MTU 20 V 4000 G43 Operating Instructions Manual
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MTU 20 V 4000 G43 Operating Instructions Manual

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Operating Instructions

Diesel engine
20 V 4000 G23
20 V 4000 G43
20 V 4000 G63, G63L
20 V 4000 G83, G83L
M015715/03E

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  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 20 V 4000 G23 20 V 4000 G43 20 V 4000 G63, G63L 20 V 4000 G83, G83L M015715/03E...
  • Page 2 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, mi- crofilming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 4.4 Safety system – Override 4.5 Starting the engine in emergency situations 1.1 Important provisions for all products (override mode) 1.2 Personnel and organizational requirements 4.6 Operational checks 1.3 Transport 4.7 Stopping the engine in manual mode (test 1.4 Crankshaft transport locking device run) 1.5 Safety regulations for startup and operation...
  • Page 4 7.14.3 Centrifugal oil filter – Cleaning and filter- 8 Appendix A sleeve replacement 8.1 Abbreviations 7.15 Coolant Circuit, General, High-Temperature 8.2 MTU contact persons/service partners Circuit 7.15.1 Engine coolant – Level check 9 Appendix B 7.15.2 Engine coolant – Change 7.15.3 Engine coolant –...

  • Page 5: Safety

    1 Safety 1.1 Important provisions for all products Nameplate The product is identified by nameplate, model designation or serial number and must match with the information on the title page of this manual. Nameplate, model designation or serial number can be found on the product. General information This product may pose a risk of injury or damage in the following cases: •...

  • Page 6: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transporta- tion. Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte- nance, repair and transport personnel at all times.

  • Page 7: Transport

    Place the engine/genset on a firm, flat surface only. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to- case basis.

  • Page 8: Crankshaft Transport Locking Device

    1.4 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Torque wrench, 60-320 Nm F30047446 Engine oil Transport locking device Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine transport.
  • Page 9 Fitting the transport locking de- vice on driving end (KS) Note: Attach plate (6) only to the upper part of the openings. Secure plates (6) with screws (4) and washers (5) at the bores on both sides of the flywheel housing and tighten to the specified tightening torque.
  • Page 10 Installing guard plates and en- gine mounting brackets (if appli- cable) on driving end (KS) Note: Always use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure them on the engine. Install engine mounting brackets (2) on both sides with guard plates (1) wash- ers (3), and screws (4).

  • Page 11: Safety Regulations For Startup And Operation

    1.5 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance the manufacturer's specifications before putting the product into service. Before the product is put into operation for the first time, all official authorizations must be available and commissioning preconditions met.

  • Page 12: Safety Regulations For Maintenance And Repair Work

    1.6 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning).
  • Page 13 Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no loose objects are in/on the product (e.g. cloths and cable ties) Safety regulations after completion of maintenance and repair work Before barring, make sure that nobody is standing in the danger zone of the product.
  • Page 14 Working on electrical and 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. De-energize the appropriate areas prior to working on assemblies. Do not damage cabling during removal work.

  • Page 15: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera- tion, make sure that the latest version is used. The applicable version may be downloaded at: http:// www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation. Auxiliary materials, fluids and lubricants might be hazardous goods or toxic substances.When using flu- ids, lubricants, auxiliary materials and other chemical substances, follow the safety instructions that ap- ply to the product.

  • Page 16: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 17: Conventions For Safety Instructions In The Text

    1.8 Conventions for safety instructions in the text DANGER In the event of immediate danger. Consequences: Death or serious injury • Remedial action WARNING In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action CAUTION In the event of dangerous situations.

  • Page 18: General Information

    2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).

  • Page 19: Engine Layout

    2.2 Engine layout 1 Oil heat exchanger 6 Oil filter 11 Belt drive 2 Exhaust turbocharger 7 Fuel filter 12 Charge-air coolant inlet 3 Lifting eye 8 LP fuel pump 13 Engine coolant outlet 4 Air supply 9 HP fuel pump 5 Oil filler neck 10 Vibration damper M015715/03E 2013-01 | General Information | 19...
  • Page 20 1 Intercooler 6 Engine coolant inlet 11 Oil pan 2 Exhaust pipework to inter- 7 Charge-air coolant outlet 12 Valve gear cooler 8 Coolant pump 13 Cylinder head 3 Air filter 9 Generator 14 Starting equipment 4 Centrifugal oil filter 10 Engine mounting 15 PTO system, driving end 5 Crankcase breather...

  • Page 21: Sensors, Actuators And Injectors - Overview

    2.3 Sensors, actuators and injectors – Overview 1 Injectors Y39.11 to 3 F33 (connection for exter- 5 B09 (charge-air tempera- Y39.20 (B side cylinders) nal sensor F33) ture) 2 Engine governor ECU-7 4 F57 (connection for exter- 6 B10 (charge-air pressure) nal sensor F57) The injectors are located below the cylinder head covers.
  • Page 22 1 B13 (crankshaft speed) 1 Injectors Y39.1 to Y39.10 2 B34 (fuel pressure after fil- 3 M8 (HP fuel pump actua- (A side cylinders) ter) tor) The injectors are located below the cylinder head covers. Injector replacement and required tasks (→...
  • Page 23 1 B05.3 (oil pressure before 4 B48 (fuel pressure after 7 B26 (charge-air coolant filter) HP pump) temperature) 2 B05 (oil pressure after fil- 5 B01 (camshaft speed) 8 B06 (coolant temperature) ter) 6 B33 (fuel temperature) 3 B07 (oil temperature) M015715/03E 2013-01 | General Information | 23...

  • Page 24: Technical Data

    3 Technical Data 3.1 20 V 4000 Gx3 engine data: Continuous operation, unrestricted 3A, optimized fuel consumption Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable...
  • Page 25 General conditions (for max. power) Number of cylin- ders Intake depression mbar (new filter) Intake depression, mbar max. Exhaust overpres- mbar sure Exhaust overpres- mbar sure, max. Model related data (basic design) Number of cylin- ders Cylinder arrange- Degrees ment: V angle Bore Stroke Cylinder displace-...
  • Page 26 Number of cylin- ders Coolant antifreeze content, max. Pressure loss in off- engine cooling sys- tem, max. Coolant system (low-temperature circuit) Number of cylin- ders Coolant tempera- °C ture before inter- cooler (at engine connection: inlet from cooling equip- ment) Coolant antifreeze content, max.
  • Page 27 Fuel system Number of cylin- ders Fuel pressure at en- -0.1 -0.1 -0.1 -0.1 -0.1 gine inlet connec- tion, min. (when en- gine is starting) Fuel pressure at en- gine inlet connec- tion, max. (when en- gine is starting) General operating data Number of cylin- ders Cold start capability:...
  • Page 28 Weights / main dimensions Number of cylin- ders Engine weight, dry 9640 9640 9640 9640 9640 (basic engine config- uration acc. to scope of supply specification) Sound Number of cylin- ders Exhaust noise, unsi- dB(A) lenced - DL (sound power level LW, ISO 6798) 28 | Technical Data | M015715/03E 2013-01...

  • Page 29: 4000 Gx3 Engine Data: Continuous

    3.2 20 V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized fuel consumption Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable...
  • Page 30 General conditions (for max. power) Number of cylin- ders Intake depression mbar (new filter) Intake depres- mbar sion, max. Exhaust overpres- mbar sure Exhaust overpres- mbar sure, max. Model related data (basic design) Number of cylin- ders Engine with ex- haust turbocharg- ing (ETC) and charge-air cooling...
  • Page 31 Number of cylin- ders Number of inlet valves per cylin- Number of ex- haust valves per cylinder Standard housing connecting flange (engine main PTO) Flywheel interface DISC Combustion air / exhaust gas Number of cylin- ders Charge-air pres- bar abs sure before cylin- der - DL Coolant system (high-temperature circuit)
  • Page 32 Coolant system (low-temperature circuit) Number of cylin- ders Coolant tempera- °C ture before inter- cooler (at engine connection: inlet from cooling equipment) Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. Lube oil system Number of cylin- ders Lube oil operating °C temperature be-...
  • Page 33 Fuel system Number of cylin- ders Fuel pressure at -0.1 -0.1 -0.1 -0.1 -0.1 -0.1 engine inlet con- nection, min. (when engine is starting) Fuel pressure at engine inlet con- nection, max. (when engine is starting) General operating data Number of cylin- ders Cold start capabil- °C...
  • Page 34 Number of cylin- ders Oil pan capacity Liters 245* 245* 245* 245* 245* 245* at dipstick mark “min.” (standard oil system) (op- tion: max. operat- ing inclinations) Oil pan capacity Liters 340* 340* 340* 340* 340* 340* at dipstick mark “max.”...

  • Page 35: Emissions (Epa2)

    3.3 20 V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized exhaust emissions (EPA2) Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable...
  • Page 36 Model related data (basic design) Number of cylinders Engine with exhaust turbocharging (ETC) and charge- air cooling (CAC) Uncooled exhaust lines Operating method: Four-stroke cycle, diesel, single-ac- tion Combustion method: direct fuel injection Cooling method: treated water Direction of rotation: c.c.w. (facing driving end) Cylinder arrangement: V angle Degrees Bore...
  • Page 37 Lube oil system Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, warning °C Lube oil temperature before engine, shutdown °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure before engine, warning Lube oil operating pressure before engine, shutdown...
  • Page 38 Sound Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, dB(A) ISO 6798) Engine surface noise with attenuated intake noise (fil- dB(A) ter) - DL (sound power level LW, ISO 6798) 38 | Technical Data | M015715/03E 2013-01...

  • Page 39: Emissions (Ta-Luft)

    3.4 20 V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized exhaust emissions (TA-Luft) Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable...
  • Page 40 Model related data (basic design) Number of cylinders Engine with exhaust turbocharging (ETC) and charge- air cooling (CAC) Uncooled exhaust lines Operating method: Four-stroke cycle, diesel, single-ac- tion Combustion method: direct fuel injection Cooling method: treated water Direction of rotation: c.c.w. (facing driving end) Cylinder arrangement: V angle Degrees Bore...
  • Page 41 Lube oil system Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, warning °C Lube oil temperature before engine, shutdown °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure before engine, warning Lube oil operating pressure before engine, shutdown...
  • Page 42 Sound Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, dB(A) ISO 6798) Engine surface noise with attenuated intake noise (fil- dB(A) ter) - DL (sound power level LW, ISO 6798) 42 | Technical Data | M015715/03E 2013-01...

  • Page 43: 4000 Gx3 Engine Data: Standby Operation 3D, Optimized Fuel Consumption

    3.5 20 V 4000 Gx3 engine data: Standby operation 3D, optimized fuel consumption Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable...
  • Page 44 Number of cylin- ders Exhaust overpres- mbar sure Exhaust overpres- mbar sure, max. Model related data (basic design) Number of cylin- ders Engine with ex- haust turbocharg- ing (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Operating meth- od: Four-stroke cycle, diesel, sin- gle-action Combustion...
  • Page 45 Number of cylin- ders Standard housing connecting flange (engine main PTO) Flywheel interface DISC Combustion air / exhaust gas Number of cylin- ders Charge-air pres- bar abs sure before cylin- der - BL Coolant system (high-temperature circuit) Number of cylin- ders Coolant tempera- °C...
  • Page 46 Lube oil system Number of cylin- ders Lube oil operating °C temperature be- fore engine, from Lube oil operating °C temperature be- fore engine, to Lube oil tempera- °C ture before en- gine, warning Lube oil tempera- °C ture before en- gine, shutdown Lube oil operating pressure before...
  • Page 47 General operating data Number of cylin- ders Cold start capabil- °C ity: air tempera- ture (w/o start aid, w/o preheat- ing) - (case A) Coolant preheat- °C ing: preheating temperature (min.) Firing speed, from R Firing speed, to Capacities Number of cylin- ders Engine coolant, Liters...
  • Page 48 Weights / main dimensions Number of cylin- ders Engine weight, 9640 9640 9640 9640 9640 9640 dry (basic engine configuration acc. to scope of sup- ply specification) Sound Number of cylin- ders Exhaust noise, un- dB(A) silenced - BL (sound power lev- el LW, ISO 6798) Engine surface dB(A)

  • Page 49: 4000 Gx3 Engine Data: Standby Operation 3D, Optimized Exhaust Emissions (Epa Stage 2)

    3.6 20 V 4000 Gx3 engine data: Standby operation 3D, optimized exhaust emissions (EPA stage 2) Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable...
  • Page 50 Number of cylinders Operating method: Four-stroke cycle, diesel, single-ac- tion Combustion method: direct fuel injection Cooling method: treated water Direction of rotation: c.c.w. (facing driving end) Cylinder arrangement: V angle Degrees Bore Stroke Cylinder displacement Liters 4.77 4.77 4.77 Total displacement Liters 95.4 95.4...
  • Page 51 Lube oil system Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, warning °C Lube oil temperature before engine, shutdown °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure before engine, warning Lube oil operating pressure before engine, shutdown...
  • Page 52 Sound Number of cylinders Exhaust noise, unsilenced - BL (sound power level LW, dB(A) ISO 6798) Engine surface noise with attenuated intake noise (fil- dB(A) ter) - BL (sound power level LW, ISO 6798) 52 | Technical Data | M015715/03E 2013-01...

  • Page 53: Firing Order

    3.7 Firing order Firing order Num- Firing order ber of cylin- ders A1-B4-A4-A2-B3-A3-B2-B1 A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 M015715/03E 2013-01 | Technical Data | 53...

  • Page 54: Engine - Main Dimensions

    3.8 Engine – Main dimensions Engine – Main dimensions Length (A) approx. 3520 mm Width (B) approx. 1620 mm Height (C) approx. 2490 mm 54 | Technical Data | M015715/03E 2013-01...

  • Page 55: Operation

    4.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. Putting the PowerPack into operation after extended out-of-service-periods (>3 months) Item...

  • Page 56: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting the engine into operation Item Task Lube oil system Check oil level (→ Page 155); Cooling system Check engine coolant level (→ Page 164); Check charge-air coolant level (→...

  • Page 57: Starting The Engine In Manual Mode (Test Run)

    4.3 Starting the engine in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network. ☑ External start interlock is not active. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! •...

  • Page 58: Safety System - Override

    4.4 Safety system – Override CAUTION Safety functions and engine shutdown alarms will be disregarded. Serious damage to plant! • Initiate emergency start only in emergency situations. CAUTION Inadmissible operational condition. Major material damage! • Use override function only in hazardous situations to ensure full capability in case of engine mal- functions.

  • Page 59: Starting The Engine In Emergency Situations (Override Mode)

    4.5 Starting the engine in emergency situations (override mode) CAUTION Safety functions and engine shutdown alarms will be disregarded. Serious damage to plant! • Initiate emergency start only in emergency situations. Preparation Item Task Operating mode switch Set to emergency mode. Starting the engine in emergency situations Item Task...

  • Page 60: Operational Checks

    4.6 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 61: Stopping The Engine In Manual Mode (Test Run)

    4.7 Stopping the engine in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network. ☑ Engine is running in manual mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! •...

  • Page 62: Emergency Stop

    4.8 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Task EMERGENCY STOP button Press. • Engine is stopped by switching off power supply to ECU; •...

  • Page 63: After Stopping The Engine - Engine Remains Ready For Operation

    4.9 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. control M015715/03E 2013-01 | Operation | 63...

  • Page 64: After Stopping The Engine - Putting The Engine Out Of Operation

    4.10 After stopping the engine – Putting the engine out of operation Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. After stopping the engine Item Action Coolant circuit Drain engine coolant (→ Page 166); Drain charge-air coolant (→ Page 174) if: •...

  • Page 65: Plant Cleaning

    4.11 Plant cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not present. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! •...

  • Page 66: Maintenance

    5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 67: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Probable cause Task Battery Low or defective Charge or replace (see manufacturer's documentation). Cable connections defective Check if cable connections are properly secured (see manufacturer's documen- tation). Starter (electric) Engine wiring or starter defective Check cable connections for secure...
  • Page 68 Defective Contact Service. Charge-air temperature too high Component Probable cause Task Engine coolant Incorrect coolant concentration Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts. Charge air pressure too low...
  • Page 69 Exhaust gas blue Component Probable cause Task Engine oil Too much engine oil in the engine Drain engine oil (→ Page 156). Oil separator of crankcase breather con- Replace (→ Page 127). taminated Exhaust turbocharger, Defective Contact Service. cylinder head, piston rings, cylinder liner Exhaust gas white Component...

  • Page 70: Fault Messages On Pau Display

    6.2 Fault messages on PAU display The fault code numbers are generated by the engine governor and, depending on the relevant control system, transmitted to the display. The display is a two-line B/W-LCD for 16 ASCII characters per line and equipped with background illu- mination.

  • Page 71: Engine Governor Adec (Ecu 7) For Series 4000 Genset Engines - Fault Messages

    6.3 Engine governor ADEC (ECU 7) for Series 4000 genset engines – Fault messages 003 – HI T-Fuel ZKP-Number: 2.0122.931 Limit value 1 Cause Corrective action Fuel temperature too high. u Contact Service. 004 – SS T-Fuel ZKP-Number: 2.0122.932 Limit value 2 Cause Corrective action Fuel temperature too high;...
  • Page 72 010 – SS T-Coolant Intercooler ZKP-Number: 2.0124.932 Limit value 2 Cause Corrective action Coolant temperature in u Reduce power. intercooler too high; Engine stop. 015 – LO P-Lube Oil ZKP-Number: 2.0100.921 Limit value 1 Cause Corrective action Lube oil pressure too low. u Check oil level, top up as necessary (→...
  • Page 73 022 – SS T-Exhaust B ZKP-Number: 2.0127.932 Limit value 2 Cause Corrective action Exhaust gas temperature (B- 1. Check wiring (→ Page 184). side) too high; Engine stop. 2. Contact Service. 023 – LO Coolant Level ZKP-Number: 2.0152.921 Limit value 1 Cause Corrective action Coolant level too low.
  • Page 74 030 – SS Engine Overspeed ZKP-Number: 2.2510.932 Limit value 2 Cause Corrective action Reduced fuel injection. 1. Acknowledge alarm. 2. Attempt to restart engine. 031 – HI ETC1 Overspeed ZKP-Number: 2.3011.931 Limit value 1 Cause Corrective action Speed of primary turbocharger u Contact Service.
  • Page 75 037 – SS ETC2 Overspeed ZKP-Number: 2.3013.912 Limit value 2 Cause Corrective action Speed of first secondary 1. Reduce power. turbocharger too high. 2. Contact Service. 038 – AL ETC Speed Deviation ZKP-Number: 1.8004.205 Cause Corrective action Synchro fault between primary 1.
  • Page 76 057 – LO P-Coolant ZKP-Number: 2.0101.921 Limit value 1 Cause Corrective action Coolant pressure too low. u Check coolant circuit. 058 – SS P-Coolant ZKP-Number: 2.0101.922 Limit value 2 Cause Corrective action Coolant pressure too low; 1. Automatic engine shutdown. Engine stop or reduced fuel 2.
  • Page 77 064 – SS P-Crank Case ZKP-Number: 2.0106.932 Limit value 2 Cause Corrective action Crankcase pressure too high; u Engine must not be started (risk of engine failure), contact Automatic engine shutdown. Service. 065 – LO P-Fuel ZKP-Number: 2.0102.921 Limit value 1 Cause Corrective action Fuel supply pressure too low.
  • Page 78 081 – AL Rail Leakage ZKP-Number: 1.8004.046 Cause Corrective action Pressure gradient in rail is too u Contact Service. low during starting or too high during stopping; HP system leaky, air in system. 082 – HI P-Fuel (Common Rail) ZKP-Number: 2.0104.931 Cause Corrective action Rail pressure >...
  • Page 79 089 – SS Engine Speed too Low ZKP-Number: 2.2500.030 Cause Corrective action Engine speed too low. u Observe additional messages. 090 – SS Idle Speed Not Reached ZKP-Number: 2.1090.925 Cause Corrective action Idling speed was not attained. u Contact Service. 091 –...
  • Page 80 095 – AL Prelubrication Fault ZKP-Number: 2.1090.920 Cause Corrective action Oil priming fault. u Check oil priming system. 102 – AL Fuel Cons. Counter Defect ZKP-Number: 1.8004.624 Cause Corrective action Consumption meter faulty. u Contact Service. 104 – AL Eng Hours Counter Defect ZKP-Number: 1.8004.623 Cause Corrective action...
  • Page 81 121 – HIHI ECU Power Supply Voltage ZKP-Number: 2.0140.932 Limit value 2 Cause Corrective action Supply voltage too high. 1. Check supply voltage of engine governor. 2. Contact Service. 122 – HI T-ECU ZKP-Number: 2.0132.921 Limit value 1 Cause Corrective action Electronic unit temperature too 1.
  • Page 82 177 – AL LifeData restore incomplete ZKP-Number: 2.4000.006 Cause Corrective action This fault message is generated u Contact Service. if a CRC is faulty during a data upload to ADEC (indicated for each individual module). 180 – AL CAN1 Node Lost ZKP-Number: 2.0500.680 Cause Corrective action...
  • Page 83 186 – AL CAN1 Bus Off ZKP-Number: 2.0500.686 Cause Corrective action CAN controller 1 is in "Bus-Off" 1. Check CAN bus for short circuit, rectify short circuit as status. necessary. 2. Check shielding, improve shielding as necessary. 3. Contact Service. 187 –...
  • Page 84 201 – SD T-Coolant ZKP-Number: 1.8004.570 Cause Corrective action Coolant temperature sensor u Check sensor and cabling (B6), replace as necessary. Error faulty; Short circuit or wire cleared after restarting the engine. break. 202 – SD T-Fuel ZKP-Number: 1.8004.572 Cause Corrective action Fuel temperature sensor faulty;...
  • Page 85 207 – SD T-Exhaust B ZKP-Number: 18.004.577 Cause Corrective action Exhaust temperature sensor on u Check sensor and cabling (B4.22), replace if necessary. B-side faulty. Short circuit or wire break 208 – SD P-Charge Air ZKP-Number: 1.8004.566 Cause Corrective action Charge-air pressure sensor u Check sensor and cabling (B10), replace as necessary.
  • Page 86 215 – SD P-HD ZKP-Number: 1.8004.567 Cause Corrective action Rail pressure sensor faulty; u Check sensor and cabling (B48), replace as necessary. Error High-pressure regulator in cleared after restarting the engine. emergency mode ==> Short circuit or wire break. 216 – SD T-Lube Oil ZKP-Number: 1.8004.575 Cause Corrective action...
  • Page 87 223 – SD Level Coolant Intercooler ZKP-Number: 1.8004.583 Cause Corrective action Sensor for intercooler coolant u Check sensor and cabling (F57), replace as necessary. Error level faulty; Short circuit or wire cleared after restarting the engine. break. 227 – SD P-Lube Oil before Filter ZKP-Number: 1.8004.620 Cause Corrective action...
  • Page 88 232 – SD Charger 1 Speed ZKP-Number: 1.3011.128 Cause Corrective action Speed sensor of primary u Check sensor and cabling (B44.1), replace as necessary. Error turbocharger faulty; Short circuit cleared after restarting the engine. or wire break. 233 – SD Charger 2 Speed ZKP-Number: 1.3011.129 Cause Corrective action...
  • Page 89 244 – SD P-Lube Oil (R) ZKP-Number: 1.8004.621 Cause Corrective action Redundant lube oil pressure u Check sensor and cabling, replace as necessary. Error cleared sensor faulty; Short circuit or after restarting the engine. wire break. 245 – SD ECU Power Supply Voltage ZKP-Number: 2.8006.589 Cause Corrective action...
  • Page 90 301 – AL Timing Cylinder A1 ZKP-Number: 1.8004.500 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears injector: Time-of flight measured frequently (→ Page 134). value extremely low or extremely high. 302 – AL Timing Cylinder A2 ZKP-Number: 1.8004.501 Cause Corrective action...
  • Page 91 306 – AL Timing Cylinder A6 ZKP-Number: 1.8004.505 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears injector: Time-of flight measured frequently (→ Page 134). value extremely low or extremely high. 307 – AL Timing Cylinder A7 ZKP-Number: 1.8004.506 Cause Corrective action...
  • Page 92 311 – AL Timing Cylinder B1 ZKP-Number: 1.8004.510 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears injector: Time-of flight measured frequently (→ Page 134). value extremely low or extremely high. 312 – AL Timing Cylinder B2 ZKP-Number: 1.8004.511 Cause Corrective action...
  • Page 93 316 – AL Timing Cylinder B6 ZKP-Number: 1.8004.515 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears injector: Time-of flight measured frequently (→ Page 134). value extremely low or extremely high. 317 – AL Timing Cylinder B7 ZKP-Number: 1.8004.516 Cause Corrective action...
  • Page 94 321 – AL Wiring Cylinder A1 ZKP-Number: 1.8004.520 Cause Corrective action Short circuit in injector cabling 1. Check solenoid valve. to cylinder. Result: Misfiring. 2. Contact Service. 322 – AL Wiring Cylinder A2 ZKP-Number: 1.8004.521 Cause Corrective action Short circuit in injector cabling 1.
  • Page 95 328 – AL Wiring Cylinder A8 ZKP-Number: 1.8004.527 Cause Corrective action Short circuit in injector cabling 1. Check solenoid valve. to cylinder. Result: Misfiring. 2. Contact Service. 329 – AL Wiring Cylinder A9 ZKP-Number: 1.8004.528 Cause Corrective action Short circuit in injector cabling 1.
  • Page 96 335 – AL Wiring Cylinder B5 ZKP-Number: 1.8004.534 Cause Corrective action Short circuit in injector cabling 1. Check solenoid valve. to cylinder. Result: Misfiring. 2. Contact Service. 336 – AL Wiring Cylinder B6 ZKP-Number: 1.8004.535 Cause Corrective action Short circuit in injector cabling 1.
  • Page 97 342 – AL Open Load Cylinder A2 ZKP-Number: 1.8004.541 Cause Corrective action Open circuit in injector wiring to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 343 – AL Open Load Cylinder A3 ZKP-Number: 1.8004.542 Cause Corrective action Open circuit in injector wiring to 1.
  • Page 98 349 – AL Open Load Cylinder A9 ZKP-Number: 1.8004.548 Cause Corrective action Open circuit in injector wiring to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 350 – AL Open Load Cylinder A10 ZKP-Number: 1.8004.549 Cause Corrective action Open circuit in injector wiring to 1.
  • Page 99 356 – AL Open Load Cylinder B6 ZKP-Number: 1.8004.555 Cause Corrective action Open circuit in injector wiring to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 357 – AL Open Load Cylinder B7 ZKP-Number: 1.8004.556 Cause Corrective action Open circuit in injector wiring to 1.
  • Page 100 362 – AL Power Stage High ZKP-Number: 1.8004.497 Cause Corrective action Internal electronic fault 1. Check solenoid valve cabling. (electronics possibly faulty: start 2. Replace engine governor. ITS).Check additional messages if ITS indicates diagnosis "Electronics OK" (e.g. cabling faulty). 363 – AL Stop Power Stage ZKP-Number: 1.8004.560 Cause Corrective action...
  • Page 101 373 – AL Wiring TO 3 ZKP-Number: 1.8004.636 Cause Corrective action Short circuit or wire break on transistor output 3 (TO 3). 374 – AL Wiring TO 4 ZKP-Number: 1.8004.637 Cause Corrective action Short circuit or wire break on transistor output 4 (TO 4). 381 –...
  • Page 102 390 – AL MCR exceeded ZKP-Number: 1.1085.009 Cause Corrective action DBR/MCR function: MCR 1. No action required if alarm only applied temporarily. exceeded. 2. Contact Service if alarm applied constantly. 392 – HI T-Coolant Red ZKP-Number: 2.0129.931 Limit value 1 Cause Corrective action Redundant coolant temperature...
  • Page 103 397 – TD P-Oil Sensor Deviation ZKP-Number: 1.0480.293 Cause Corrective action Maximum lube oil pressure 1. Check cabling and sensor. deviation. 2. Contact Service. 400 – AL Open Load Digital Input 1 ZKP-Number: 2.8006.625 Cause Corrective action Line disruption on digital input 1.
  • Page 104 405 – AL Open Load Digital Input 6 ZKP-Number: 2.8006.630 Cause Corrective action Line disruption on digital input 1. Check cabling. 6; Cabling faulty or no 2. Check target device input. resistance over switch. 3. Contact Service. 406 – AL Open Load Digital Input 7 ZKP-Number: 2.8006.631 Cause Corrective action...
  • Page 105 412 – HI U-PDU ZKP-Number: 2.0141.931 Limit value 1 Cause Corrective action Injector voltage too high. 1. Check cabling. 2. Check supply. 3. Contact Service. 413 – HIHI U-PDU ZKP-Number: 2.0141.932 Limit value 2 Cause Corrective action Injector voltage too high. 1.
  • Page 106 417 – SD Level Water Fuel Prefilter ZKP-Number: 1.8004.594 Cause Corrective action Sensor for water level in fuel u Check sensor and cabling, replace as necessary. Error cleared prefilter faulty; Short circuit or after restarting the engine. wire break. 419 – SD T-Coolant b.Engine ZKP-Number: 18.004.604 Cause Corrective action...
  • Page 107 430 – LO P-Coolant before Engine ZKP-Number: 20.168.921 Limit value 1 Cause Corrective action Coolant pressure too low. u Check coolant circuit. 431 – SS P-Coolant before Engine ZKP-Number: 20.168.922 Limit value 2 Cause Corrective action Coolant pressure too low. u Check coolant circuit.
  • Page 108 444 – SD U-PDU ZKP-Number: 1.8004.578 Cause Corrective action Injector power stage sensor u Replace engine governor. defect; Internal fault in ECU. 445 – SD P-Ambient Air ZKP-Number: 1.8004.580 Cause Corrective action Ambient air pressure sensor u Replace engine governor. faulty.
  • Page 109 455 – AL L1 Aux1 Plant ZKP-Number: 2.8006.650 Limit value 1 Cause Corrective action Input signal of Aux 1 (plant side) u Determine cause of limit value violation and rectify fault. has exceeded/not attained limit value 1, depending on configuration. 456 –...
  • Page 110 464 – SD P-AUX 1 ZKP-Number: 1.8004.589 Cause Corrective action Analog input signal for Aux 1 u Check pressure transmitter and cabling, replace as necessary. pressure faulty; Short circuit or Error cleared after restarting the engine. wire break. 467 – AL L2 T-Aux 1 ZKP-Number: 2.0130.922 Limit value 2 Cause...
  • Page 111 472 – AL Stop SD ZKP-Number: 2.8006.593 Cause Corrective action Engine stop, since all shutdown 1. Check cabling. channels have "sensor faulty". 2. Contact Service. 473 – AL Wiring PWM_CM2 ZKP-Number: 1.8004.593 Cause Corrective action Cable break or short circuit on 1.
  • Page 112 480 – AL Ext. Engine Protection ZKP-Number: 20.291.921 Cause Corrective action External engine protection u Monitoring of plant signal by ECU active (plant side). Check function active. plant signal. 482 – SD T-Exhaust C ZKP-Number: 18.004.596 Cause Corrective action Exhaust temperature sensor on u Check sensor and cabling (B4.23), replace if necessary.
  • Page 113 487 – SS T-Exhaust D ZKP-Number: 20.134.932 Limit value 2 Cause Corrective action Exhaust gas temperature (D- 1. Reduce power. side) too high. 2. Contact Service. 488 – HI ETC3 Overspeed ZKP-Number: 23.014.931 Limit value 1 Cause Corrective action Speed of second secondary u Reduce power.
  • Page 114 493 – AL ETC3 Cutin Failure ZKP-Number: 18.004.203 Cause Corrective action ETC3 failed to cut in. u Check control valve at turbocharger 3. 500 – AL Wiring POM Starter 1 ZKP-Number: 14.500.900 Cause Corrective action A cabling fault in connection of u Check connection between POM and starter.
  • Page 115 506 – AL Low Starter Voltage ZKP-Number: 14.500.906 Cause Corrective action The battery voltage is too low for u Check starter battery and cabling. the starting process. 507 – AL POM Error ZKP-Number: 14.500.907 Cause Corrective action A general POM fault occurred. u Replace POM.
  • Page 116 521 – SS P-Lube Oil Mid Val ZKP-Number: 20.480.289 Limit value 1 Cause Corrective action Average oil pressure value from u Check oil level, top up as necessary. three sources is too low. 523 – SS T-Coolant Red Mid Val ZKP-Number: 20.480.189 Limit value 2 Cause...
  • Page 117 528 – SD Engine Speed 3rd Sensor ZKP-Number: 12.500.102 Cause Corrective action Redundant crankshaft speed u Check sensor and cabling, replace as necessary. sensor faulty; Short circuit or wire break. 529 – SS T-Coolant Red2 ZKP-Number: 20.480.195 Limit value 2 Cause Corrective action Second redundant coolant...
  • Page 118 Limit value 2 Cause Corrective action Camshaft overspeed. 1. Acknowledge alarm. 2. Attempt to restart engine. 555 – AL Call MTU Field Service ZKP-Number: 20.555.001 Cause Corrective action This fault becomes active if a u Request enabling code via internet.
  • Page 119 576 – AL ESCM Override ZKP-Number: 11.075.083 Cause Corrective action Violation of corrected MCR or u Reduce power. DBR/MCR curve. Engine overload! 577 – SD T-Lube Oil Pan ZKP-Number: 10.137.900 Cause Corrective action Oil pan temperature sensor u Check sensor and cabling, replace as necessary. faulty.

  • Page 120: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 121: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, ensure that nobody is in the danger zone. • After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.

  • Page 122: Engine - Test Run

    7.1.3 Engine – Test run DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 123: Cylinder Liner

    7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 132). Remove injector (→...
  • Page 124 Compile endoscopy report using the table. Use technical terms for description of the liner surface (→ Page 125). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 125: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    7.2.2 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 ex- amination report. Findings Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 126 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 127: Crankcase Breather

    7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet F30027340 Engine oil Filter element...
  • Page 128 Checking diaphragm Remove cover (4). Remove spring (5), gasket (2) and dia- phragm (3). Check diaphragm (3) for damage, fit new diaphragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).

  • Page 129: Valve Drive

    7.4 Valve Drive 7.4.1 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication Remove cylinder head covers (→ Page 132). Fill oil chambers of valve bridges with oil.

  • Page 130: Valve Clearance - Check And Adjustment

    7.4.2 Valve clearance – Check and adjustment Preconditions ☑ Engine shut down and starting disabled. ☑ Engine coolant temperature is max. 40°C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20098771 Torque wrench, 60-320Nm F30452768 Box wrench socket, 24mm...

  • Page 131: Adjusting Valve Clearance

    1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Use feeler gauge to determine the distance between valve bridge and rocker arm. If the deviation from the set value exceeds 0.1mm, adjust valve clearance. Adjusting valve clearance Release locknut (1).

  • Page 132: Cylinder Head Cover - Removal And Installation

    7.4.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 O-ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal.

  • Page 133: Injection Pump / Hp Pump

    7.5 Injection Pump / HP Pump 7.5.1 HP pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 134: Injection Valve / Injector

    7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 135). 134 | Task Description | M015715/03E 2013-01...

  • Page 135: Injector - Removal And Installation

    7.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal tool F6789889 Milling cutter F30452739 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30452769 Torque wrench, 60-320 Nm F30452768...
  • Page 136 Remove HP fuel line (4). Remove return line (5). Note: The injector accumulator will be emptied when removing the adapter. Remove adapter (3). Remove screw (2) and take off hold-down clamp (1). Install installation/removal tool on cylinder head. Remove injector with installation/removal tool.
  • Page 137 Installing injector Remove plug before installing the injector. (Do not remove the plug from the HP line before installing the adapter.) Coat injector with assembly paste at the seat of the nozzle clamping nut. Fit new sealing ring (4) (included in the scope of supply of the injector) with grease on injector, observe installation position of sealing ring (4).
  • Page 138 Coat screw head mating face (2) and thread with engine oil. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the speci- fied initial tightening torque. Name Size Type Lubricant Value/Standard Screw Preload torque (Engine oil) 5 Nm to 10 Nm...
  • Page 139 Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening sequence: 1 Adapter (4) 2 Rail (6) Name Size Type Lubricant Value/Standard Union nut / thrust Tightening torque 40 Nm + 5 Nm screw Fit cable connector onto injector.

  • Page 140: Fuel System

    7.7 Fuel System 7.7.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 141: Replacement

    7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 142 7.8.2 Fuel prefilter cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Sealing ring (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 143: Fuel Prefilter – Differential Pressure Gauge

    7.8.3 Fuel prefilter – Differential pressure gauge check and adjustment DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...
  • Page 144 7.8.4 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 145 7.8.5 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Gasket (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Fuels are combustible.
  • Page 146 Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing valve toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the un- filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6).

  • Page 147: Replacement

    7.8.6 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible.
  • Page 148 Open threaded vent plug (5) of contaminat- ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele- ment (3).

  • Page 149: Intercooler – Checking Condensate Drain For

    7.9 Charge-Air Cooling 7.9.1 Intercooler – Checking condensate drain for coolant discharge and obstructions DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A).

  • Page 150: Air Filter

    7.10 Air Filter 7.10.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Air filter – Replacement Remove air filter and install new one (→ Page 152). Reset signal ring of service indicator (→ Page 153). 150 | Task Description | M015715/03E 2013-01...
  • Page 151 7.10.2 Air filter – Check Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Checking air filter Check entire circumference of air filter for damage. Fit new air filter if damaged (→ Page 152). M015715/03E 2013-01 | Task Description | 151...
  • Page 152 7.10.3 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4-20Nm F30044239 Removing and installing air fil- Release clamp (2). Remove air filter (1) and clamp (2) from connecting flange of intake housing (3).

  • Page 153: Air Intake

    7.11 Air Intake 7.11.1 Service indicator – Signal ring position check (optional) Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 150). After installation of new filter, press reset button (1).

  • Page 154: Starting Equipment

    7.12 Starting Equipment 7.12.1 Air starter – Manual operation DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A).

  • Page 155: Lube Oil System, Lube Oil Circuit

    7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Engine oil – Level check Preconditions ☑ Engine is stopped and starting disabled. Checking oil level prior to en- gine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to stop, withdraw after approx.
  • Page 156 7.13.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU fluids and lubricants specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 40-200 Nm...
  • Page 157 Tighten drain (2) and (3) with torque wrench to specified tightening torque. Name Size Type Lubricant Value/Standard Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm Filling with new engine oil Open cover on filler neck. Pour engine oil through the filler neck up to the "max."...
  • Page 158 7.13.3 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Unguarded rotating and moving engine components.

  • Page 159: Oil Filtration / Cooling

    7.14 Oil Filtration / Cooling 7.14.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Hot oil.
  • Page 160 7.14.2 Oil indicator filter – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner (Snow-White 11-0) 40460 Cleaner (Hakupur 312) 30390 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
  • Page 161 Cleaning strainer Shake coarse contamination out of strainer (5). Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312). Use a soft brush to remove stubborn deposits from strainer if required. Ensure that the mesh is not damaged.

  • Page 162: Centrifugal Oil Filter – Cleaning And Filter

    7.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Cold cleaner (Hakutex 60) X00056750 Filter sleeve (→...
  • Page 163 Centrifugal oil filter – Cleaning and filter-sleeve replacement Remove clamp (14). Release cover screw (2) and take off cov- er (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3).

  • Page 164: Coolant Circuit, General, High-Temperature

    7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 165 7.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 166). Fill with engine coolant (→ Page 167). M015715/03E 2013-01 | Task Description | 165...
  • Page 166 7.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps Provide an appropriate container to drain the coolant into.
  • Page 167 7.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING Coolant is hot and under pressure.
  • Page 168 Filling coolant with pump Connect a suitable pump with a hose to the drain valve of the engine coolant pump (ar- rowed). Open vent points at distributor and exhaust turbochargers (arrowed). Open drain valve and pump coolant into en- gine at 0.5 bar minimum. When coolant emerges from the vent points, close vent points one by one, pro- ceeding from the lowest point upwards.
  • Page 169 Alternatively: Filling coolant through filler neck Open vent points at distributor and exhaust turbochargers (arrowed). Fill in coolant via filler neck on expansion tank until coolant level remains constant at top edge of filler neck. When coolant emerges from the vent points, close vent points one by one, pro- ceeding from the lowest point upwards.

  • Page 170: Engine Coolant Pump – Relief Bore Check

    7.15.5 Engine coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 171: Engine Coolant – Sample Extraction And

    7.15.6 Engine coolant – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Unguarded rotating and moving engine components.

  • Page 172: Low-Temperature Circuit

    7.16 Low-Temperature Circuit 7.16.1 Charge-air coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 173: Charge-Air Coolant – Change

    7.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 174). Fill with charge-air coolant (→ Page 175). M015715/03E 2013-01 | Task Description | 173...

  • Page 174: Draining Charge-Air Coolant

    7.16.3 Draining charge-air coolant Preconditions ☑ Engine shut down and secured against being restarted. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 175: Charge-Air Coolant – Filling

    7.16.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
  • Page 176 Filling with coolant using a pump Connect a suitable pump with a hose to the drain valve (arrowed). Undo the vent line union at the distributor piece (arrowed). Open drain valve and pump coolant into en- gine at 0.5 bar minimum. Tighten the union (arrowed) if coolant leaks out at the loose union.
  • Page 177 Alternatively: Filling with cool- ant through filler neck Undo the vent line union at the distributor piece (arrowed). Top up coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. Tighten the union (arrowed) if coolant leaks out at the loose union.

  • Page 178: Charge-Air Coolant Pump – Relief Bore Check

    7.16.5 Charge-air coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 179: Engine Mounting / Support

    7.17 Engine Mounting / Support 7.17.1 Engine mounting – Check Engine mounting – Check Item Findings Action Visually inspect mounts. • Damage Replace (contact Service). • Brittleness • Deformation • Crack formation • Swelling visible M015715/03E 2013-01 | Task Description | 179...

  • Page 180: Belt Drive

    7.18 Belt Drive 7.18.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt Belt is oily, shows signs of over- Replace (→...

  • Page 181: Battery-Charging Generator

    7.19 Battery-Charging Generator 7.19.1 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60-320 Nm F30452768 Ratchet F30027341 Torque wrench, 10-60 Nm F30452769 Ratchet F30027340...
  • Page 182 Install protective cover. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 183). 182 | Task Description | M015715/03E 2013-01...

  • Page 183: Battery-Charging Generator Drive – Drive Belt

    7.19.2 Battery-charging generator drive – Drive belt tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60-320 Nm F30452768 Ratchet F30027341 Torque wrench, 10-60 Nm F30452769 Ratchet F30027340 WARNING...

  • Page 184: Wiring (General) For Engine/Gearbox/Unit

    7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

  • Page 185: Accessories For (Electronic) Engine

    7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 CDC parameters – Reset with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Resetting CDC parameters (DiaSys® is available) Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer ap- plicable.

  • Page 186: Engine Governor And Connectors – Cleaning

    7.21.2 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent.

  • Page 187: Engine Governor Plug Connections – Check

    7.21.3 Engine governor plug connections – Check Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test plugs to check the connections. Never use test leads. Otherwise, the contacts might be bent. Engine governor plug connections – Check Check all plug connections for secure seating.

  • Page 188: Ecu 7 Engine Governor – Removal And

    7.21.4 ECU 7 engine governor – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. CAUTION Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.

  • Page 189: Appendix A

    Abgasturbolader Exhaust turbocharger Backup Data Module Data backup module Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica- tion No. A01061/.. Controller Area Network Data bus system, bus standard CaPoS Capacitor Power System Starting system based on capacitors Calibration Drift Compensation Resets the drift correction with DiaSys®...
  • Page 190 Abbre- Meaning Explanation viation Initial Injector Equalization Input of the injector code with DiaSys® in engine governor to ensure optimum emission and consump- tion behavior International Organization for Standardiza- International umbrella organization for all national tion standardization institutes Integrated Test System Kraftgegenseite Engine free end in accordance with DIN ISO 1204 Kraftseite...

  • Page 191: Mtu Contact Persons/Service Partners

    Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –...

  • Page 192: Appendix B

    9 Appendix B 9.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 120) Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 123) Box wrench socket, 24mm Part No.: F30039526 Qty.: Used in:...
  • Page 193 Feeler gauge Part No.: Y20098771 Qty.: Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 130) Filter wrench Part No.: F30379104 Qty.: Used in: 7.8.1 Fuel filter – Replacement (→ Page 141) Qty.: Used in: 7.14.1 Engine oil filter – Replacement (→ Page 159) Installation/removal tool Part No.: F6789889...
  • Page 194 MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.13.3 Engine oil – Sample extraction and analysis (→ Page 158) Qty.: Used in: 7.15.6 Engine coolant – Sample extraction and analysis (→ Page 171) Ratchet Part No.: F30027340 Qty.: Used in: 7.3.1 Crankcase breather –...
  • Page 195 Steam jet cleaner Part No.: Qty.: Used in: 4.11 Plant cleaning (→ Page 65) Torque wrench, 0.5-5 Nm Part No.: 0015384230 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 135) Torque wrench, 10-60 Nm Part No.: F30510423 Qty.: Used in: 1.4 Crankshaft transport locking device (→...
  • Page 196 Torque wrench, 4-20Nm Part No.: F30044239 Qty.: Used in: 7.10.3 Air filter – Removal and installation (→ Page 152) Torque wrench, 40-200 Nm Part No.: F30027337 Qty.: Used in: 7.13.2 Engine oil – Change (→ Page 156) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.:...
  • Page 197 Torque wrench, 60-320 Nm Part No.: F30047446 Qty.: Used in: 1.4 Crankshaft transport locking device (→ Page 8) M015715/03E 2013-01 | Appendix B | 197...

  • Page 198: Index

    9.2 Index Numerics Crankshaft transport locking device  – Removal/installation  8 20 V 4000 Gx3 engine data  Cylinder   – Continuous operation, unrestricted 3A   – Designation  18 – Optimized fuel consumption  24 Cylinder head cover  – Continuous operation, variable 3B   –...
  • Page 199 – Lubrication  129 – Checking condensate drain for obstructions  149 Wiring - engine  – Check  184 Maintenance task reference table [QL1] 66 MTU contact persons 191 Oil indicator filter  – Check  160 Operational checks  60 Overview  – Sensors, actuators and injectors  21 PAU ...

This manual is also suitable for:

20 v 4000 g2320 v 4000 g63l20 v 4000 g8320 v 4000 g83l20 v 4000 g63

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