1 (TOP 1). Alarm configuration.497 363 AL Stop Power Stage 1.634 372 AL Wiring TO 2 Alarm configuration. 2. Check recirculation valve/cabling. Internal electronic fault (electronics possibly faulty: Start ITS). Replace ECU. 1. note further fault messages (e.638 M015710/01E 07-02 © MTU . Replace ECU.g.g.8004. If bit "1. Alarm configuration. Internal electronic fault (electronics possibly faulty: Start ITS). 1. If the ITS diagnosis result is "electronics OK". Injector cabling fault.8004.635 373 AL Wiring TO 3 Alarm configuration. 1. Task 1. cabling faults). Alarm configuration. Short circuit or wire break on transistor output 1 (TO 1). Replace ECU. Replace ECU. Check cabling 2. 2.8004. Alarm configuration.8004.8004. engine will be shut down as additional measure. Check cabling 2. cabling faults).021" (Power Stage Failure: Stop Engine) is set.637 381 AL Wiring TOP 1 Check cabling to plant. Check turbocharger valve/cabling. Alarm configuration. 361 Designation AL Power Stage Low Meaning Alarm configuration. Alarm configuration. 1. Attempt to restart engine.8004. Check solenoid valve cabling.8004. If the ITS diagnosis result is "electronics OK". Short circuit of negative connection of one or more injectors to ground . 1. 2. Check solenoid valve cabling.560 365 AL Stop MV-Wiring Ground 1. - 1. Short circuit or wire break on transistor output. repair as necessary. Short circuit or wire break on transistor output 2 (TO 2). 1. Attempt to restart engine. 2. 1.88 Troubleshooting Fault code No. Internal electronic fault (electronics possibly faulty: Start ITS). note further fault messages (e.561 371 AL Wiring TO 1 1.496 362 AL Power Stage High 1. 1.8006.

1. Alarm configuration.625 M015710/01E 07-02 © MTU . if alarm is continuously active. contact Service. 2. Alarm configuration limit value 1.921 395 SS P-Lube Oil Redundant 2. Preliminary warning: Redundant lube oil pressure reading too low. Contact Service. Line disruption on digital input 1. Check cabling and sensor. Check cabling and sensor. 1.8004. 2. 1. 2. Cabling faulty or no resistance over switch. Task Check cabling to plant. 1. 2. 1. 2. Short circuit or wire break on transistor output. Check cabling and sensor.0112. plant-side 2 (TOP 2). 3.625 400 AL Open Load Digital Input 1 Alarm configuration. Alarm configuration limit value 2.641 390 AL MCR exceeded 1. Short circuit or wire break on transistor output. Maximum coolant temperature deviation. Alarm configuration limit value 1. Preliminary warning: Redundant coolant temperature reading too high.009 392 HI T-Coolant Redundant Alarm configuration limit value 1. no action required.Troubleshooting 89 Fault code No.1085.922 396 AL T-Coolant Max Deviation 1. Check input of target device. 382 Designation AL Wiring TOP 2 Meaning Alarm configuration. Alarm configuration.639 383 AL Wiring TOP 3 Check cabling to plant.0112. Contact Service. DBR/MCR function: MCR has been exceeded.8006. Check cabling and sensor.640 384 AL Wiring TOP 4 Check cabling to plant.932 394 LO P-Lube Oil Redundant 2. Contact Service.0129. Contact Service.626 397 AL P-Oil Max Deviation Alarm configuration. plant-side 3 (TOP 3). 2. Check cabling 2. Engine stop. Main warning: Redundant coolant temperature reading too high.8004. Check cabling 2. Contact Service. 2. Related parameter No. Alarm configuration. If alarm is only temporary. Contact Service.8006. 1.931 393 SS T-Coolant Redundant 2. Maximum lube oil pressure deviation. Check cabling and sensor. 1. 2. plant-side 4 (TOP 4). 1. Short circuit or wire break on transistor output.0129. Alarm configuration. 2. Main warning: Redundant lube oil pressure reading too low.8006. 2. 1.8006. 2. Contact Service.

Contact Service. Alarm configuration.8006. Line disruption on digital input 5. 1. 1. Cabling faulty or no resistance over switch.627 403 AL Open Load Digital Input 4 2.632 408 AL Open Load Emerg. Check cabling. Check input of target device. Check input of target device. 1. Check power supply. Alarm configuration. 3.8006. 401 Designation AL Open Load Digital Input 2 Meaning Alarm configuration. 3. Alarm configuration.90 Troubleshooting Fault code No. Alarm configuration. Check cabling 2.8006. Check input of target device.8006. Cabling faulty or no resistance over switch. Check cabling 2. Check power supply. Line disruption on digital input 7.629 405 AL Open Load Digital Input 6 2. Check input of target device.921 411 LOLO U-PDU Alarm configuration limit value 2. Cabling faulty or no resistance over switch. 1. 3. Contact Service. 3. Check cabling 2. Line disruption on digital input 4. 2. Check cabling 2. Line disruption on the input for emergency stop. Preliminary warning: Injector voltage too low. Check cabling 2.630 406 AL Open Load Digital Input 7 2. Alarm configuration limit value 1.8006. Check cabling 2.0141. Cabling faulty or no resistance over switch. 1. Check cabling 2. Check cabling 2.8006. 2. Check cabling 2. 3. 3.0141. Line disruption on digital input 8. Contact Service.631 407 AL Open Load Digital Input 8 2. Task 1. Line disruption on digital input 6. Cabling faulty or no resistance over switch. 3.626 402 AL Open Load Digital Input 3 2. Contact Service.922 M015710/01E 07-02 © MTU . 3. Cabling faulty or no resistance over switch. Check input of target device. 1. 3. Related parameter No. Alarm configuration. 1. Contact Service. Check input of target device. Contact Service. Alarm configuration.8006. Contact Service. Contact Service. 3. Line disruption on digital input 3.8006. Stop Input ESI 2. Cabling faulty or no resistance over switch. 2. Alarm configuration. Check input of target device. Check input of target device. Line disruption on digital input 2. Main warning: Injector voltage too low. 1. Contact Service. Contact Service.628 404 AL Open Load Digital Input 5 2.633 410 LO U-PDU 2. Cabling faulty or no resistance over switch. 1.

1. Alarm configuration limit value 1. Preliminary warning: Temperature signal of Aux 2 has exceeded / not attained limit value 1. Alarm configuration limit value 1. Task 1. Drain water (→ Page 118). 2. 2. Sensor for water level in fuel prefilter faulty. 412 Designation HI U-PDU Meaning Alarm configuration limit value 1.921 Determine and rectify reason for limit value violation. Input signal of Aux 1 has exceeded/not attained limit value 2.922 Top up coolant (→ Page 147). SD alarm configuration.931 413 HIHI U-PDU Alarm configuration limit value 2.0141. Main warning: Injector voltage too high.931 415 2. Main warning: Coolant pressure in intercooler too low. Check power supply. Input signal of Aux 1 has exceeded/not attained limit value 1. depending on configuration.0156. 3.0107. replace as necessary. Alarm configuration limit value 1. depending on configuration. Alarm configuration limit value 1. Alarm configuration limit value 1. short circuit or wire break.594 416 SS P-Coolant Intercooler 417 SD Water Level Fuel Prefilter 420 L1 Aux 1 2.Troubleshooting 91 Fault code No. depending on configuration.0130. 2.921 Top up coolant (→ Page 147). 1.921 Determine and rectify reason for limit value violation.0107. Alarm configuration limit value 2. 2. Contact Service. Check cabling 2.8004.932 414 HI Water Level Fuel Prefilter LO P-Coolant Intercooler Alarm configuration limit value 1. Check cabling 2. 421 L2 Aux 1 428 L1 T-Aux 1 432 L1 T-Aux 2 M015710/01E 07-02 © MTU .0131. Warning: water level in fuel prefilter too high. Related parameter No. 2. Engine stop. 2. 3.0160. Contact Service. Preliminary warning: Injector voltage too high.922 Determine and rectify reason for limit value violation.921 Determine and rectify reason for limit value violation. 2. depending on configuration. Check power supply. Preliminary warning: Coolant pressure in intercooler too low. Check sensor and cabling. Preliminary warning: Temperature signal of Aux 1 has exceeded / not attained limit value 1. Error cleared after restarting the engine.0141.0160.

Alarm configuration limit value 2. Internal fault in ECU. 2. depending on configuration.0103.931 Contact Service.8004. 2. Input signal for initial/final torque faulty. 2.92 Troubleshooting Fault code No.0111.580 Replace ECU.8006. 433 Designation L2 T-Aux 2 Meaning Alarm configuration limit value 2.0103.592 436 L1 P-Aux 2 437 L2 P-Aux 2 440 L1 P-Aux 1 442 L2 P-Aux 1 444 SD U-PDU 445 SD P-Ambient Air 448 HI P-Charge Air 449 SS P-Charge Air 450 SD Idle/End-Torque Input [%] M015710/01E 07-02 © MTU . short circuit or wire break.921 Determine and rectify reason for limit value violation. depending on configuration. Preliminary warning: Pressure signal of Aux 2 has exceeded / not attained limit value 2. replace as necessary.0110. Alarm configuration limit value 1. 2. SD alarm configuration.0111. Error cleared after restarting the engine. Injector power stage sensor defect. Preliminary warning: Charge-air pressure too high.931 Determine and rectify reason for limit value violation. 1.0131. Alarm configuration limit value 1. 2. Preliminary warning: Pressure signal of Aux 1 has exceeded / not attained limit value 2. 2. depending on configuration. Preliminary warning: Temperature signal of Aux 2 has exceeded / not attained limit value 2. Alarm configuration limit value 2.922 Determine and rectify reason for limit value violation. 1.932 Contact Service. 2. Preliminary warning: Pressure signal of Aux 2 has exceeded / not attained limit value 1. Preliminary warning: Pressure signal of Aux 1 has exceeded / not attained limit value 1.578 Replace ECU. Alarm configuration limit value 2. Ambient air pressure sensor faulty. depending on configuration. 2.921 Determine and rectify reason for limit value violation.8004. SD alarm configuration. Main warning: Charge-air pressure too high.922 Determine and rectify reason for limit value violation. Check signal transmitter and cabling. Task Related parameter No.0110. Alarm configuration limit value 1. SD alarm configuration. depending on configuration.

653 462 AL Coolant EMU L1 2. 1. Check cabling 2. Determine and rectify reason for power reduction. Check cabling 2.8004. Check configuration with DiaSys.650 Determine and rectify reason for limit value violation. depending on configuration. 1. 2. power reduction is active. short circuit or wire break. Note further fault messages. short circuit or wire break. Contact Service. Alarm configuration limit value. EMU exhaust temperature value too low.Troubleshooting 93 Fault code No.8004. 1. Analog input signal for Aux 2 temperature faulty. Error cleared after restarting the engine. Check pressure transmitter and cabling.8006.8006. 1. Check signal transmitter and cabling. Task 1. depending on configuration. Error cleared after restarting the engine. Related parameter No.652 456 AL Aux 1 Plant L2 460 AL Exhaust EMU High 461 AL Exhaust EMU Low 2. Alarm configuration limit value 2. Analog input signal for Aux 2 faulty. Analog input signal for Aux 1 pressure faulty. 454 Designation SS Power Reduction Active Meaning Alarm configuration. Check pressure transmitter and cabling. replace as necessary.8006. replace as necessary.588 466 SD T-AUX 2 SD alarm configuration.651 Determine and rectify reason for limit value violation. EMU coolant temperature value too high / low. 2. 1. 2. Check temperature sensor and cabling.8004. 1.654 463 SD AUX 2 464 SD P-AUX 1 SD alarm configuration.586 M015710/01E 07-02 © MTU . Alarm configuration limit value. short circuit or wire break.591 2. EMU exhaust temperature value too high. Input signal of Aux 1 (plant side) has exceeded/not attained limit value 2. 2. replace as necessary. SD alarm configuration. Alarm configuration limit value.589 465 SD P-AUX 2 SD alarm configuration.8006. Input signal of Aux 1 (plant side) has exceeded/not attained limit value 1. Error cleared after restarting the engine.7000. short circuit or wire break. Contact Service. Analog input signal for Aux 2 pressure faulty. replace as necessary. Error cleared after restarting the engine.8004.8006.011 455 AL Aux 1 Plant L1 Alarm configuration limit value 1.

1. SD alarm configuration. short circuit or wire break.579 Replace ECU. Alarm configuration.8004. Check cabling 2.8006. SD alarm configuration.007 2. replace as necessary. Cable break or short circuit on channel FO. Alarm configuration.587 471 SD Coil Current 1. Alarm configuration. Alarm configuration. Check setting with DiaSys. Combined alarm YELLOW from plant. depending on configuration. Task Related parameter No. Combined alarm RED from plant. 1. 1. Engine shutdown.8006.592 472 Al Stop SD 2. 1.8004. Alarm configuration. SD alarm configuration.8004. Preliminary warning: Temperature signal of Aux 1 has exceeded / not attained limit value 2.593 473 AL Cabling PWM_CM2 1. since all shutdown channels have "sensor faulty".8006. replace as necessary.0130.001 2.002 M015710/01E 07-02 © MTU .8010.8010. 1. 2. Note further fault messages. Check signal transmitter and cabling.8004.8006. Error cleared after restarting the engine. Check sensor and cabling. Check cabling 2. Contact Service. short circuit or wire break. Note further fault messages.590 468 SD T-AUX 1 469 SD AUX 1 470 SD T-ECU SD alarm configuration. Alarm Red (Plant) 1. Analog input for Aux 1 temperature faulty.009 476 478 479 1. Check sensor and cabling. Cable break or short circuit on channel PWM_CM2. Analog input signal for Aux 1 faulty.655 475 AL CR Trigger Engine Stop AL Crash Rec. Crash recorder initialization error. Tripped by crash recorder triggering due to engine shutdown.8004.593 474 AL Wiring FO 2. Contact Service. Init. Determine and rectify cause of triggering / engine shutdown. Alarm configuration.94 Troubleshooting Fault code No. Control of HP fuel control block faulty. Alarm Yel (Plant) AL Comb. replace as necessary.922 Determine and rectify reason for limit value violation. Temperature sensor for ECU faulty. short circuit or wire break. Check cabling 2. 467 Designation L2 T-Aux 1 Meaning Alarm configuration limit value 2. Error AL Comb. Error cleared after restarting the engine. Contact Service. Error cleared after restarting the engine. Alarm configuration. 1.

3. Qty. there should be no abnormal resistance. Risk of serious injury — danger to life! • Before barring the engine.1. Apart from the normal compression resistance.Task Description 95 6 6. 5. Remove guard plate. 2. Special tools Designation / Use Barring tool Ratchet Part No. 1 1 DANGER Engine – Barring manually 1.1 Task Description Engine Engine – Barring manually Preconditions • Engine is stopped and starting disabled.1 6. M015710/01E 07-02 © MTU . For barring-tool removal follow reverse sequence of working steps. 4. F6555766 F30006212 Unguarded rotating and moving engine components. Rotate crankshaft in engine direction of rotation. Set ratchet (1) onto barring tool (2). ensure that nobody is in the danger zone. Engage barring tool (2) with ring gear (3) and mount on flywheel housing.

Disconnect connector from ECU. 20 seconds. Engine start is automatically interrupted when specified starting period is expired. DANGER Engine – Barring with starting system 1. 5. If necessary. • After working on the engine. re-start the engine after approx. 4. Let the crankshaft rotate until oil pressure is indicated. Release latch of connector X4. M015710/01E 07-02 © MTU . Risk of serious injury . 3.1. 2.danger to life! • Before barring or starting the engine. check that all protective devices have been reinstalled and all tools removed from the engine.2 Engine – Barring with starting system Unguarded rotating and moving engine components. 6.96 Task Description 6. Bar engine in unloaded condition: Press START button. Connect connector X4 to ECU and latch in position. ensure that nobody is in the danger zone.

ensure that nobody is in the danger zone. Perform test run at not below 1/3 load and at least until steady-state temperature is reached. Engine noise above 85 dB (A).3 Engine test run Unguarded rotating and moving engine components. Stop engine (→ Page 60). Risk of serious injury — danger to life! • Before barring or starting the engine. Carry out operational checks (→ Page 59).Task Description 97 6. M015710/01E 07-02 © MTU . 3. 4. Start engine (→ Page 57).1. 2. Risk of damage to hearing! • Wear ear protectors. DANGER WARNING Engine test run 1.

Special tools Designation / Use Rigid endoscope Preparatory steps 1. remaining circumference cannot be faulted • Piston rings cannot be faulted • On the entire circumference not only bright discoloration (not critical for operation) clearly visible darker stripes that begin at the top piston ring • Heat discoloration in the direction of stroke and honing pattern damage • Heat discoloration of piston rings Further endoscopic examination required as part of maintenance work Cylinder liner must be replaced. Positioning crankshaft at BDC 1. Depending on findings: • Do not take any action or • carry out further endoscopic examination as part of maintenance work or • contact Service: cylinder liner must be replaced. Y20097353 Qty. Compile endoscopy report using the table. Cylinder liner .Endoscopic examination Findings • • • • • • • • • Thin carbon coating on carbon scraper ring Slight localized additive deposits at top edge Localized smooth areas at lower edge Carbon deposits on entire circumference between top piston ring and lower edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless. turn crankshaft until crankpin of the cylinder to be tested has reached BDC. Service must be contacted 1.2. even honing pattern First signs of marks left by lower cooling bores Running pattern seems darker Task No actions required Part No. Insert endoscope into cylinder liner through injector seat. 1 • Darker areas of even or varying color intensity • Beginning and end of the discoloration are not sharply defined and do not cover the entire stroke area • Dark areas in the upper section of the cooling bore. 3.1 Cylinder Liner Cylinder liner – Endoscopic examination Preconditions • Engine is stopped and starting disabled. Remove injector (→ Page 110). 2.98 Task Description 6. 2. M015710/01E 07-02 © MTU . Using barring device. Remove cylinder-head cover (→ Page 108).2 6. 2. Use technical terms for description of the liner surface (→ Page 100).

M015710/01E 07-02 © MTU . 2. Install injector (→ Page 110). Install cylinder-head cover (→ Page 108).Task Description 99 Final steps 1.

Polished areas are on the running surface and show local removal of the honing pattern. broken-off burrs). Can be caused by either the piston skirt or the piston crown. Findings not critical. The honing pattern is undisturbed. Cylinders with a number of black lines around the running surface have limited service life and should be replaced. In most cases. Findings not critical. Severe. 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. They usually start in the TDC area and cross through the hone pattern in the direction of stroke.100 Task Description 6. The circumferential length varies. They are clearly visible due to the dark color of the honing groove bottom. Replace liner. These areas consist of scores of different length and depth next to one another. Minor dirt scores Light scoring can take place during the assembly of a new engine (honing products. These are caused by a disturbance in the liner / ring tribosystem. Clearly visible scores from hard particles. Removed cylinders clearly show such scoring on the running surface under endoscope magnification. This corrosion is not critical unless there are corrosion pittings.2. The damaged surface is usually discolored. Findings not critical. Grooves from honing process are not visible any more. they are found at the 6-o’clock and 12-o’clock positions (inlet/exhaust) along the transverse engine axis. Usually they run over the whole ring-travel area (TDC/BDC). Black lines are a step towards heat discoloration. Cannot be felt with the fingernail. Smoothened areas appear brighter and more brilliant than the surrounding running surface. Smoothened areas are on the running surface but almost the whole honing pattern is still visible. Material deposits on the liner (smear). Liners with heat discoloration starting in the TDC-ring 1 have to be replaced. It appears rather darker within the honed structure in contrast to the bright metallic running surface. Findings not critical. Discolorations extend in stroke direction and may be interrupted.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report. Corrosion fields / spots result from water (condensed water) with the valves in the overlap (open) position. particles. Findings not critical. heavy discoloration. starting at the first TDC-ring and becoming more visible from the second TDC-ring onwards and less pronounced from TDC-ring 1. Seizure marks M015710/01E 07-02 © MTU . Irregular circumference lengths and depths. This is caused by oxidation (surface discoloration through oil or fuel) and temperature differences around the liner. Single scores Scored area Smoothened area Polished area Discoloration Corrosion fields / spots Black lines Discolorations (Heat) Seizures. The honing pattern is usually no longer visible and displays a clearly defined (straight) edge to the undisturbed surface. visible scoring.

M015710/01E 07-02 © MTU . Thorough investigation and compliance with the above evaluation criteria allows a definite evaluation.Task Description 101 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. it is recommended that another inspection be carried out after further operation of the engine. To avoid unnecessary disassembly work.

3. Oil can contain combustion residues which are harmful to health. Fit cover (2) with new O-ring. 2.3 6. 5. • Avoid contact with skin. 4. gloves. Remove cover (2) with O-ring (3). diaphragm check and replacement Preconditions • Engine is stopped and starting disabled. Part No. Special tools Designation / Use Torque wrench 6-50 Nm Part No. 1 Spare parts Designation / Use Filter element Diaphragm Seal Hot oil. F30027336 Qty. Use torque wrench to tighten the screws of cover (2) to specified torque 10 Nm -2 Nm. 3. • Do not inhale oil vapor. Replace further oil separator elements in the same way. Risk of injury and poisoning! • Wear protective clothing. 6. Insert new filter element in housing (4). M015710/01E 07-02 © MTU . WARNING Replacing oil separator 1.102 Task Description 6.1 Crankcase Breather Crankcase breather – Oil separator replacement. Remove filter element (1) from housing (4). and goggles / safety mask. Qty.

Task Description 103 Checking diaphragm 1. 2. Remove cover (4). Use torque wrench to tighten the screws of cover (4) to specified torque 10 Nm -2 Nm. seal (2) and diaphragm (3). M015710/01E 07-02 © MTU . 3. Check diaphragms in further oil separators in the same way. Check diaphragm (3) for damage. Mount diaphragm (3) on housing (1). 5. 7. Install new seal (2) and spring (5) together with cover (4). 4. fit new diaphragm if used one is damaged. 6. Take off spring (5).

4. Fill oil chambers of rocker arms and adjusting screws with oil. Material Designation / Use Engine oil Valve gear – Lubrication 1. Fill oil chambers of valve bridges with oil. M015710/01E 07-02 © MTU . Install cylinder head covers (→ Page 108). 2.4. Remove cylinder head covers (→ Page 108). 3.4 6.104 Task Description 6.1 Valve Drive Valve gear – Lubrication Preconditions • Engine is stopped and starting disabled. Part No. Qty.

Special tools Designation / Use Feeler gauge Torque wrench 60-320 Nm Ring socket. Install barring tool (→ Page 95).2 Valve clearance – Check and adjustment Preconditions • Engine is stopped and starting disabled. Part No. 40 °C. • Valves are closed. Remove cylinder head cover (→ Page 108). Rotate crankshaft with barring tool in engine direction of rotation until marking "OT-A1" and pointer are aligned. • Engine coolant temperature is max. 1 1 1 Diagram • Two crankshaft positions • Applicable to 12V engines M015710/01E 07-02 © MTU . 24 mm Preparatory steps 1. Y20010128 F30047446 F30039526 Qty.4. 3. 2.Task Description 105 6.

2.5 mm 3. Check valve clearance with cold engine: • Inlet valves (long rocker arm) = 0. • If the rocker arms are loaded on cylinder A1. If the deviation from the reference value exceeds 0.2 mm • Exhaust valves (short rocker arm) = 0.106 Task Description Diagram • Two crankshaft positions • Applicable to 16V engines Diagram • Two crankshaft positions • Applicable to 20V engines 1 2 I X Cylinder A1 is in firing TDC Cylinder A1 is in overlap TDC Inlet valve Exhaust valve Checking valve clearance at two crankshaft positions 1. Check all valve clearances at two crankshaft positions (firing and overlap TDC for cylinder A1) as per diagram. the piston is in overlap TDC. the piston is in firing TDC. M015710/01E 07-02 © MTU .1 mm. Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1. 5. 4. Use feeler gauge to determine the distance between valve bridge and rocker arm. adjust valve clearance.

2. Tighten locknut (1) to 90 +9 Nm. Using Allen key. 3. set adjusting screw (2) so that the specified valve clearance is provided. Install cylinder head cover (→ Page 108). 4. Check valve clearance.Task Description 107 Adjusting valve clearance 1. Release locknut (1). 6. holding adjusting screw (2) firm. 7. 5. Insert feeler gauge between valve bridge and rocker arm. Final steps 1. Feeler gauge must just pass through the gap. Remove barring tool (→ Page 95). 2. M015710/01E 07-02 © MTU . Replace or rectify adjusting screws and/or locknuts which do not move freely.

Special tools Designation / Use Torque wrench 10-60 Nm Part No. Clean very dirty cylinder head covers prior to removal. Place gasket and cylinder head cover on cylinder head. M015710/01E 07-02 © MTU .4.3 Cylinder head cover – Remove and install Preconditions • Engine is stopped and starting disabled. Part No. 1 Spare parts Designation / Use Gasket Remove cylinder head cover 1. Install screws and tighten to 42 Nm. Remove screws. 2. Clean mating faces. Qty. Install cylinder head cover 1. Remove cylinder head cover with gasket from cylinder head. Check condition of gasket. replace if necessary. F30510423 Qty. 2. 4. 3.108 Task Description 6. 3.

5.1 Injector Injector – Replacement Spare parts Designation / Use Injector Remove injector and install new one (→ Page 110). M015710/01E 07-02 © MTU .5 6. Qty.Task Description 109 6. Part No.

19 mm Torque wrench 60-320 Nm Ratchet adapter Part No.110 Task Description 6. Risk of fire and explosion! • Avoid naked flames. F6784183 F6784167 F30510423 F30025896 F30025897 F30047446 F30027341 Qty. 1 1 1 1 1 1 1 Material Designation / Use Petroleum jelly Fuels are combustible.2 Injector – Removal and Installation Preconditions • Engine is stopped and starting disabled. electrical sparks and ignition sources.5. 17 mm Socket wrench. Part No. Shut off fuel supply to engine. Qty. 2. M015710/01E 07-02 © MTU . • Do not smoke. Remove cylinder head cover (→ Page 108). WARNING Preparatory steps 1. Special tools Designation / Use Puller Press-in tool Torque wrench 10-60 Nm Socket wrench.

6. Remove HP fuel line (4). Fit puller and withdraw injector. Remove screw (2) and take off hold-down clamp (1). Unscrew adapter (3) until only the last two to three courses of the thread are engaged. Unscrew adapter completely. 5.Task Description 111 Injector removal 1. Note: The injector accumulator will be emptied when removing the adapter. 2. M015710/01E 07-02 © MTU . Allow the fuel to drain off and collect it in a suitable container. 3. Withdraw cable connector on injector. 7. 4.

9. Cover all connections and bores.112 Task Description 8. M015710/01E 07-02 © MTU . Insert injector into cylinder head. ensuring that correct adapter connection alignment. 10. 2. Clean sealing surface on cylinder head. 6. Use press-in tool to insert injector into cylinder head. 3. Remove all plugs prior to installation. 5. Lock press-in tool in position between the rocker arms in the cylinder head recess (arrowed). 4. Coat new O-rings (scope of supply of injector) with petroleum jelly and fit on injector. Remove O-rings (2) from injector. 7. observe installation position of sealing ring. Injector installation 1. Remove sealing ring (1) from injector or use a self-made hook to take it out of the cylinder head. Fit new sealing ring with petroleum jelly on injector. or seal with suitable plugs.

2. 11. Open fuel supply to engine.Task Description 113 8. Mount HP line (5) and use torque wrench to tighten to the specified torque: • Injector side (4): 20 Nm +5 Nm • Rail side (6): 30 Nm +5 Nm 15. M015710/01E 07-02 © MTU . 12. Install cylinder head cover (→ Page 108). 13. 9. Tighten screw (2) and adapter (3) to specified tightening torque of 100 Nm +10 Nm using a torque wrench. 14. Coat screw head mating face and thread with engine oil. Coat thread and sealing cone of HP fuel line with engine oil. Fit cable connector. 10. Place hold-down clamp (1) in correct installation position and pretighten screw (2) with torque wrench to between 5 Nm and 10 Nm. Final steps 1. Coat thread and sealing cone of adapter (3) with engine oil. Mount adapter (3) and use torque wrench to pretighten to between 5 Nm and 10 Nm.

Unlock fuel priming pump (2). Open vent plug (1).6.1 Fuel System Fuel system – Venting Preconditions • Engine is stopped and starting disabled. WARNING Venting LP fuel system 1. Screw in handle. Operate the pump with the handle (2) until bubble-free fuel emerges from the vent plug (1). screw out handle by turning it counterclockwise. Part No. Close vent plug (1). 2. turning it clockwise. Qty. Material Designation / Use Diesel fuel Fuels are combustible. • Do not smoke. 3. electrical sparks and ignition sources. M015710/01E 07-02 © MTU . Risk of fire and explosion! • Avoid naked flames.114 Task Description 6. 4. 6. Verify that fuel priming pump (2) is locked: Handle must be tightened.6 6. 5.

electrical sparks and ignition sources. Qty. Qty.1 Fuel Filter Fuel filter – Replacement Preconditions • Engine is stopped and starting disabled.Task Description 115 6. Risk of fire and explosion! • Avoid naked flames. M015710/01E 07-02 © MTU . Special tools Designation / Use Filter wrench Part No. F30379104 Qty. 2. Part No. Screw on easy-change filter by hand until the seal connects and tighten manually. 4. Clean the sealing surface of the filter head. WARNING Fuel filter – Replacement 1. 1 Material Designation / Use Engine oil Part No. • Do not smoke. 3. Spare parts Designation / Use Easy-change filter Fuels are combustible. Remove easy-change filter using filter wrench. Slightly lubricate seal on the easy-change filter.7 6.7.

M015710/01E 07-02 © MTU . 4. 8. 9. 6. Insert filter element into filter housing and secure with nut. 10. Wash filter housing with clean fuel. 3. Place new sealing ring into groove in filter head. Remove filter-element securing nut and remove filter element by pulling it downwards. Material Designation / Use Diesel fuel Part No. Open fuel supply. electrical sparks and ignition sources. Shut off fuel supply. 2. Wash filter element in clean fuel using a smooth brush. Qty. Part No. Qty. Fit cover with seal and secure it with nuts crosswise. Risk of fire and explosion! • Avoid naked flames. 5. WARNING Fuel prefilter cleaning 1. 7. • Do not smoke.7. Spare parts Designation / Use Sealing ring Fuels are combustible. Take off filter housing and drain fuel into appropriate container.116 Task Description 6. Remove nuts from filter head.2 Fuel prefilter cleaning Preconditions • Engine is stopped and starting disabled.

align adjustable pointer (2) with pressure-indicating pointer (3) of pressure gauge (1). Risk of damage to hearing! • Wear ear protectors. Risk of serious injury – danger to life! • Take special care when working on a running engine. M015710/01E 07-02 © MTU . Engine noise above 85 dB (A). 2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating pointer (3) of pressure gauge is ≥ 0. With the engine running at full load or rated power.3 bar. 2. DANGER WARNING Setting adjustable pointer of differential pressure gauge 1. After installation of a new filter element. flush filter element of the cut-in filter (→ Page 120). read off pressure at gauge (1).Task Description 117 6.3 Fuel prefilter – differential pressure check and adjustment of gauge Unguarded rotating and moving engine components.7. Fuel prefilter – checking differential pressure 1. Verify that differential pressure is within the limit.

7. • Do not smoke. Qty.118 Task Description 6. electrical sparks and ignition sources. Qty.4 Fuel prefilter – draining Preconditions • Engine is stopped and starting disabled. Material Designation / Use Diesel fuel Part No. Risk of fire and explosion! • Avoid naked flames. Spare parts Designation / Use Gasket Fuels are combustible. Part No. WARNING M015710/01E 07-02 © MTU .

Fit cover with gasket and secure it with screws. I Left filter cut in II Right filter cut in 2. 8. 11. M015710/01E 07-02 © MTU . 9. Cut the cut-out filter in again. close vent plug (5). Place new gasket in cover (2). 6. Drain water and contaminants from the filter until pure fuel emerges. Unlock drain cock (6) by pressing toggle and open it. 4.Task Description 119 Fuel prefilter – draining 1. 3. When fuel emerges from system. 7. Remove screws securing the cover and take off cover (2). Fill filter housing with clean fuel. Open vent plug (5) of the filter to be drained. 5. 10. Close drain cock (6). Cut out the filter to be drained.

120 Task Description 6. Engine noise above 85 dB (A). Part No. Qty. Risk of serious injury – danger to life! • Take special care when working on a running engine. DANGER WARNING WARNING M015710/01E 07-02 © MTU . Fuels are combustible. Risk of damage to hearing! • Wear ear protectors. electrical sparks and ignition sources. • Do not smoke.5 Material Fuel prefilter – flushing Designation / Use Diesel fuel Part No. Spare parts Designation / Use Gasket Unguarded rotating and moving engine components. Risk of fire and explosion! • Avoid naked flames.7. Qty.

replace filter element (→ Page 122). Cut out the contaminated filter. Result: Fuel flows from filtered side back to the unfiltered side. Check differential pressure (→ Page 117). open it and drain fuel. flushing the filter deposits downwards out of the filter. Place new gasket in cover (2). Remove screws securing the cover and take off cover (2). 4.Task Description 121 Fuel prefilter – flushing 1. 2. 4. Open vent plug (5) of the filter to be flushed. 6. Close vent plug (5) and drain cock (6). 3. Fit cover with gasket and secure it with screws. Fuel prefilter – filling fuel 1. Result: If flushing did not lead to an improvement of the differential pressure. 5. 3. I Left filter cut in II Right filter cut in 2. M015710/01E 07-02 © MTU . Fill filter housing with clean fuel. Stop engine (→ Page 60)and disable engine start. Unlock drain cock (6) by pressing toggle.

Qty. Material Designation / Use Diesel fuel Part No.122 Task Description 6. • Do not smoke.6 Fuel prefilter – filter element replacement Preconditions • Engine is stopped and starting disabled. Risk of fire and explosion! • Avoid naked flames. Spare parts Designation / Use Filter element Gasket Fuels are combustible. Part No. WARNING M015710/01E 07-02 © MTU . electrical sparks and ignition sources. Qty.7.

Remove screws securing the cover and take off cover (2). Cut the cut-out filter in again. 9. Open vent plug (5) of the contaminated filter. 14. Align adjustable pointer of differential pressure gauge with pressure-indicating pointer. 6. 5. Fill filter housing with clean fuel. 11. 10. Unlock drain cock (6) by pressing toggle and open it. Fit cover with gasket and secure it with screws. 3. (→ Page 117). Insert new filter element (3) and spring (4). I Left filter cut in II Right filter cut in 2. Close drain cock (6). 13. 7.Task Description 123 Fuel prefilter – filter element replacement 1. Close vent plug (5) when fuel emerges. 4. Place new gasket in cover (2). Drain water and contaminants from the filter. 8. Remove spring (4) and filter element (3). M015710/01E 07-02 © MTU . 12. Cut out the contaminated filter.

Bar engine with starting system to blow out combustion chambers (→ Page 96). Clean drain bore(s) and blow out with compressed air. 3. Remove injectors (→ Page 110).1 Charge-air Cooling. 2.8 6. Engine noise above 85 dB (A). Bar engine manually (→ Page 95).124 Task Description 6. Risk of injury! • Do not direct compressed-air jet at persons. 4. Install injectors (→ Page 110). With the engine running. Risk of damage to hearing! • Wear ear protectors. General. DANGER WARNING WARNING Intercooler – Checking condensate drains for coolant discharge and obstructions 1.8. the intercooler is leaking. 3. If no air emerges: 2. Emergency measures prior to engine start with a leaking intercooler 1. left and right engine side. Left Side Intercooler – Checking condensate drains for coolant discharge and obstructions Unguarded rotating and moving engine components. M015710/01E 07-02 © MTU . Risk of serious injury – danger to life! • Take special care when working on a running engine. • Wear protective goggles / safety mask and ear protectors. verify that air emerges from the condensate drain(s) at driving end. Contact Service. Compressed air. If a large amount of coolant is continuously discharged.

Part No.1 Air Filter Air filter replacement Spare parts Designation / Use Air filter Remove air filter and install new one (→ Page 127).Task Description 125 6.9. Reset signal ring of service indicator (→ Page 129). Qty.9 6. M015710/01E 07-02 © MTU .

Qty.2 Air filter – Check Spare parts Designation / Use Air filter Air filter – Check 1. Part No. Fit new air filter if damaged (→ Page 127).9. Check entire circumference of air filter for damage.126 Task Description 6. M015710/01E 07-02 © MTU . 2.

2. 5.Task Description 127 6. Verify that there are no objects in the flange of the intake housing (1) and clean it. Remove air filter (3) and clamp (2) from flange of intake housing (1). 3. Place new air filter (3) with clamp (2) onto intake housing (1). Air filter removal and installation 1. Loosen clamp (2). M015710/01E 07-02 © MTU .3 Air filter removal and installation Preconditions • Engine is stopped and starting disabled. 4.9. Tighten clamp (2).

7. 4 Replacing rubber sleeves 1. Qty. 2. 3.9. Part No. 5. Pull off rubber sleeve (2) from turbocharger intake flange. 4. loosen clamps (1) and take off elbow (4). Clean connecting flange of turbocharger and check for obstructions. Fit both clamps (1) on rubber sleeve (2). Align clamps (1) and tighten. Replace further rubber sleeves in the same way. M015710/01E 07-02 © MTU . Remove four screws (3).128 Task Description 6. slide on elbow (4) and secure with screws (3). Spare parts Designation / Use Rubber sleeve Remove air filter (→ Page 125).4 Rubber sleeves between air intake elbow and turbocharger – Replacement Preconditions • Engine is stopped and starting disabled. Fit new rubber sleeve (2) on turbocharger intake flange. 6.

replace air filter (→ Page 125). press reset button (1).1 Air Intake Service indicator – Signal ring position check Preconditions • Engine is stopped and starting disabled.10. Result: Engaged piston with signal ring moves back to initial position. After installation of new filter. M015710/01E 07-02 © MTU . If the signal ring is completely visible in the control window (2).Task Description 129 6.10 6. 2. Signal ring position check 1.

Release pushbutton. Press pushbutton for manual start and hold it. DANGER WARNING Air starter – manual operation 1. Engine noise above 85 dB (A). 3. ensure that nobody is in the danger zone.11. 2.130 Task Description 6.1 Staring Equipment Air starter – manual operation Unguarded rotating and moving engine components. Risk of serious injury — danger to life! • Before barring or starting the engine. M015710/01E 07-02 © MTU . Allow compressed air to enter the air starter until the engine fires evenly. Risk of damage to hearing! • Wear ear protectors.11 6.

2 Starter – Condition check Preconditions • Engine is stopped and starting disabled. 3. 2. M015710/01E 07-02 © MTU . Check starter securing screws for secure seating. Check wiring (→ Page 155).Task Description 131 6. Starter – Condition check 1. Tighten loose screw connections.11.

M015710/01E 07-02 © MTU . • Avoid contact with skin. Install drain plug(s) with new sealing ring. • Do not inhale oil vapor. Risk of injury and poisoning! • Wear protective clothing. Part No. Spare parts Designation / Use Sealing ring Hot oil. Remove drain plug(s) and drain oil.) is available. 3.132 Task Description 6. • Engine is at operating temperature. Oil can contain combustion residues which are harmful to health. Special tools Designation / Use Torque wrench Ratchet adapter Part No. • MTU Fluids and Lubricants Specification (A001061/. 1 1 Material Designation / Use Engine oil Part No. Lube-oil Circuit Engine oil – Change Preconditions • Engine is stopped and starting disabled. Oil change using semirotary hand pump: Oil extraction 1. gloves. 2.12 6. Qty. Provide a suitable container in which to collect the oil. 2. Provide a suitable container in which to collect the oil. WARNING Oil change without semirotary hand pump: Draining oil at drain plug(s) on oil pan 1. F30027337 F30027341 Qty.. Extract all oil from oil pan using the hand pump. Qty. and goggles / safety mask.1 Lube-oil System.12.

Task Description

133

Draining residual oil at equipment carrier 1. Provide a suitable container in which to collect the oil. 2. Remove drain plug (1) and drain oil (approx. 7 liters) from oil heat exchanger and oil filter. 3. Remove drain plugs (2) and (3) and drain oil: • at drain plug (2) approx. 12 liters • at drain plug (3) approx. 5 liters 4. Replace engine oil filter (→ Page 136). 5. Install drain plug(s) with new sealing ring. 6. Tighten drain plugs (2) and (3) with torque wrench to the specified torque 100 Nm +10 Nm.

Filling with new oil 1. Open cover of filler neck. 2. Pour oil in at filler neck up to "max." mark at oil dipstick. 3. Close cover of filler neck. 4. Check engine oil level (→ Page 134). 5. After oil change and oil filter replacement, bar engine with starting system (→ Page 96).

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134

Task Description

6.12.2

Engine oil – Level check

Preconditions
• Engine is stopped and starting disabled. Checking oil level prior to engine start 1. Withdraw dipstick from guide tube and wipe it. 2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. Note: After extended standstill, the oil level may exceed the mark (1) by up to 2 cm. This can be caused by oil flowing from e.g. oil filter or heat exchanger back to the oil pan. 3. The oil level must reach the mark (1) or exceed the mark (1) by up to 2 cm. 4. If necessary, top up to the mark (1) (→ Page 132). 5. Insert dipstick into guide tube up to the stop.

Checking oil level after the engine is stopped 1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it. 2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. 3. Oil level must be between marks (1) and (2). 4. If necessary, top up to the mark (1) (→ Page 132). 5. Insert dipstick into guide tube up to the stop.

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Task Description

135

6.12.3

Engine oil – Sample extraction and analysis

Preconditions
• MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools
Designation / Use MTU test kit Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. 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. Part No. 5605892099/00 Qty. 1

DANGER

WARNING

WARNING

Engine oil – Sample extraction and analysis 1. With the engine running at operating temperature, open screw on centrifugal oil filter carrier by 1 to 2 rotations. 2. Drain approx. 2 liters engine oil to flush out the oil sludge. 3. Drain approx. 1 liter engine oil into a clean container. 4. Close screw. 5. Using the equipment and chemicals of the MTU test kit, examine the engine oil for: • Dispersion capability (spot test); • Water content; • Dilution by fuel.

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Qty. Check oil level (→ Page 134). Qty. Risk of injury and poisoning! • Wear protective clothing. 7. F30379104 Qty. Spare parts Designation / Use Oil filter Hot oil. 2. After each oil change and filter replacement. WARNING Engine oil filter – Replacement 1. Replace further oil filters in the same way. Special tools Designation / Use Filter wrench Part No. Check condition of the new sealing ring and coat it with oil. Screw on and tighten new oil filter by hand.1 Oil Filtration/Cooling Engine oil filter – Replacement Preconditions • Engine is stopped and starting disabled. Clean the sealing surface of the filter head. bar engine with starting system (→ Page 96). 4. Remove oil filter using the filter wrench. M015710/01E 07-02 © MTU .13 6. • Do not inhale oil vapor. Oil can contain combustion residues which are harmful to health. Part No. Material Designation / Use Engine oil Part No.13. • Avoid contact with skin.136 Task Description 6. and goggles / safety mask. 3. 6. gloves. 5.

Oil can contain combustion residues which are harmful to health. Qty. Part No. Compressed air. gloves. Qty. Spare parts Designation / Use Filter sleeve Sealing ring Sealing ring Hot oil.Task Description 137 6. Special tools Designation / Use Torque wrench 6-50 Nm Part No.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement Preconditions • Engine is stopped and starting disabled. • Do not inhale oil vapor. Risk of injury and poisoning! • Wear protective clothing. • Wear protective goggles / safety mask and ear protectors. WARNING WARNING M015710/01E 07-02 © MTU . and goggles / safety mask. • Avoid contact with skin. Risk of injury! • Do not direct compressed-air jet at persons. F30027336 Qty.13. 1 Material Designation / Use Cleaner Hakutex 60 Part No.

shorten maintenance interval. Mount rotor cover (8) with sealing ring (9). fit new one if necessary. 17. 15. 14. allow oil to drain and remove from housing. conical disk (12) and rotor base (14). rotor tube (11). 20. Carefully lift rotor (6). 12. 16. Disassemble rotor tube (11). Check sealing ring (13). M015710/01E 07-02 © MTU . Wash rotor cover (8). Assemble rotor tube (11). Tighten cover nut (1) with 5 Nm to 7 Nm. Release Tommy nut (1) and take off cover (2). 24. conical disk (12) and rotor base (14) with sealing ring (13). 13. conical disk (12) and rotor base (14) with cleaner. Measure thickness of oil residues on filter sleeve (10). 5. Blow out with compressed air. 21. 10. Insert new filter sleeve (10) in rotor tube (11) with the smooth paper surface facing the wall. Tighten rotor cover nut (7) with 35 Nm to 45 Nm. Holding the rotor (6) firmly.138 Task Description Centrifugal oil filter – Cleaning and filter-sleeve replacement 1. Remove filter sleeve (10). 19. Fit clamp (3) and tighten with 8 Nm to 10 Nm. If maximum layer thickness of oil residues exceeds 45 mm. 2. 9. Remove clamp (3). 4. 11. 18. Tighten Tommy nut (1) by hand. fit new one if necessary. Fit cover (2). 7. fit new one if necessary. 3. Check sealing ring (4). Fit sealing ring (4) on housing (5). 8. 22. 23. Place rotor (6) in housing (5) and check for ease of movement. Check sealing ring (9). release rotor cover nut (7). Take off rotor cover (8). 6.

Part No. Qty.Task Description 139 6. General. M015710/01E 07-02 © MTU . Fill engine coolant system (→ Page 140).14.1 Material Cooling Circuit. HT Circuit Engine coolant – Change Designation / Use Engine coolant Drain engine coolant (→ Page 142).14 6.

and goggles / safety mask.. • Wear protective clothing. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape. 2.140 Task Description 6. Risk of injury and scalding! • Let the engine cool down. gloves. Part No. • MTU Fluids and Lubricants Specifications (A001061/. Cold coolant in hot engine can cause thermal stress.14. WARNING CAUTION Preparatory steps 1. Continue to turn breather valve counterclockwise and remove. Qty.) are available. Formation of cracks in components! • Fill / top up coolant only into cold engine.2 Engine coolant – Filling Preconditions • Engine is stopped and starting disabled. Material Designation / Use Engine coolant Coolant is hot and under pressure. M015710/01E 07-02 © MTU .

3. Set breather valve onto filler neck and close until first stop is reached. Alternatively: Fill in coolant in expansion tank until the coolant level at top edge of filler neck remains constant. clean sealing faces if required. Connect appropriate pump with hose to drain valve. Repeat the steps from "Start engine" → 7. 6. 7. 5. 11. 4. 11. After the engine has run at unloaded condition for 10 seconds. Set breather valve onto filler neck and close it. Turn breather valve counterclockwise and remove. 2. 8. Check proper condition of breather valve. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape. Fill expansion tank until overflow edge is reached. Open drain valve and pump coolant into engine at 0. 7.3. Final steps 1. 9. Start the engine and operate it at unloaded condition for some minutes. Check coolant level (→ Page 143) and top up if required. Check proper condition of breather valve. Check coolant level (→ Page 143) and top up if required: 7. 11. until coolant is no longer needed to be topped up. Close drain valve. Disconnect pump and hose.2. Fill in coolant in expansion tank until the coolant level at top edge of filler neck remains constant. Set breather valve onto filler neck and close it. 3. After the engine has run at unloaded condition for 10 seconds. Set breather valve onto filler neck and close it. clean sealing faces if required. stop engine (→ Page 60). 6. 2. Continue to turn breather valve counterclockwise and remove.4.2. M015710/01E 07-02 © MTU . stop engine (→ Page 60). 4. until coolant is no longer needed to be topped up.5 bar minimum. Repeat the steps from "Start engine" → 4. 5. Check coolant level (→ Page 143) and top up if required: 11.1. 7. 2. Start engine (→ Page 57). Start engine (→ Page 57).1.Task Description 141 Filling coolant with pump 1. 7. clean sealing faces if required. 11.3. Check proper condition of breather valve. 10. Filling coolant through filler neck 1.

6. Continue to turn breather valve counterclockwise and remove. 2. Close all open drain points. • Crankcase. 4. 2. Risk of injury and scalding! • Let the engine cool down. Provide an appropriate container to drain the coolant into.142 Task Description 6. • Thermostat housing (arrow) • U-bend (arrow) • HT coolant pump elbow. Open drain cocks or drain plugs and drain coolant at the following points: • Preheating unit. Engine coolant – Draining 1. M015710/01E 07-02 © MTU . • Wear protective clothing. WARNING Preparatory steps 1. and goggles / safety mask.14. 5. Switch off preheating unit.3 Engine coolant – Draining Preconditions • Engine is stopped and starting disabled. Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape. Place breather valve on filler neck and close. 3. Coolant is hot and under pressure. gloves. Draw off segregated corrosion inhibitor oil in expansion tank through the filler neck. left and right side.

• Wear protective clothing. Coolant is hot and under pressure. If required. top up with treated coolant (→ Page 140). and goggles / safety mask. top up with treated coolant (→ Page 140). If required. 3. 2. 2. 4.14. Coolant-level check at external cooler: 1.Task Description 143 6.4 Engine coolant level – Check Preconditions • Engine is stopped and starting disabled. Switch on engine control system and check readings on the display. Check and clean breather valve. M015710/01E 07-02 © MTU . • MTU Fluids and Lubricants Specification (A001061/. 2. Continue to turn breather valve counterclockwise and remove. Check coolant level (coolant must be visible at the lower edge of the cast-in eye). Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape. WARNING Coolant-level check at filler neck: 1.) is available. Set breather valve onto filler neck and close it. 3. Coolant-level check by means of level sensor: 1.. Risk of injury and scalding! • Let the engine cool down. Check coolant level (coolant must be visible at marking plate). gloves.

M015710/01E 07-02 © MTU .14. • Permissible coolant discharge: up to 10 drops per hour. Stop the engine (→ Page 60) and disable engine start. Risk of damage to hearing! • Wear ear protectors.5 Engine coolant pump – Relief bore check Unguarded rotating and moving engine components. observe general safety instructions. • Permissible oil discharge: up to 5 drops/hour. 2. Engine noise above 85 dB (A). 3. Check relief bore for oil and water discharge. If discharge exceeds the specified limits: Contact Service. Risk of serious injury – danger to life! • Take special care when working on a running engine. DANGER WARNING Engine coolant pump – Relief bore check 1.144 Task Description 6. Clean the relief bore with a wire if it is dirty. 4.

1 DANGER WARNING WARNING Engine coolant – Sample extraction and analysis 1. Part No. Flush sample-extraction point by draining approx. • corrosion inhibitor concentration. 1 liter coolant into a clean container. With the engine running.. Risk of damage to hearing! • Wear ear protectors.6 Engine coolant – Sample extraction and analysis Preconditions • MTU Fluids and Lubricants Specification (A001061/. • Wear protective clothing. 6. • pH value. examine coolant for: • antifreeze concentration.) is available. and goggles / safety mask. 5605892099/00 Qty. 5. gloves. Risk of injury and scalding! • Let the engine cool down. open drain valve. Close drain valve. Risk of serious injury – danger to life! • Take special care when working on a running engine. 1 liter coolant. 4. Engine noise above 85 dB (A). M015710/01E 07-02 © MTU .Task Description 145 6. For engine coolant change intervals (→MTU Fluids and Lubricants Specifications). Using the equipment and chemicals of the MTU test kit. Drain approx. 2.14. Special tools Designation / Use MTU test kit Unguarded rotating and moving engine components. 3. Coolant is hot and under pressure.

Qty. M015710/01E 07-02 © MTU . Fill charge-air coolant system (→ Page 147).1 Material LT Circuit Charge-air coolant change Designation / Use Coolant Drain charge-air coolant system (→ Page 149). Part No.146 Task Description 6.15 6.15.

Material Designation / Use Charge-air coolant Coolant is hot and under pressure. Formation of cracks in components! • Fill / top up coolant only into cold engine. Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape. • MTU Fluids and Lubricants Specifications (A001061/.15. Part No. and goggles / safety mask. Qty.) are available. Continue to turn breather valve counterclockwise and remove. • Wear protective clothing. Risk of injury and scalding! • Let the engine cool down. Cold coolant in hot engine can cause thermal stress. M015710/01E 07-02 © MTU . gloves.. WARNING CAUTION Preparatory steps 1.2 Charge-air coolant – Filling Preconditions • Engine is stopped and starting disabled. 2.Task Description 147 6.

until coolant is no longer needed to be topped up. 5. Place breather valve on filler neck and close. Open drain valve and pump coolant into engine at 0.1. After the engine has run at unloaded condition for 10 seconds. 7. stop engine (→ Page 60). 8.2. Check proper condition of breather valve and clean sealing faces if required. 11. Fill expansion tank until overflow edge is reached. Continue to turn breather valve counterclockwise and remove. Alternatively: Fill in coolant in expansion tank until the coolant level at top edge of filler neck remains constant. 7. 7.5 bar minimum. After the engine has run at unloaded condition for 10 seconds. 11.1. Check proper condition of breather valve and clean sealing faces if required. Disconnect pump and hose. 3. Final steps 1.2.4. 7. Filling coolant through filler neck 1. Place breather valve on filler neck and close. Start engine (→ Page 57). 9. Check coolant level (→ Page 150) and top up if required: 11. 2. 11. Start engine (→ Page 57). Check coolant level (→ Page 150) and top up if required: 7. Fill in coolant in expansion tank until the coolant level at top edge of filler neck remains constant.3. Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape. Connect a suitable pump with a hose to the drain valve (arrow). Check proper condition of breather valve and clean sealing faces if required. Start the engine and operate it at unloaded condition for some minutes. Turn breather valve counterclockwise and remove. Set breather valve onto filler neck and close until first stop is reached. M015710/01E 07-02 © MTU . 5.3. Place breather valve on filler neck and close. until coolant is no longer needed to be topped up. 6. 3. 4. Repeat the steps from "Start engine" → 7. 11. Check coolant level (→ Page 150) and top up if required.148 Task Description Filling with charge-air coolant using pump 1. 4. 6. Repeat the steps from "Start engine" → 4. Close drain valve. 2. stop engine (→ Page 60). 2. 10.

Task Description 149 6. Provide an appropriate container to drain the coolant into. Risk of injury and scalding! • Let the engine cool down. Draining of residual coolant: • at the intercooler 7. Draw off segregated corrosion inhibitor oil in expansion tank through the filler neck. 2. Open drain valves and drain plugs and drain coolant at the following points: • at the LT coolant pump • at the LT thermostat housing. Close all drain valves and install drain plugs with new sealing rings.3 Charge-air coolant – Draining Preconditions • Engine is stopped and starting disabled. 5. Qty. 4. Spare parts Designation / Use Sealing ring Coolant is hot and under pressure. gloves. 3. WARNING Charge-air coolant – Draining 1. Place breather valve on filler neck and close. Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape. Continue to turn breather valve counterclockwise and remove. Part No. M015710/01E 07-02 © MTU . 8.15. and goggles / safety mask. 6. • Wear protective clothing.

and goggles / safety mask. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape.15. WARNING Charge-air coolant level check at filler neck: 1. 2. top up with treated coolant (→ Page 147). 2. Coolant is hot and under pressure. Check coolant level (coolant must be visible at marking plate).) is available. • Wear protective clothing.. Fit breather valve onto filler neck and close it. gloves. M015710/01E 07-02 © MTU . If required. If required. top up with treated coolant (→ Page 147). Charge-air coolant level check by means of level sensor: 1. 6. 4. • MTU Fluids and Lubricants Specification (A001061/. Continue to turn breather valve counterclockwise and remove. 3. Switch engine control system ON and check display (coolant level is automatically monitored by the engine control system). Check proper condition of breather valve.4 Charge-air coolant level check Preconditions • Engine is stopped and starting disabled.150 Task Description 6. Risk of injury and scalding! • Let the engine cool down. 5. clean sealing faces if required.

M015710/01E 07-02 © MTU . • Permissible coolant discharge: up to 10 drops per hour. 3. • Permissible oil discharge: up to 5 drops per hour.15. Risk of damage to hearing! • Wear ear protectors. 2. observe general safety instructions. 4. Check relief bore for oil and water discharge. Stop the engine (→ Page 60) and disable engine start. DANGER WARNING Charge-air coolant pump – Relief bore check 1. Engine noise above 85 dB (A). If discharge exceeds the specified limits: Contact Service. Clean the relief bore with a wire if it is dirty. Risk of serious injury – danger to life! • Take special care when working on a running engine.Task Description 151 6.5 Charge-air coolant pump – Relief bore check Unguarded rotating and moving engine components.

• Guard is removed. shows signs of overheating Breaks around the entire circumference Areas of belt material missing Task None Replace (→ Page 154) M015710/01E 07-02 © MTU .16 6.152 Task Description 6.16.1 Belt Drive Drive belt – Condition check Preconditions • Engine is stopped and starting disabled. Item Drive belt A Drive belt Drive belt B Drive belt C Findings Breaks in a few individual places Belt is oily.

Task Description 153 6. Use torque wrench to tighten screw (1) to the specified torque 42 Nm and screw (2) to 60 Nm up to 65 Nm. Result: Belt tensioner moves against the drive belt and tensions it. WARNING Adjusting belt tension 1.17. 4. Spring/circlip/tensioning roller preload. M015710/01E 07-02 © MTU . Install guard cover. Slacken screws (1) and (2) by half a turn. Risk of injury! • Only use specified tool and equipment. 3. 2.17 6. Remove guard cover.1 Battery-charging Generator Battery-charging generator drive – Drive belt tension adjustment Preconditions • Engine is stopped and starting disabled.

5. Slacken screws (1) and (2) by half a turn. Spare parts Designation / Use Drive belt Spring/circlip/tensioning roller preload.17. 3. WARNING Battery-charging generator drive – Drive belt replacement 1. 10. 8. Use torque wrench to tighten screw (1) to the specified torque 42 Nm and screw (2) to 60 Nm up to 65 Nm. 7. 4.154 Task Description 6.2 Battery-charging generator drive – Drive belt replacement Preconditions • Engine is stopped and starting disabled. Slacken screw (2) by half a turn. Place socket adapter or box wrench on screw (3) and press belt tensioner in the direction indicated by the arrow as far as it will go. Readjust belt tension after 30 minutes and again after 8 hours engine runtime. Install guard cover. Part No. (→ Page 153) M015710/01E 07-02 © MTU . Remove guard cover. 6. Risk of injury! • Only use specified tool and equipment. Tighten screw (2). Remove the used drive belt. Fit new drive belt. Result: Belt tensioner moves against the drive belt and tensions it. 2. Qty. 9.

Replace defective cable binders. M015710/01E 07-02 © MTU .18. (→Contact Service). 46181 Qty. 1 Engine wiring – Check 1. 3. Clean dirty connector housings. Material Designation / Use Isopropyl alcohol Part No. Check cable binders for secure seating. • plug-in contacts. 7. • connector sockets.Task Description 155 6. 4.1 Cabling. 5. Make certain that cables are securely seated in clamps and cannot move freely. 6. Check securing screws of cable clamps on the engine and tighten loose screw connections. • cables and terminals. • contacts. If conductors are damaged. General for Engine / Gearbox / Plant Engine wiring – Check Preconditions • Engine is stopped and starting disabled.18 6. sockets and contacts with isopropyl alcohol. 2. tighten loose cable binders. Inspect electrical components visually for damage: • connector housings.

Check legibility of cable labels. 3. Material Designation / Use Isopropyl alcohol ECU and connectors – Cleaning 1. Qty. Part No. Remove dirt from connector and cable surfaces with isopropyl alcohol. sockets and all contacts are dry: Fit connectors and secure latches.1 Accessories for Engine Governor (Electronic) / Control System ECU and connectors – Cleaning Preconditions • Engine is stopped and starting disabled. 3.19 6.19. connector socket housings and all contacts with isopropyl alcohol.156 Task Description 6. Cleaning severely contaminated connectors on ECU 1. When connectors. M015710/01E 07-02 © MTU . 2. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. Clean connector housings. Clean or replace illegible labels. 2. Release latches of connectors and withdraw connectors.

Secure loose connectors and latch.2 ECU – Checking plug-in connections Preconditions • Engine is stopped and starting disabled. 2. M015710/01E 07-02 © MTU .Task Description 157 6. Verify that all plug-in connections are securely seated. ECU – Checking plug-in connections 1.19.

158 Task Description M015710/01E 07-02 © MTU .

1 F30006212 Ratchet 1 M015710/01E 07-02 © MTU .1 Part No. F6555766 Special Tools Special tools Designation / Use Barring tool Qty.Special Tools 159 7 7.

160 Special Tools Part No. Y20097353 Designation / Use Rigid endoscope Qty. 1 F30027336 Torque wrench 6-50 Nm 1 M015710/01E 07-02 © MTU .

Special Tools 161 Part No. Y20010128 Designation / Use Feeler gauge Qty. 1 F30047446 Torque wrench 60-320 Nm 1 M015710/01E 07-02 © MTU .

24 mm Qty.162 Special Tools Part No. F30039526 Designation / Use Ring socket. 1 F30510423 Torque wrench 10-60 Nm 1 M015710/01E 07-02 © MTU .

1 F6784167 Press-in tool 1 M015710/01E 07-02 © MTU . F6784183 Designation / Use Puller Qty.Special Tools 163 Part No.

19 mm 1 M015710/01E 07-02 © MTU .164 Special Tools Part No. 1 F30025897 Socket wrench. 17 mm Qty. F30025896 Designation / Use Socket wrench.

Special Tools 165 Part No. 1 F30379104 Filter wrench 1 M015710/01E 07-02 © MTU . F30027341 Designation / Use Ratchet adapter Qty.

F30027337 Designation / Use Torque wrench Qty.166 Special Tools Part No. 1 5605892099/00 MTU test kit 1 M015710/01E 07-02 © MTU .

Annex 167 8 8. M015710/01E 07-02 © MTU .1 Annex Manufacturer’s documentation See Manufacturer’s documentation.

in the left-hand navigation margin.mtu-online. worldwide.2 MTU contact person/service partner You will find the MTU contact person/service partner for your region at www. M015710/01E 07-02 © MTU .168 Annex 8.com.

at the same time identifier of German standards ("Deutsche Industrie-Norm") Alarm: Default CAN bus failure Monitors coolant level Monitors coolant pressure Monitors coolant temperature Engine control system made by Detroit Diesel DL DT ECM ECU EDM EEPROM EFPA EGR EMU EUI FLS FPS Default Lost Diagnostic Tool Electronic Control Module Engine Control Unit Engine Data Module Electrically Erasable Programmable Read Only Memory Electronic Foot Pedal Assembly Exhaust Gas Recirculation Engine Monitoring Unit Electronic Unit Injector Fluids and Lubricants Specification Fuel Pressure Sensor Electronic control unit of the DDEC system Engine governor MTU Publication No.. Monitors fuel pressure M015710/01E 07-02 © MTU . A01061/.Annex 169 8. German Standardization Organization.3 Abbreviations Meaning Analog/Digital Air Filter Restriction Sensor American National Standards Institute Abgasturbolader Air Temperature Sensor Baureihe Controller Area Network Check Engine Light 1st function: Warning lamp (rectify fault as soon as possible) 2nd function: Read out fault codes Engine Series Exhaust turbocharger (ETC) Explanation Transformer: transforms sensor voltages into numeric values Abbreviation A/D AFRS ANSI ATL ATS BR CAN CEL CKT CLS CPS CTS DDEC DDL DDR DIN Circuit Coolant level sensor Coolant pressure sensor Coolant temperature sensor Detroit Diesel Electronic Controls Diagnostic Data Link Diagnostic Data Reader Deutsches Institut für Normung e. V.

S. standardization organization Alarm: Sensor failure M015710/01E 07-02 © MTU .170 Annex Abbreviation FRS FTS GND HI HIHI HT IDM INJ ISO KGS KS LED LO LOLO LSG N/A OEM OI OLS OPS OTS OT PAN PIM PWM P-xyz RL SAE SD Meaning Fuel Differential Pressure Sensor Fuel Temperature Sensor Ground High High High High Temperature Interface Data Module Injector International Organization for Standardization Kraftgegenseite Kraftseite Light Emitting Diode LOW Low Low Limiting Speed Governor Not Applicable Original Equipment Manufacturer Optimized Idle Oil Level Sensor Oil Pressure Sensor Oil Temperature Sensor Oberer Totpunkt Panel Peripheral Interface Module Pulsewidth modulated Pressure-xyz Redundancy Lost Society of Automotive Engineers Sensor Defect Explanation Monitors fuel temperature Alarm: Measured value exceeds 1st maximum limit Alarm: Measured value exceeds 2nd maximum limit Engine free end in accordance with DIN ISO 1204 Engine driving end in accordance with DIN ISO 1204 Alarm: Measured value lower than 1st minimum limit Alarm: Measured value lower than 2nd minimum limit Monitors oil level Monitors oil pressure Monitors oil temperature Top dead center (TDC) Pressure measuring point xyz Alarm: Redundant CAN bus failure U.

Annex 171 Abbreviation SEL Meaning Stop Engine Light Explanation 1st function: Warning lamp (stop engine and rectify fault) 2nd function: Read out fault codes SID SPC SRS SS TBS TC TCI TCO TD TPS TRS T-xyz UT VNT VSG VSS System Identifier Spare Parts Catalog Synchronous Reference Sensor Safety System Turbocharger Boost Sensor Tools Catalog Turbo Compressor Inlet Turbo Compressor Outlet Transmitter Deviation Throttle Position Sensor Timing Reference Sensor Temperature-xyz Unterer Totpunkt Variable nozzle turbine Variable Speed Governor Vehicle Speed Sensor Temperature measuring point xyz Bottom dead center (BDC) Alarm: Sensor-comparison failure TDC cylinder 1 Indicated alarm is initiated by the safety system Monitors charge-air pressure M015710/01E 07-02 © MTU .

172 Annex M015710/01E 07-02 © MTU .

. . . . . Instructions and comments on endoscopic and visual examination of cylinder liners . . Auxiliary materials. . . . . . General. . . . . . . . Air filter removal and installation . . . . . . .. . . . . . . . . . . . . Left Side . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal oil filter – Cleaning and filter-sleeve replacement . . . . . . . . . . . . . . . . . Cooling Circuit. . 169 156 157 156 62 63 125 126 127 125 128 126 127 125 129 129 130 11 B Battery-charging Generator . . . . . . . . optimized exhaust emission (EPA stage 2) . . . . . . . . . . . . . . . . . . . . . . . . . HT Circuit . . . . . . . . . . . . . . . . Engine coolant level – Check . . . . . . . . . . Belt Drive . . . . . . .. . . . . . . . . . . . . . . Battery-charging generator drive – Drive belt replacement . . Crankcase breather – Oil separator replacement. variable 3B. . . . . . . . . . . . . . . . . . Service indicator – Signal ring position check . . Battery-charging generator drive – Drive belt replacement . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16V 4000 Gx3 engine data: Standby operation 3D. . After stopping the engine – putting the engine out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter . . . . . . Air filter – Check . . . . . . . variable 3B. . . . . . . . . . . . . . . . . . . . . . ECU and connectors – Cleaning . . . . . . . . . . Cylinder liner – Endoscopic examination . . . . . . . . . . . . . . . diaphragm check and replacement . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant – Change . . . . . . . . . . . . . . . . . . . . 157 156 M015710/01E 07-02 © MTU . . . . . . . . . . . . . . . . . . . . . . . . . ECU and connectors – Cleaning . . . . . .. . . . . . . . . . . . . . . . . . . .. . . 12V 4000 Gx3 engine data: Continuous operation. . . . . . . . . . . . . . Charge-air coolant level check . . . . . . . . . . . . . . . . . . Air starter – manual operation . . . . . .4 Index 46 Battery-charging generator drive – Drive belt tension adjustment . . . . . . . . . . . . . . . . . . . . . . optimized fuel consumption . . . . . . . . . . . . . . . . . . . . . . . Air filter replacement . Charge-air Cooling. . . . . . . . . . . . . . . . . . . . . . . . . optimized fuel consumption . . . . . Cylinder liner – Endoscopic examination . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . 155 155 137 149 147 146 150 151 124 124 139 139 142 140 145 143 144 102 102 102 108 98 98 100 98 36 21 41 26 A Abbreviations . . . . . 12V 4000 Gx3 engine data: Standby operation 3D. . . . . variable 3B. . . . . . . variable 3B. . . . . . . . Crankcase Breather . . . . diaphragm check and replacement . 16V 4000 Gx3 engine data: Continuous operation. . . . . . . . . . . . . . . . . . . . Charge-air coolant change . . . . . . . . .. . . . Cylinder Liner . Charge-air coolant – Filling . . . . . . optimized fuel consumption . . Crankcase breather – Oil separator replacement. . . . . . . . . . . Drive belt – Condition check . . . Cylinder head cover – Remove and install . . . . . . Engine coolant pump – Relief bore check . . . . . . . . . . . . Air filter – Check . . . . . . . . . . . . . . . . . optimized fuel consumption . . . . . . . . . . . . Charge-air coolant – Draining . . . Air Intake . . . . 12V 4000 Gx3 engine data: Continuous operation. . . . . Battery-charging generator drive – Drive belt tension adjustment . .. . . . . 152 E ECU – Checking plug-in connections .Annex 173 8. . . . . Charge-air coolant pump – Relief bore check . . . . . . . . Air filter removal and installation . . . . . 153 152 152 12/16 V 4000 Gx3 engine data: Continuous operation. . . . General. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . Intercooler – Checking condensate drains for coolant discharge and obstructions . Accessories for Engine Governor (Electronic) / Control System . . Air filter replacement . . . . . . . . . . General for Engine / Gearbox / Plant . . . . . . . . fire prevention and environmental protection . . . . . After stopping the engine – engine remains ready for operation . . 153 154 153 154 D Drive belt – Condition check . . . . . . . . . . . . . . . . . . . . . . optimized exhaust emissions (TA-Luft) . Rubber sleeves between air intake elbow and turbocharger – Replacement . . . . . . . . . . . . . . . . . . . . . . . Engine coolant – Filling . . . . . . . . . . . . . . . . . . . . Engine coolant – Sample extraction and analysis . . . . . . . . . . . Engine coolant – Draining . Engine wiring – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 C Cabling. . . . . . . . . . . . . . . ECU – Checking plug-in connections . . . . .

. . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . Engine coolant – Draining . . . . . . . . . . . . . . . . . . . Engine – Main dimensions . . . . . . . . . . .. . . . . . . . . . . . . . . . . Engine – Barring manually . . . . . . Engine test run .. . . . . . . . . . . . . . . . . . . . . Fuel prefilter – draining . . . . . . . . . . Engine oil – Sample extraction and analysis . . Injector – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge-air coolant – Draining . . . . . . . . . . . . . . 05 I Index . . . . . Charge-air coolant level check . . .. . . . . . . . . . . . . .Fault messages . . Charge-air coolant – Filling . . . . . . . . . . . . . Fuel prefilter – differential pressure check and adjustment of gauge .. . . . . . . . . . . . . Final compression pressure . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . Engine – Barring with starting system . . . . Fuel prefilter – differential pressure check and adjustment of gauge . . . . . . . . . . . . .174 Annex Emergency start (override mode) .. . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant pump – Relief bore check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector – Removal and Installation . . . . Engine Side and Cylinder Designations . .. . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel filter – Replacement . . Engine oil filter – Replacement . . . . Engine coolant level – Check . . . . . . . . . . . . . . . . . . Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . optimized exhaust emissions (EPA stage 2) . . . . . . . . . . . . . . . . . . . . . .. . . . . . . Fuel prefilter – flushing . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . Injector – Replacement . Fuel system – Venting . . Fuel prefilter – filter element replacement . . . . . Firing Order . . . . . . . . . . . . . . Intercooler – Checking condensate drains for coolant discharge and obstructions . . . . . . . . . . . . . . . . . . . . . . . . . . Charge-air coolant pump – Relief bore check . . . . . . .. . . Maintenance schedule matrix . . . . . . . . . . . . . . . . . . . . . MTU contact person/service partner . . . . . . . 58 61 95 95 96 97 95 96 18 139 142 140 145 143 144 Fuel prefilter – flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lube-oil System. . . . . . . Engine layout . Engine oil – Sample extraction and analysis . . . . . . . . . . . . . . . Engine – Barring with starting system . . . Lube-oil Circuit . Engine – Main dimensions . . .. Engine coolant – Sample extraction and analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant – Change . . . . . . . . . . . . . . . . Engine coolant – Filling . . . Engine side and cylinder designations . . . . . 173 109 110 109 110 109 100 124 31 74 15 15 15 132 134 135 136 17 17 17 97 155 L LT Circuit . . . . . . . . . . . . . . . . . . . . . . Manufacturer’s documentation . . . . . . .. . . . . . . . . . . . Engine oil – Change . Fuel prefilter – filter element replacement . . . . . . . . . . . Engine . . . . . Engine oil – Level check . . Final Compression Pressure . . . . . . . . Engine Layout . . . . . . . . . . . . . . . . . . . Engine oil – Level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 18 66 68 167 168 M015710/01E 07-02 © MTU . . . . . . . . . 20 20 20 19 19 19 115 115 117 118 122 M Main Engine Dimensions . . . . Engine test run . . . . . . . . . . . . . . . . . . . . . . Engine side and cylinder designations . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . Fuel filter – Replacement . . . . . . 120 116 115 117 118 122 120 116 114 114 114 G General conditions . . . . . . . . . . . . . . . . . . Injector – Removal and Installation . . . . . . . . . . Firing order . . . . . . . . . . . . Fuel system – Venting . . . Fuel prefilter – draining . . . . . . . . Injector . Charge-air coolant change . . . Emergency stop . . . . . . . . . . Engine data 12/16V 4000 Gx3: Standby operation 3D. . . . . . . . . . . . . . . . . Engine – Barring manually . Fuel prefilter cleaning . . . . . . . . . . . . . . Engine wiring – Check . .. . . . . . . Engine layout . . . . . .. . . . . . . . . . . . . . . . . . Engine governor ADEC (ECU 7) for Series 4000 genset engines . . . 146 149 147 146 150 151 132 132 134 135 F Final compression pressure . . . . . . . . . . . . . . . . Instructions and comments on endoscopic and visual examination of cylinder liners . . . . . . . . . . . . . . . . . . . . . . . Engine oil – Change . . . . . . . . . . Fuel prefilter cleaning . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . 105 104 108 105 104 104 M015710/01E 07-02 © MTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . optimized fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . optimized fuel consumption . . . . . . . . . . . . . . . . . . . . . . Engine data 12/16V 4000 Gx3: Standby operation 3D. Transport . . . . . . . . . . . . . . . . . . . . . . Starter – Condition check . . . . . . . . . . . . . 12/16 V 4000 Gx3 engine data: Continuous operation. . . . variable 3B. . Valve clearance – Check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Putting the engine into operation after extended out-of-service-periods (>3 months) . . . . . . . . . Air starter – manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . variable 3B. . . . . . . . . Starter – Condition check . . . . . . . . . . . Putting the engine into operation after scheduled out-of-service-period . . . . . . . . . . . . Troubleshooting . . . . . . . Engine oil filter – Replacement . . . . . . . . . . . . . . . . . . . Cylinder head cover – Remove and install . 12V 4000 Gx3 engine data: Continuous operation. . . . . . . . . . . . . . . . . . . optimized exhaust emissions (TA-Luft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Annex 175 O Oil Filtration/Cooling . . . . . . . . . . . . . . . . . . . . . optimized exhaust emission (EPA stage 2) . . . . . . . . . . . . . . . . . . . . . . . . . variable 3B. . . . . . . . . . . optimized fuel consumption . . . . . . . . . . . . . Service indicator – Signal ring position check . . . . . 08 129 159 13 130 130 131 131 57 60 V Valve clearance – Check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06 65 55 56 R Rubber sleeves between air intake elbow and turbocharger – Replacement . . . . . . . . . . . . . Valve Drive . . . . . . . . . . optimized fuel consumption . . . . . . . . . Valve gear – Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 S Safety requirements when working on the engine . . . . . . . . . . . . . 136 137 136 59 T Technical Data . . . . . . . . . . . . . . . . . 16V 4000 Gx3 engine data: Standby operation 3D. . . . . . . . . . . . . . . . . . . Valve gear – Lubrication . . . . 12V 4000 Gx3 engine data: Continuous operation. . . . . . . . Centrifugal oil filter – Cleaning and filter-sleeve replacement . . Staring Equipment . variable 3B. . . . . . . . . . optimized exhaust emissions (EPA stage 2) . . . . . . . . . Starting the engine in manual mode . 16V 4000 Gx3 engine data: Continuous operation. . . . Operational checks . . . . . . . . . . . . . Standards for warning notices in the publication . . . . . Preface . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . 12V 4000 Gx3 engine data: Standby operation 3D. . . . . . Stopping the engine in manual mode . 21 46 51 36 21 41 26 31 07 71 P Personnel and organizational requirements . . . .

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