Diesel engine 12 V 4000 G21R, 12 V 4000 G41R. Operating Instructions (2011)

Table of Contents

1 Safety

4.5 Operational checks

4.6 Stop engine in manual mode (testing

1.1 General conditions

mode)

1.2 Personnel and organizational requirements

4.7 Emergency stop

1.3 Transport

4.8 After stopping the engine - Engine remains

1.4 Crankshaft transport locking device

ready for operation

1.5 Safety regulations for startup and operation

4.9 After stopping the engine - putting the

1.6 Explosion hazard when removing

engine out of service

inspection port cover on engine

4.10 Plant - Cleaning

1.7 Safety regulations for maintenance and

repair work

1.8 Fluids and lubricants, fire prevention and

environmental protection

5 Maintenance

1.9 Conventions for safety instructions in the

5.1 Maintenance task reference table [QL1]

text

6 Troubleshooting

2 General Information

6.1 Troubleshooting

2.1 Engine side and cylinder designations

6.2 Fault messages on engine governor

2.2 Engine layout

7 Task Description

3 Technical Data

7.1 Engine

3.1 12V 4000 engine data, continuous

7.1.1

Engine - Barring manually

operation, variable 3B, optimized fuel

7.1.2

Engine - Barring with starting system

consumption

7.1.3

Engine - Test run

3.2 12V 4000 engine data, continuous

operation, variable 3B, emissions optimized

7.2 Cylinder Liner

w/o certificate

7.2.1

Cylinder liner - Endoscopic examination

7.2.2

Cylinder liner - Instructions and comments on

3.3 12V 4000 engine data, continuous

endoscopic and visual examination

operation, variable 3B, emissions optimized

(TA-Luft)

7.3 Crankcase Breather

3.4 Final compression pressure

7.3.1

Crankcase breather - Oil separator

3.5 Firing order

replacement, diaphragm check and

3.6 Engine - Main dimensions

replacement

7.4 Valve Drive

7.4.1

Valve gear - Lubrication

4 Operation

7.4.2

Valve clearance - Check and adjustment

7.4.3

Cylinder head cover - Removal and

4.1 Putting the engine into operation after

installation

extended out-of-service periods (>3

7.5 Injection Pump / HP Pump

months)

7.5.1

HP pump - Relief bore check

4.2 Putting the engine into operation after

scheduled out-of-service-period

7.6 Injection Valve / Injector

4.3 Start engine in manual mode (testing

7.6.1

Injector - Replacement

mode)

7.6.2

Injector - Removal and installation

4.4 Starting the engine in emergency situations

7.7 Fuel System

(override mode)

7.7.1

Fuel system - Venting

MS150064/01E 2011-11 | Table of Contents | 5

7.15.6

Coolant - Sample extraction and analysis

112

7.8 Fuel Filter

7.8.1

Fuel filter - Replacement

7.16 Low-Temperature Circuit

113

7.8.2

Fuel prefilter cleaning

7.16.1

Charge-air coolant - Level check

113

7.8.3

Fuel prefilter - Differential pressure gauge

7.16.2

Charge-air coolant - Change

114

check and adjustment

7.16.3

Charge-air coolant - Draining

115

7.8.4

Fuel prefilter - Draining

7.16.4

Charge-air coolant - Filling

116

7.8.5

Fuel prefilter - Flushing

7.16.5

Charge-air coolant - Sample extraction and

7.8.6

Fuel prefilter - Filter element replacement

analysis

119

7.16.6

Charge-air coolant pump - Relief bore check

120

7.9 Charge-Air Cooling

7.9.1

Intercooler - Check drain for coolant leakage

7.17 Belt Drive

121

and obstruction

7.17.1

Drive belt - Condition check

121

7.10 Air Filter

7.18 Battery-Charging Generator

122

7.10.1

Air filter - Replacement

7.18.1

Battery-charging generator drive - Drive belt

7.10.2

Air filter - Removal and installation

tension adjustment

122

7.18.2

Battery-charging generator drive - Drive belt

7.11 Air Intake

tension check

123

7.11.1

Contamination indicator - Signal ring position

7.18.3

Battery-charging generator drive - Drive belt

check

replacement

124

7.12 Starting Equipment

7.19 Wiring (General) for Engine/Gearbox/Unit

125

7.12.1

Air starter - Manual operation

7.19.1

Engine wiring - Check

125

7.12.2

Starter - Condition check

7.20 Accessories for (Electronic) Engine

7.13 Lube Oil System, Lube Oil Circuit

Governor / Control System

126

7.13.1

Engine oil level - Check

7.20.1

Engine control unit and connectors - Cleaning

126

7.13.2

Engine oil - Change

7.20.2

Engine control unit plug connections - Check

127

7.13.3

Engine oil - Sample extraction and analysis

101

7.14 Oil Filtration / Cooling

102

7.14.1

Engine oil filter - Replacement

102

7.14.2

Centrifugal oil filter - Cleaning and filter

8 Appendix A

sleeve replacement

103

8.1 Abbreviations

128

7.15 Coolant Circuit, General, High-

8.2 MTU contacts/service partners

131

Temperature Circuit

105

7.15.1

Coolant level - Check

105

7.15.2

Engine coolant - Change

106

7.15.3

Engine coolant - Draining

107

9 Appendix B

7.15.4

Engine coolant - Filling

108

7.15.5

Engine coolant pump - Relief bore check

111

9.1 Special Tools

132

9.2 Index

135

6 | Table of Contents | MS150064/01E 2011-11

1 Safety

1.1

General conditions

General

In addition to the instructions in this publication, the applicable country-specific legislation and other com-

pulsory regulations regarding accident prevention and environmental protection must be observed. This

state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may

nevertheless present a risk of injury or damage in the following cases:

• Incorrect use

• Operation, maintenance and repair by unqualified personnel

• Modifications or conversions

• Noncompliance with the Safety Instructions

Correct use

The engine is intended solely for use in accordance with contractual agreements and the purpose envis-

aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no

liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user

alone.

Correct use also includes observation of and compliance with the operating instructions and mainte-

nance and repair specifications.

Modifications or conversions

Unauthorized modifications to the engine represent a safety risk.

MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or

conversions.

Spare parts

Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no

liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall

be voided in such case.

Reworking components

Repair or engine overhaul must be carried out in workshops authorized by MTU.

MS150064/01E 2011-11 | Safety

1.2

Personnel and organizational requirements

Personnel requirements

Work on the engine must only be carried out by appropriately qualified and instructed personnel.

Observe the minimum legal age.

Responsibilities of the operating, maintenance and repair personnel must be specified by the operating

company.

Organizational measures

This publication must be issued to all personnel involved in operation, maintenance, repair or transporta-

tion.

Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and

transport personnel at all times.

Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person-

nel must have read and understood the safety-relevant instructions.

This is especially important for personnel who work on the engine only on an occasional basis. These

persons shall receive repeated instruction.

Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.

Working clothes and protective equipment

Wear proper protective clothing for all work.

Depending on the kind of work, use the necessary personal protective equipment.

8 | Safety | MS150064/01E 2011-11

1.3

Transport

Engine transport

Lift the engine only with the lifting eyes provided.

Use only the transport and lifting equipment approved by MTU.

Take note of the engine center of gravity.

In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans-

port pallet or transport with equipment for heavy loads (forklift truck).

Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and

engine mounts.

Secure the engine against tilting during transportation. The engine must be especially secured against

slipping or tilting when going up or down inclines and ramps.

Setting the engine down after transport

Place the engine only on an even, firm surface.

Ensure appropriate consistency and load-bearing capacity of the ground or support surface.

Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to

do so.

MS150064/01E 2011-11 | Safety

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.

For installation and removal of the transport locking device, follow the instructions

below:

The transport locking device must remain installed as long as possible during engine installation in order

to avoid damage.

Starting or barring the engine is allowed only with the transport locking device removed. If the generator

is already mounted on the engine, ensure that the transport locking device of the generator is also re-

moved.

Prior to every engine transport, the transport locking device must be reinstalled on both sides according

to the instructions.

If the engine is to be moved together with the generator, the transport locking device for the generator

must also be installed.

Removing guard plates and engine

mounting brackets (if applicable)

on driving end (KS)

Remove screws (4) om both sides and take

off with washers (3), guard plates (1) and

engine mounting brackets (2).

Store the removed parts of the transport

locking device carefully for possible reuse.

10 | Safety | MS150064/01E 2011-11

Fitting the transport locking device

on driving end (KS)

Note:

Always use the screws supplied with or installed in the transport locking device to secure it on the en-

gine.

Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel

housing and tighten to the specified tightening torque.

Name

Size

Type

Lubricant

Value/Standard

Screw

M16

Tightening torque

(Engine oil)

250 Nm +25 Nm

Screw nut (3) onto screws (4) up to the end of the thread.

Fit the locks (1) through the openings of plates (2) and fasten with the screws (4).

Tighten screws (4) alternately with torque wrench to the specified tightening torque.

Name

Size

Type

Lubricant

Value/Standard

Screw

M10

Tightening torque

(Engine oil)

30 Nm +3 Nm

Screw on nuts (3) of both screws (4) at plates (2) and secure.

Fit label (7) to mark the engine as "Fitted with transport locking device".

Removing the transport locking

device from driving end (KS)

Release the locknuts (3) on both sides of

the flywheel housing, remove screws (4)

and take off the two locks (1).

Remove screws (6) with washers (5), label

(7) and plates (2)..

Store the removed parts of the transport

locking device carefully for possible reuse.

MS150064/01E 2011-11 | Safety

1.5

Safety regulations for startup and operation

Safety requirements for initial operation

Prior to initial operation of the unit, install the assembly or unit according to the specifications and check

the installation according to the MTU specifications.

Before putting the device or plant into operation, always ensure:

• that all maintenance and repair work is completed,

• that all loose parts have been removed from rotating machine components,

• that nobody is in the danger area of moving machine parts.

Immediately after putting the device or plant into operation, make sure that all control and display instru-

ments as well as the signaling and alarm systems work properly.

Safety requirements for operators

The procedures for cases of emergency must be practiced regularly.

The operator must be familiar with the control and display elements.

The operator must be familiar with the consequences of any operations performed.

During operation, the display instruments and monitoring units must be permanently observed with re-

gard to present operating status, violation of limit values and warning or alarm messages.

The following steps must be taken if a malfunction of the system is recognized or reported by the system:

• inform supervisor(s) in charge,

• analyze the message,

• if required, carry out emergency operations e.g. emergency engine stop.

Engine operation

The following conditions must be fulfilled before starting the engine:

• Wear ear protection.

• Ensure that the engine room is well ventilated.

• Do not inhale engine exhaust gases.

• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.

• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.

• Protect battery terminals, battery-charger terminals and cables against accidental contact.

• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.

Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.

Observe the safety instructions for these devices.

MS150064/01E 2011-11 | Safety

1.7

Safety regulations for maintenance and repair work

Have maintenance and repair work carried out by qualified and authorized personnel only.

Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).

Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.

Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug

with a rag to prevent fluids escaping under pressure.

Take special care when draining hot fluids ⇒ Risk of injury.

When changing the engine oil or working on the fuel system, ensure that the engine room is adequately

ventilated.

Allow the engine / system to cool down before starting to work.

Observe the maintenance and repair instructions.

Never carry out maintenance and repair work with the engine running unless expressly instructed to do

so.

Secure the engine against accidental starting.

Disconnect the battery when electrical starters are fitted.

Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic

starters are fitted.

Disconnect the control equipment from the assembly or system.

Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.

Carry out work only on assembles and/or units which are properly secured.

Never use lines for climbing.

Keep fuel injection lines and connections clean.

Always seal connections with caps or covers if a line is removed or opened.

Take care not to damage lines, in particular fuel lines, during maintenance and repair work.

Ensure that all retainers and dampers are installed correctly.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con-

tact with other components. Do not place fuel or oil lines near hot components.

Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper-

ly protected.

Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.

When working high on the engine, always use suitable ladders and work platforms. Make sure compo-

nents are placed on stable surfaces.

Observe special cleanness when conducting maintenance and repair work on the assembly or system.

After completion of maintenance and repair work, make sure that no loose objects are in/on the assem-

bly or system.

Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards

have been reinstalled and that all tools and loose parts have been removed after working on the engine.

The following additional instructions apply to starters with beryllium copper pinion:

• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz-

ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or

the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de-

vice as an additional measure.

MS150064/01E 2011-11 | Safety

Welding work

Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when

welding in its vicinity.

Do not use the assembly or system as ground terminal.

Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current

may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage

the electrical system.

Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.

Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified

devices for hydraulic removal/installation procedures.

Observe the max. permissible push-on pressure specified for the equipment.

Do not attempt to bend or apply force to lines.

Before starting work, pay attention to the following:

• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the

equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).

• For hydraulic installation, screw on the tool with the piston retracted.

• For hydraulic removal, screw on the tool with the piston extended.

For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft

end until correct sealing is established.

During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the

component to be installed/removed.

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.

De-energize the appropriate areas prior to working on assemblies.

Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during

operation by contact with sharp objects, by rubbing against other components or by a hot surface.

Do not secure cables on lines carrying fluids.

Do not use cable binders to secure cables.

Always use connector pliers to tighten connectors.

Subject the device or system to a function check on completion of all repair work.

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de-

fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par-

ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.

Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra-

diation.

Laser equipment must be fitted with the protective devices necessary for safe operation according to

type and application.

16 | Safety | MS150064/01E 2011-11

1.8

Fluids and lubricants, 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 lubri-

cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.

Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.

When starting the engine with an external 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 external power source to

the ground lead of the engine or to the ground terminal of the starter.

Always keep suitable firefighting 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 noises indicating

danger are drowned.

Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).

Environmental protection and disposal

Modification or removal of mechanical or electronic components or the installation of additional compo-

nents as well as the execution of calibration processes that might affect the emission characteristics of

the engine are prohibited by emission regulations. Emission control units/systems may only be main-

tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva-

lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act

and involves the termination of the operating license by the emission authorities. MTU does not accept

any liability for violations of the emission regulations. MTU will provide assistance and advice if emission-

relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili-

ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.

Use only fuel of prescribed quality to comply with emission limit values.

Dispose of used fluids, lubricants and filters in accordance with local regulations.

Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are

subjected to proper recycling procedures.

Fluids and lubricants

Use only fluids and lubricants that have been tested and approved by MTU.

Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and

other chemical substances, follow the safety instructions that apply to the product. Take special care

when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do

not smoke.

Used oil

Used oil contains harmful combustion residues.

Rub barrier cream into hands.

Wash hands after contact with used oil.

18 | Safety | MS150064/01E 2011-11

Lead

• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not

inhale lead vapors.

• Adopt suitable measures to avoid the formation of lead dust.

• Switch on extraction system.

• Wash hands after contact with lead or lead-containing substances.

Compressed air

Observe special safety precautions when working with compressed air:

• Pay special attention to the pressure level in the compressed air network and pressure vessel.

• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per-

mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing

valve and safety valve (set to permitted pressure) must form an intermediate connection.

• Hose couplings and connections must be securely attached.

• Wear goggles when blowing off components or blowing away chips.

• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).

• First shut off compressed air lines before compressed air equipment is disconnected from the supply

line, or before equipment or tool is to be replaced.

• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of

containers, results in a risk of explosion.

• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for

drying purposes or to check for leaks, results in a risk of bursting.

• Carry out leak test in accordance with the specifications.

Painting

• When carrying out painting work outside the spray stands provided with fume extraction systems, en-

sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.

• No open flames.

• No smoking.

• Observe fire prevention regulations.

• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen

• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.

• Avoid body contact (eyes, hands).

• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.

• Make sure that working area is well ventilated.

• Avoid all knocks and jars to the containers, fixtures or workpieces.

Acids and alkaline solutions

• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective

clothing.

• If such solutions are spilled onto clothing, remove the affected clothing immediately.

• Rinse injured parts of the body thoroughly with clean water.

• Rinse eyes immediately with eyedrops or clean tap water.

MS150064/01E 2011-11 | Safety

1.9

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.

Consequences: Minor injury or material damage

• Remedial action

Note:

This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which

begin with one of the signal words listed above depending on the severity of the hazard.

Safety instructions

Read and familiarize yourself with all safety notices before starting up or repairing the product.

Pass on all safety instructions to your operating, maintenance, repair and transport personnel.

20 | Safety | MS150064/01E 2011-11

2.2

Engine layout

Illustration valid for 8/12/16V 4000 Gxy engines

1 Coolant line

8 Air supply

16 Fuel line (low pressure)

2 Exhaust system

9 Starting equipment

17 Lube oil filter

3 Exhaust turbocharger

10 Oil filler neck

18 Fuel pump (high pres-

4 Air intake

11 Mounting / support

sure)

5 Intercooler

12 Oil pan

19 Gear train

6 Engine governor

13 Fuel line (high pressure)

20 Running gear

7 PTO systems, driving end

14 Inspection port cover

21 Coolant system

and free end (coupling)

15 Cylinder head

22 Lube oil system

Engine model designation

Key to the engine model designations 8/12/16V 4000 Gxy

Designation

Meaning

8/12/16

Number of cylinders

Cylinder arrangement: V engine

4000

Series

Application

Application segment (2, 4, 6, 8)

Design index (1, 2,...)

22 | General Information | MS150064/01E 2011-11

3 Technical Data

3.1

12V 4000 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 changes (e.g. of power set-

ting)

Not yet defined value

Not applicable

Applicable

REFERENCE CONDITIONS

Engine model

12V

4000 G21R

4000 G41R

Application group

Intake air temperature

°C

Charge-air coolant temperature

°C

Barometric pressure

mbar

1000

Site altitude above sea level

100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)

Number of cylinders

Engine rated speed

rpm

1500

1800

Continuous power ISO 3046 (10%

1102

1246

overload capability) (design power

DIN 6280, ISO 8528)

GENERAL CONDITIONS (for maximum power)

Number of cylinders

Intake air depression (new filter)

mbar

Intake air depression, max.

mbar

Exhaust pressure

mbar

Exhaust pressure, max.

mbar

MS150064/01E 2011-11 | Technical Data | 23

CONSUMPTION

Number of cylinders

Lube oil consumption after engine

% of B

0.5

run-in (B = hourly fuel consumption)

MODEL RELATED DATA (basic design)

Number of cylinders

Cylinder arrangement: V angle

Degrees (°)

Bore

165

Stroke

190

Displacement per cylinder

liter

4.06

Displacement, total

liter

48.7

65.0

Compression ratio

15.5

Number of inlet valves per cylinder

Number of exhaust valves per cylin-

der

Standard flywheel housing flange (en-

SAE

gine main PTO)

COMBUSTION AIR / EXHAUST GAS

Number of cylinders

Charge air pressure before cylinder,

bar ABS

2.4

2.8

COOLING SYSTEM (HT circuit)

Number of cylinders

Coolant temperature (at engine outlet

°C

to cooling equipment)

Coolant temperature after engine,

°C

alarm

Coolant temperature after engine,

°C

shutdown

Coolant antifreeze content, max.

Pressure loss in external raw water

bar

0.7

system, max.

COOLING SYSTEM (LT circuit)

Number of cylinders

Coolant temperature before intercool-

°C

er (at engine inlet from cooling equip-

ment)

Coolant antifreeze content, max.

Pressure loss in external raw water

bar

0.7

system, max.

24 | Technical Data | MS150064/01E 2011-11

LUBE OIL SYSTEM

Number of cylinders

Lube oil temperature before engine,

°C

from

Lube oil operating temperature before

°C

engine, to

Lube oil temperature before engine,

°C

alarm

Lube oil operating pressure before

bar

5.0

engine, from

Lube oil operating pressure before

bar

6.0

engine, to

Lube oil pressure before engine,

bar

4.5

alarm

Lube oil pressure before engine,

bar

4.0

shutdown

FUEL SYSTEM

Number of cylinders

Fuel pressure at supply connection to

bar

-0.1

engine, min. (when engine is starting)

Fuel pressure at engine supply con-

bar

1.5

nection, max. (when engine is start-

ing)

GENERAL OPERATING DATA

Number of cylinders

Cold start capability: air temperature

°C

(w/o start aid, w/o preheating) (case

Coolant preheating, preheating tem-

°C

perature (min.)

Firing speed, from

rpm

Firing speed, to

rpm

120

MS150064/01E 2011-11 | Technical Data | 25

CAPACITIES

Number of cylinders

Engine coolant capacity (without cool-

liter

160

ing equipment)

Charge-air coolant capacity, engine

liter

side

Engine oil at initial filling (standard oil

liter

260

system) (Option: max. operating incli-

nations)

Oil pan capacity at dipstick mark

liter

160

"min." (standard oil system) (Option:

max. operating inclinations)

Oil pan capacity at dipstick mark

liter

200

"max." (standard oil system) (Option:

max. operating inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders

Engine weight, dry (basic engine con-

5650

figuration acc. to scope of supply

specification)

ACOUSTICS

Number of cylinders

Exhaust noise, unsilenced, BL (free-

dB(A)

115

118

115

field sound pressure level Lp, 1m dis-

tance, ISO 6798, +3dB(A) tolerance)

Engine surface noise with attenuated

dB(A)

106

108

106

intake noise (filter), BL, (free-field

sound-pressure level Lp, 1m dis-

tance, ISO 6798+2dB(A) tolerance)

26 | Technical Data | MS150064/01E 2011-11

3.2

12V 4000 engine data, continuous operation, variable 3B,

emissions optimized w/o certificate

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 changes (e.g. of power set-

ting)

Not yet defined value

Not applicable

Applicable

REFERENCE CONDITIONS

Engine model

12V

4000 G21R

4000 G41R

Application group

Intake air temperature

°C

Charge-air coolant temperature

°C

Barometric pressure

mbar

1000

Site altitude above sea level

100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)

Number of cylinders

Engine rated speed

rpm

1800

Continuous power ISO 3046 (10% overload

1246

capability, design power DIN 6280, ISO

8528)

GENERAL CONDITIONS (for maximum power)

Number of cylinders

Intake air depression (new filter)

mbar

Intake air depression, max.

mbar

Exhaust pressure

mbar

Exhaust pressure, max.

mbar

CONSUMPTION

Number of cylinders

Lube oil consumption after engine run-in (B

% of B

0.5

= hourly fuel consumption)

MS150064/01E 2011-11 | Technical Data | 27

MODEL RELATED DATA (basic design)

Number of cylinders

Cylinder arrangement: V angle

Degrees (°)

Bore

165

Stroke

190

Displacement per cylinder

liter

4.06

Displacement, total

liter

48.7

Compression ratio

15.5

Number of inlet valves per cylinder

Number of exhaust valves per cylinder

Standard flywheel housing flange (engine

SAE

main PTO)

COMBUSTION AIR / EXHAUST GAS

Number of cylinders

Charge air pressure before cylinder, BL

bar ABS

3.1

COOLING SYSTEM (HT circuit)

Number of cylinders

Coolant temperature (at engine outlet to

°C

cooling equipment)

Coolant temperature after engine, alarm

°C

Coolant temperature after engine, shutdown

°C

Coolant antifreeze content, max.

Pressure loss in external raw water system,

bar

0.7

max.

COOLING SYSTEM (LT circuit)

Number of cylinders

Coolant temperature before intercooler (at

°C

engine inlet from cooling equipment)

Coolant antifreeze content, max.

Pressure loss in external raw water system,

bar

0.7

max.

LUBE OIL SYSTEM

Number of cylinders

Lube oil temperature before engine, from

°C

Lube oil operating temperature before en-

°C

gine, to

Lube oil temperature before engine, alarm

°C

Lube oil operating pressure before engine,

bar

5.0

from

28 | Technical Data | MS150064/01E 2011-11

Number of cylinders

Lube oil operating pressure before engine,

bar

6.0

Lube oil pressure before engine, alarm

bar

4.5

Lube oil pressure before engine, shutdown

bar

4.0

FUEL SYSTEM

Number of cylinders

Fuel pressure at supply connection to en-

bar

-0.1

gine, min. (when engine is starting)

Fuel pressure at engine supply connection,

bar

1.5

max. (when engine is starting)

GENERAL OPERATING DATA

Number of cylinders

Cold start capability: air temperature (w/o

°C

start aid, w/o preheating) (case A)

Coolant preheating, preheating temperature

°C

(min.)

Firing speed, from

rpm

Firing speed, to

rpm

120

CAPACITIES

Number of cylinders

Engine coolant capacity (without cooling

liter

160

equipment)

Charge-air coolant capacity, engine side

liter

Engine oil at initial filling (standard oil sys-

liter

260

tem) (Option: max. operating inclinations)

Oil pan capacity at dipstick mark "min."

liter

160

(standard oil system) (Option: max. operat-

ing inclinations)

Oil pan capacity at dipstick mark "max."

liter

200

(standard oil system) (Option: max. operat-

ing inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders

Engine weight, dry (basic engine configura-

5650

tion acc. to scope of supply specification)

MS150064/01E 2011-11 | Technical Data | 29

3.3

12V 4000 engine data, continuous operation, variable 3B,

emissions optimized (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 changes (e.g. of power set-

ting)

Not yet defined value

Not applicable

Applicable

REFERENCE CONDITIONS

Engine model

12V

4000 G21R

Application group

Intake air temperature

°C

Charge-air coolant temperature

°C

Barometric pressure

mbar

1000

Site altitude above sea level

100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)

Number of cylinders

Engine rated speed

rpm

1500

Continuous power ISO 3046 (10% overload capabili-

1102

ty) (design power DIN 6280, ISO 8528)

GENERAL CONDITIONS (for maximum power)

Number of cylinders

Intake air depression (new filter)

mbar

Intake air depression, max.

mbar

Exhaust pressure

mbar

Exhaust pressure, max.

mbar

CONSUMPTION

Number of cylinders

Lube oil consumption after engine run-in (B = hourly

% of B

0.5

fuel consumption)

MS150064/01E 2011-11 | Technical Data | 31

MODEL RELATED DATA (basic design)

Number of cylinders

Cylinder arrangement: V angle

Degrees (°)

Bore

165

Stroke

190

Displacement per cylinder

liter

4.06

Displacement, total

liter

48.7

Compression ratio

15.5

Number of inlet valves per cylinder

Number of exhaust valves per cylinder

Standard flywheel housing flange (engine main PTO)

SAE

COMBUSTION AIR / EXHAUST GAS

Number of cylinders

Charge air pressure before cylinder, BL

bar ABS

3.0

COOLING SYSTEM (HT circuit)

Number of cylinders

Coolant temperature (at engine outlet to cooling

°C

equipment)

Coolant temperature after engine, alarm

°C

Coolant temperature after engine, shutdown

°C

Coolant antifreeze content, max.

Pressure loss in external raw water system, max.

bar

0.7

COOLING SYSTEM (LT circuit)

Number of cylinders

Coolant temperature before intercooler (at engine in-

°C

let from cooling equipment)

Coolant antifreeze content, max.

Pressure loss in external raw water system, max.

bar

0.7

LUBE OIL SYSTEM

Number of cylinders

Lube oil temperature before engine, from

°C

Lube oil operating temperature before engine, to

°C

Lube oil temperature before engine, alarm

°C

Lube oil operating pressure before engine, from

bar

5.0

Lube oil operating pressure before engine, to

bar

6.0

Lube oil pressure before engine, alarm

bar

4.5

Lube oil pressure before engine, shutdown

bar

4.0

32 | Technical Data | MS150064/01E 2011-11

FUEL SYSTEM

Number of cylinders

Fuel pressure at supply connection to engine, min.

bar

-0.1

(when engine is starting)

Fuel pressure at engine supply connection, max.

bar

1.5

(when engine is starting)

GENERAL OPERATING DATA

Number of cylinders

Cold start capability: air temperature (w/o start aid, w/

°C

o preheating) (case A)

Coolant preheating, preheating temperature (min.)

°C

Firing speed, from

rpm

Firing speed, to

rpm

120

CAPACITIES

Number of cylinders

Engine coolant capacity (without cooling equipment)

liter

160

Charge-air coolant capacity, engine side

liter

Engine oil at initial filling (standard oil system) (Op-

liter

260

tion: max. operating inclinations)

Oil pan capacity at dipstick mark "min." (standard oil

liter

160

system) (Option: max. operating inclinations)

Oil pan capacity at dipstick mark "max." (standard oil

liter

200

system) (Option: max. operating inclinations)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders

Engine weight, dry (basic engine configuration acc. to

5650

scope of supply specification)

ACOUSTICS

Number of cylinders

Exhaust noise, unsilenced, BL (free-field sound pres-

dB(A)

115

sure level Lp, 1m distance, ISO 6798, +3dB(A) toler-

ance)

Engine surface noise with attenuated intake noise (fil-

dB(A)

106

ter), BL, (free-field sound-pressure level Lp, 1m dis-

tance, ISO 6798+2dB(A) tolerance)

MS150064/01E 2011-11 | Technical Data | 33

4 Operation

4.1

Putting the engine into operation after extended out-of-

service periods (>3 months)

Preconditions

☑ Engine is stopped and starting disabled.

☑ MTU Fluids and Lubricants Specification (A001061/..) is available.

Putting the engine into operation after extended out-of-service-periods (>3 months)

Item

Task

Engine

Depreserve (→ MTU Fluids and Lubricants Specification A001061/..).

Valve Gear

Lubricate valve gear (→ Page 72);

Lube oil system

Check oil level (→ Page 98);

Fuel prefilter

Prime (→ Page 90).

Fuel prefilter, pressure

Align adjustable pointer with position of pressure indicator (→ Page 86).

gauge

Fuel system

Vent (→ Page 83).

Cooling system

If engine is out of service for more than one year, change engine coolant

(→ Page 106);

Change charge-air coolant (→ Page 114).

Cooling system

Check engine coolant level (→ Page 105);

Check charge-air coolant level (→ Page 113).

Cooling system

Preheat coolant with preheating unit.

ECU

Check plug-in connections (→ Page 127).

Monitoring equipment

Carry out lamp test (see manufacturer's documentation).

Engine/generator control

Switch ON;

system

Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPER-

ATION.

MS150064/01E 2011-11 | Operation | 37

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 98);

Cooling system

Check engine coolant level (→ Page 105);

Check charge-air coolant level (→ Page 113).

Cooling system

Preheat coolant with preheating unit.

Fuel prefilter

Drain (→ Page 87).

Monitoring equipment

Carry out lamp test (see manufacturer's documentation).

Engine/generator control

Switch ON;

system

Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPER-

ATION.

38 | Operation | MS150064/01E 2011-11

4.3

Start engine in manual mode (testing mode)

Preconditions

☑ Generator (if provided) not connected to network.

☑ External start interlock is not activated.

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!

• Wear ear protectors.

Preparation

Item

Task

Operating mode selector

Change to manual mode.

switch (if provided)

Preheating pump (if provid-

Switch ON.

ed)

Starting the engine

Item

Task

Switchgear cabinet, control

If coolant temperature is

panel etc. (depending on

•

> 40 °C (with preheating equipment), or

manufacturer)

•

> 5 °C (without preheating equipment):

Press start button.

• Automatic starting sequence is performed;

• Engine speed display instrument indicates increasing crankshaft speed;

• After the starting sequence is completed, engine is running at rated

speed.

Connect generator to network (if provided), run engine to reach operating

temperature )

Item

Task

Switchgear cabinet, control

Close the generator circuit breaker.

panel etc. (depending on

manufacturer)

Engine

Apply full load only after engine has reached operating temperature (cool-

ant temperature approx. 75 °C).

MS150064/01E 2011-11 | Operation | 39

4.4

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

Control cabinet

Actuate switch/button for ECU override input.

Control cabinet

• Automatic starting procedure is performed; any safety functions and

alarms leading to engine shutdown are disregarded;

• Tachometer indicates increasing crankshaft speed;

• Engine is running at rated speed when the starting sequence is com-

pleted.

Connecting the generator (if fitted) to mains

Item

Task

Control cabinet

If generator is not connected to mains: Close generator circuit breaker.

Engine

Operate engine at rated power.

40 | Operation | MS150064/01E 2011-11

4.5

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!

• Wear ear protectors.

Operational checks

Item

Task

Control and display panels

Check indicated operating parameters (speed, temperatures, pressures).

Engine under load

Check engine/system and lines for leak-tightness, perform maintenance

work on lines showing leakage while motor is turned off (exhaust mani-

Engine at nominal speed

folds and turbocharger turbine housing may be glowing with heat. If maxi-

mum exhaust temperatures are within the limit, restricted engine operation

is not required);

Check for abnormal running noises and vibrations.

HP pump

Check relief bore (→ Page 76).

Fuel prefilter

Check if suction-side pressure indicated at the fuel prefilter pressure

gauge is within the limit (→ Page 86).

Exhaust system

Check exhaust color (→ Page 48).

Intercooler

Check condensate drain(s) for water discharge and obstruction

(→ Page 92).

Air filter

Check signal ring position of service indicator (→ Page 95);

Replace air filter (→ Page 93), if the signal ring is completely visible in the

service indicator control window.

Engine coolant pump

Check relief bore (→ Page 111).

Charge-air coolant pump

Check relief bore (→ Page 120).

Compressed-air system (if

Check operating pressure at pressure gauge.

installed)

Fill compressed-air tank to maximum pressure.

Drain condensate from compressed-air tank, pressure drop must not ex-

ceed 1 bar.

MS150064/01E 2011-11 | Operation | 41

4.6

Stop engine in manual mode (testing mode)

Preconditions

☑ Generator (if provided) 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!

• Before stopping the engine, operate it at idle speed until operating temperatures decrease and

stable values are indicated.

Preparing the generator drive (only with generator breaker)

Item

Task

Engine

After opening the generator breaker (if provided), allow to cool down off-

load for approx. 5 minutes.

Preparing the pump drive (diesel-mechanical/diesel-electric)

Item

Task

Engine

Allow to cool down for approx. 5 minutes at reduced engine speed. Ob-

serve natural resonance of engine (installation-dependent)!

Stopping the engine

Item

Task

Switchgear cabinet, control

Press stop button.

panel etc. (depending on

• Automatic stopping sequence is performed;

manufacturer)

• Engine is stopped.

After stopping the engine

Item

Task

Coolant pump

Allow to run on for sufficient time after stopping.

42 | Operation | MS150064/01E 2011-11

4.9

After stopping the engine - putting the engine out of service

Preconditions

☑ MTU Fluids and Lubricants Specifications (A001061/..) is available.

After stopping the engine

Item

Task

Cooling system

Drain engine coolant (→ Page 107);

Drain charge-air coolant (→ Page 115) if:

• freezing temperatures are expected and the engine is to remain out of

service for an extended period and coolant has no antifreeze additive;

• the engine room is not heated;

• the coolant is not maintained at a suitable temperature;

• the antifreeze concentration is insufficient for the engine-room tempera-

ture;

• antifreeze concentration is 50 % and engine-room temperature is below

-40°C.

Engine/generator/pump

Switch OFF.

controller

Air intake and exhaust sys-

If the engine is to remain out of service for more than 1 week, seal the

tem

engine's air and exhaust sides. If the engine is to remain out of service for

more than 1 month, preserve engine (→ MTU Fluids and Lubricants Speci-

fications A001061/.. ).

MS150064/01E 2011-11 | Operation | 45

4.10

Plant - Cleaning

Preconditions

☑ Engine is stopped and starting disabled.

☑ Operating voltage is not applied.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Steam jet cleaner

Cleaner (Hakupur 312)

30390

WARNING

Compressed air

Risk of injury!

• Do not direct compressed-air jet at persons.

• Wear protective goggles / safety mask and ear protectors.

WARNING

Water jet.

Risk of injury and scalding!

• Do not direct water jet at persons.

• Wear protective clothing, gloves, and goggles / safety mask.

CAUTION

Excessive reaction time of cleaning agents on components.

Damage to component!

• Observe manufacturer's instructions.

• Wear protective clothing, gloves, and goggles / safety mask.

Note:

There is a risk of damaging sensors with compressed air.

Plant - Cleaning

Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro-

tection).

Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit

carefully and observe the safety precautions.

For external cleaning with high-pressure jet, use a flat-mouth nozzle only.

Carry out external cleaning as follows:

a) Remove coarse dirt.

b) Spray on cleaner sparingly and leave it for 1 to 5 minutes.

c) Use the high-pressure jet to remove the loosened dirt.

d) During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet

(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m

must be observed. The temperature of the cleaning medium must not exceed 80 °C.

46 | Operation | MS150064/01E 2011-11

5 Maintenance

5.1

Maintenance task reference table [QL1]

The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The

Maintenance Schedule is a stand-alone publication.

The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance

Schedule.

Task

Maintenance tasks

W0500

Check engine oil level

(→ Page 98)

W0501

Visually inspect engine for leaks and general condition

(→ Page 41)

W0502

Check intercooler drain (if fitted)

(→ Page 92)

W0503

Check signal ring position of service indicator on air filter

(→ Page 95)

W0504

Check HP fuel pump weep holes

(→ Page 41)

W0505

Check relief bores of coolant pump(s)

(→ Page 111)

W0506

Check engine for abnormal running noises, exhaust color

(→ Page 41)

and vibrations

W0507

Drain water and contaminants from fuel prefilter (if fitted)

(→ Page 41)

W0508

Check reading on differential pressure gauge of fuel prefilter

(→ Page 41)

(if fitted)

W0534

Carry out test run, minimum duration: until steady-state tem-

(→ Page 65)

perature is reached, no less than 1/3 load (monthly)

W1001

Replace fuel filter or fuel filter element

(→ Page 84)

W1002

Check valve clearance

(→ Page 73)

W1003

Check drive belt condition and tension, replace if necessary

(→ Page 121)

W1005

Replace air filter

(→ Page 93)

W1006

Replace fuel injectors

(→ Page 77)

W1008

Replace engine oil filter at each oil change or when the time

(→ Page 102)

limit (years) is reached, at the latest

W1009

Check layer thickness of oil residue, clean and replace filter

(→ Page 103)

sleeve (if fitted)

W1011

Perform endoscopic inspection of combustion chambers

(→ Page 66)

W1046

Crankcase breather: Replace filter or filter element

(→ Page 70)

Table 1: Maintenance task reference table [QL1]

MS150064/01E 2011-11 | Maintenance | 47

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 proper-

ly secured (see manufacturer's docu-

mentation).

Starter (electric)

Engine wiring or starter defective

Check cable connections for secure

seating,

Contact Service.

Starter (compressed

Cabling on starting valve or starter de-

Check cable connections for secure

air)

fective

seating,

Contact Service.

Engine wiring

Defective

Check (→ Page 125).

Engine/generator

Secure seating of assemblies or con-

Perform visual inspection (see manu-

control system

nectors not provided

facturer's documentation).

Engine Governor

Plug-in connections are loose

Check plug connections (→ Page 127).

Engine

Running gear blocked (engine cannot

Contact Service.

be barred manually)

Engine turns but does not fire

Component

Probable cause

Task

Starter (electric)

Poor rotation by starter: Battery low or

Charge or replace battery (see manu-

defective

facturer's documentation).

Starter (compressed

Poor rotation by starter: Air pressure

Check compressed air system.

air)

too low

Engine wiring

Defective

Check (→ Page 125).

Fuel system

Not vented

Vent fuel system (→ Page 83).

Engine Governor

Defective

Contact Service.

Engine fires unevenly

Component

Probable cause

Task

Fuel injection equip-

Injector defective

Replace (→ Page 77).

ment

Engine wiring

Defective

Check (→ Page 125).

Fuel system

Not vented

Vent fuel system (→ Page 83).

Engine Governor

Defective

Contact Service.

48 | Troubleshooting | MS150064/01E 2011-11

Engine does not reach nominal speed

Component

Probable cause

Task

Fuel supply

Fuel prefilter clogged

Replace (→ Page 90).

Easy-change fuel filter clogged

Replace (→ Page 84).

Air supply

Air filter clogged

Check signal ring position of service in-

dicator (→ Page 95).

Fuel injection equip-

Injector defective

Replace (→ Page 77).

ment

Engine wiring

Defective

Check (→ Page 125).

Engine

Overloaded

Contact Service.

Engine speed not steady

Component

Probable cause

Task

Fuel injection equip-

Injector defective

Replace (→ Page 77).

ment

Speed sensor

Defective

Contact Service.

Fuel system

Not vented

Vent fuel system (→ Page 83).

Engine Governor

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

Component

Probable cause

Task

Air supply

Air filter clogged

Check signal ring position of service in-

dicator (→ Page 95).

Intercooler

Contaminated

Contact Service.

Exhaust turbocharger

Defective

Contact Service.

Coolant leaks on intercooler

Component

Probable cause

Task

Intercooler

Leaking, major coolant discharge

Contact Service.

Exhaust gas black

Component

Probable cause

Task

Air supply

Air filter clogged

Check signal ring position of service in-

dicator (→ Page 95).

Fuel injection equip-

Injector defective

Replace (→ Page 77).

ment

Engine

Overloaded

Contact Service.

MS150064/01E 2011-11 | Troubleshooting | 49

6.2

Fault messages on engine governor

The engine governor generates alarms which are indicated in different ways depending on the equip-

ment configuration:

• as four-digit code on a PIM

• as alarm text on a display

• as four-digit code on a dialog PC

The four-digit code consists of one letter and three figures:

• The letter encodes when the fault occurred the last time:

A = currently present

B = within the last operating hour

C = one to four operating hours ago

D = four to twelve operating hours ago

Alarms that occurred more than twelve hours ago are deleted automatically.

• The three figures encode the fault itself as listed in the table below.

Alarms can also be caused by defective sensors / actuators. If troubleshooting in accordance with the

following table is not successful, contact Service to have the sensors / actuators checked and, if re-

quired, replaced.

Fault

Alarm text

Meaning

Task

code

005

L1 T-CHARGE

Charge-air temperature too

Reduce power. Change over to idle and

AIR

high (1st limit value)

contact Service.

006

L2 T-CHARGE

Charge-air temperature too

Reduce power. Change over to idle and

AIR

high (2nd limit value)

contact Service.

009

L1 T-INTER-

Charge-air coolant tempera-

Reduce power. Change over to idle and

COOLER

ture too high (1st limit value)

contact Service.

015

L1 P-LUBE OIL

Lube oil pressure too low (1st

Check engine-oil level and top up, if re-

limit value)

quired (→ Page 98).

016

L2 P-LUBE OIL

Lube oil pressure too low (2nd

1. Check engine-oil level and top up, if

limit value)

required (→ Page 98).

2. Try to re-start the engine

automatic engine shutdown

(→ Page 39).

3. Contact Service.

MS150064/01E 2011-11 | Troubleshooting | 51

Fault

Alarm text

Meaning

Task

code

023

L1 COOLANT

Engine coolant level too low

Check coolant level and top up, if re-

LEVEL

quired (→ Page 105).

024

L2 COOLANT

Engine coolant level too low

Check coolant level and top up, if re-

LEVEL

quired (→ Page 105).

030

ENGINE OVER-

Engine overspeed; automatic

1. Acknowledge alarm.

SPEED

engine shutdown

2. Try to re-start the engine

(→ Page 39).

3. Contact Service.

044

L1 LEVEL IN-

Charge-air coolant level too

Check coolant level and top up, if re-

TERCOOLER

low (1st limit value)

quired (→ Page 113).

045

L2 LEVEL IN-

Charge-air coolant level too

1. Check coolant level and top up, if re-

TERCOOLER

low (2nd limit value)

quired (→ Page 113).

2. If fault occurs repeatedly: Contact

Service.

051

L1 T-LUBE OIL

Lube oil temperature too high

Reduce power. Change over to idle and

(1st limit value)

contact Service.

052

L2 T-LUBE OIL

Lube oil temperature too high

1. Reduce power. Change over to idle

(2nd limit value)

and contact Service.

2. If fault occurs repeatedly: Contact

Service.

065

L1 P-FUEL

Fuel supply pressure too low

1. Check fuel lines for leaks; repair de-

(1st limit value)

fective lines.

2. Clean fuel prefilter (→ Page 85);

3. Flush fuel prefilter (→ Page 88);

4. Replace filter element of fuel prefilter

(→ Page 90);

5. Replace fuel filter (→ Page 84);

6. If fault is not rectified: Contact Serv-

ice.

066

L2 P-FUEL

Fuel supply pressure too low

1. Check fuel lines for leaks; repair de-

(2nd limit value)

fective lines.

2. Clean fuel prefilter (→ Page 85);

3. Flush fuel prefilter (→ Page 88);

4. Replace filter element of fuel prefilter

(→ Page 90);

5. Replace fuel filter (→ Page 84);

6. If fault is not rectified: Contact Serv-

ice.

067

L1 T-COOLANT

Coolant temperature too high

Reduce power. Change over to idle and

(1st limit value) warning

contact Service.

068

L2 T-COOLANT

Coolant temperature too high

1. Allow the engine to cool down.

(2nd limit value)

2. Check coolant cooler (elements etc.)

and clean contaminated parts (see

automatic engine shutdown

manufacturer's documentation).

3. Re-start the engine (→ Page 39);

4. If fault occurs repeatedly: Contact

Service.

069

L1 T-EXTERN 1

Violation of first limit for exter-

(Depending on the corresponding meas-

nal temperature channel 1

uring point, which is read via CAN bus)

52 | Troubleshooting | MS150064/01E 2011-11

Fault

Alarm text

Meaning

Task

code

070

L2 T-EXTERN 1

Violation of second limit for

(Depending on the corresponding meas-

external temperature channel

uring point, which is read via CAN bus)

071

L1 T-EXTERN 2

Violation of first limit for exter-

(Depending on the corresponding meas-

nal temperature channel 2

uring point, which is read via CAN bus)

072

L2 T-EXTERN 2

Violation of second limit for

(Depending on the corresponding meas-

external temperature channel

uring point, which is read via CAN bus)

073

L1 P-EXTERN 1

Violation of first limit for exter-

(Depending on the corresponding meas-

nal pressure channel 1

uring point, which is read via CAN bus)

074

L2 P-EXTERN 1

Violation of second limit for

(Depending on the corresponding meas-

external pressure channel 1

uring point, which is read via CAN bus)

075

L1 P-EXTERN 2

Violation of first limit for exter-

(Depending on the corresponding meas-

nal pressure channel 2

uring point, which is read via CAN bus)

076

L2 P-EXTERN 2

Violation of second limit for

(Depending on the corresponding meas-

external pressure channel 2

uring point, which is read via CAN bus)

077

LIM EXT.COOL-

Alarm from external coolant

(Depending on the corresponding meas-

ANT LEV.

level monitoring

uring point, which is read via CAN bus)

078

LIM INTER-

Alarm from external charge-air

(Depending on the corresponding meas-

COOLER LEV.

coolant level monitoring

uring point, which is read via CAN bus)

079

L Bin-EXTERN 3

Alarm from external binary

(Depending on the corresponding meas-

channel 3

uring point, which is read via CAN bus)

080

L Bin-EXTERN 4

Alarm from external binary

(Depending on the corresponding meas-

channel 4

uring point, which is read via CAN bus)

081

RAIL LEAKAGE

HP fuel system leaking, sys-

Contact Service.

tem contains air

082

RAIL PRESSURE

Pressure in HP fuel system

Contact Service.

HIGH

exceeds specified value;

Solenoid valve of HP fuel con-

trol block jamming or wiring to

solenoid valve defective

083

RAIL PRESSURE

Pressure in HP fuel system

Contact Service.

LOW

lower than the specified value;

HP fuel control block defective

or system leaking

NOTE:

With very large generators

having a run-out time of more

than > 20 sec this alarm is not

a relevant fault.

089

ENGINE SPEED

Engine speed lower than 200

Re-start the engine (→ Page 39);

LOW

rpm;

automatic engine shutdown

090

IDLE SPEED

Idle speed not reached within

Note further alarms.

LOW

a specified period;

Termination of starting proce-

dure.

MS150064/01E 2011-11 | Troubleshooting | 53

Fault

Alarm text

Meaning

Task

code

091

RUN UP SPEED

Run-up speed not reached

Note further alarms.

LOW

within a specified period;

Termination of starting proce-

dure.

092

START SPEED

Starter speed not reached

Note further alarms.

LOW

within a specified period;

Termination of starting proce-

dure.

093

PREHEAT

Coolant preheating tempera-

Check preheating pump / preheating sys-

TEMP. LIMIT2

ture too low during start (2nd

tem (see manufacturer's documentation).

limit value);

Termination of starting proce-

dure (depending on project

design)

094

PREHEAT

Coolant preheating tempera-

Check preheating pump / preheating sys-

TEMP. LIMIT1

ture too low during start (1st

tem (see manufacturer's documentation).

limit value)

100

EDM NOT VALID

Check sum error of measur-

If fault occurs repeatedly: Contact Serv-

ing-point data in EDM

ice.

101

IDM NOT VALID

Check sum error of measur-

If fault occurs repeatedly: Contact Serv-

ing-point data in IDM

ice.

102

INVALID FUEL

Check sum error of accumu-

If fault occurs repeatedly: Contact Serv-

CONS. 1

lated fuel consumption data in

ice.

EDM (redundant data record

103

INVALID FUEL

Check sum error of accumu-

If fault occurs repeatedly: Contact Serv-

CONS. 2

lated fuel consumption data in

ice.

EDM (redundant data record

104

OP HOURS1

Check sum error of hour me-

If fault occurs repeatedly: Contact Serv-

NOT VALID

ter data in EDM

ice.

105

OP HOURS2

Check sum error of hour me-

If fault occurs repeatedly: Contact Serv-

NOT VALID

ter data in IDM

ice.

106

ERR REC1 NOT

Check sum error of fault mem-

If fault occurs repeatedly: Contact Serv-

VALID

ory in EDM (redundant data

ice.

record 1)

107

ERR REC2 NOT

Check sum error of fault mem-

If fault occurs repeatedly: Contact Serv-

VALID

ory in EDM (redundant data

ice.

record 2)

118

L1 SUPPLY

Supply voltage too low (1st

Check engine governor supply voltage.

VOLT. LOW

limit value)

119

L2 SUPPLY

Supply voltage too low (2nd

Check engine governor supply voltage.

VOLT. LOW

limit value)

120

L1 SUPPLY

Supply voltage too high (1st

Check engine governor supply voltage.

VOLT. HIGH

limit value)

54 | Troubleshooting | MS150064/01E 2011-11

Fault

Alarm text

Meaning

Task

code

121

L2 SUPPLY

Supply voltage too high (2nd

Check engine governor supply voltage.

VOLT. HIGH

limit value);

If engine was stopped: Start engine

automatic engine shutdown

(→ Page 39).

(depending on project design)

122

L1 T-ELEC-

Temperature in engine gover-

1. Improve engine room ventilation.

TRONIC

nor housing too high (1st limit

2. Reduce engine power. Change over

value)

to idle and contact Service.

134

15V POS ECU

Electronic equipment defec-

Contact Service.

DEFECT

tive;

automatic engine shutdown

136

15V NEG ECU

Electronic equipment defec-

Contact Service.

DEFECT

tive;

automatic engine shutdown

137

L1 5V BUFFER

Power supply for pressure

1. Disconnect connectors X2 and X3

TEST

sensors defective.

from engine governor. If alarm does

not disappear: Contact Service.

2. Check wiring (pressure sensors).

3. Contact Service.

138

SENSORPO-

Power supply for pressure

1. Disconnect connectors X2 and X3

WERDEFECT

sensors defective.

from engine governor. If alarm does

not disappear: Contact Service.

2. Check wiring (pressure sensors).

3. Contact Service.

139

L1 TE BUFFER

Internal electronic fault (tem-

Contact Service.

TEST

perature sensors)

140

TE BUF. ECU

Internal electronic fault (tem-

Contact Service.

DEFECT

perature sensors)

142

BANK1 ECU DE-

Internal electronic fault;

Contact Service.

FECT

Engine does not start

144

BANK2 ECU DE-

Internal electronic fault;

Contact Service.

FECT

Engine does not start

145

15V_GOOD ECU

Electronic equipment defec-

Contact Service.

DEFECT

tive;

automatic engine shutdown

146

L1 AD-TEST1

A/D-converter supply voltage

Contact Service.

SUPPLY

too low

147

AD-TEST1 ECU

Electronic equipment defec-

Contact Service.

DEFECT

tive;

automatic engine shutdown

148

L1 AD-TEST2

A/D-converter supply voltage

Contact Service.

SUPPLY

too low

149

AD-TEST2 ECU

Electronic equipment defec-

Contact Service.

DEFECT

tive;

automatic engine shutdown

150

L1 AD-TEST3

A/D-converter supply voltage

Contact Service.

SUPPLY

too low

MS150064/01E 2011-11 | Troubleshooting | 55

Fault

Alarm text

Meaning

Task

code

151

AD-TEST3 ECU

Electronic equipment defec-

Contact Service.

DEFECT

tive;

automatic engine shutdown

170

MI MODULE

Module in maintenance pre-

Contact Service.

FAIL

dictor either defective or miss-

ing

171

MI NOT ACTIVE

Maintenance predictor no

Contact Service.

more activated

173

MODULE WRITE

EEPROM write limit reached

Contact Service.

LIMIT

180

CAN1 NODE

At least one device not detect-

1. Check wiring (CAN bus).

LOST

ed on Default CAN bus

2. Contact Service.

181

CAN2 NODE

At least one device not detect-

1. Check wiring (CAN bus).

LOST

ed on Redundant CAN bus

2. Contact Service.

182

CAN WRONG

Consistency error in CAN pa-

Contact Service.

PARAMETERS

rameters

183

CAN NO PU-DA-

Error during project design da-

Contact Service.

ta download in engine gover-

nor.

184

CAN PU-DATA

Error during project design da-

Contact Service.

EE-FAIL

ta download in EEPROMs

185

CAN LESS MAIL-

Error during CAN initialization.

Contact Service.

BOXES

186

CAN1 BUS OFF

Severe fault on Default CAN

Contact Service.

bus;

automatic change-over to Re-

dundant CAN bus

187

CAN1 ERROR

Light fault on Default CAN bus

(none)

PASSIVE

(e.g. short-time overload)

188

CAN2 BUS OFF

Severe fault on Redundant

Contact Service.

CAN bus;

automatic change-over to De-

fault CAN bus

189

CAN2 ERROR

Light fault on Redundant CAN

(none)

PASSIVE

bus (e.g. short-time overload)

201

SD T-COOLANT

Sensor defect (coolant tem-

1. Check wiring.

perature)

2. Contact Service.

202

SD T-FUEL

Sensor defect (Fuel tempera-

1. Check wiring.

ture)

2. Contact Service.

203

SD T-CHARGE

Sensor defect (charge-air

1. Check wiring.

AIR

temperature)

2. Contact Service.

205

SD T-COOLANT

Sensor defect (charge-air

1. Check wiring.

INTERC.

coolant temperature)

2. Contact Service.

208

SD P-CHARGE

Sensor defect (charge-air

1. Check wiring.

AIR

pressure)

2. Contact Service.

56 | Troubleshooting | MS150064/01E 2011-11

Fault

Alarm text

Meaning

Task

code

211

SD P-LUBE OIL

Sensor defect (lube oil pres-

1. Check wiring.

sure)

2. Contact Service.

215

SD P-RAIL FUEL

Sensor defect (common rail

1. Check wiring.

pressure);

2. Contact Service.

HP controller in emergency

mode

216

SD T-LUBE OIL

Sensor defect (lube oil tem-

1. Check wiring.

perature)

2. Contact Service.

220

SD COOLANT

Sensor defect (coolant level)

1. Check wiring.

LEVEL

2. Contact Service.

223

SD LEVEL IN-

Sensor defect (charge-air

1. Check wiring.

TERCOOLER

coolant level)

2. Contact Service.

229

SD ENG.SPEED

Sensor defect (crankshaft

1. Check wiring.

SENSORS

speed) and sensor defect

2. Contact Service.

(camshaft speed)

230

SD CRANK-

Sensor defect (crankshaft

1. Check wiring.

SHAFT SPEED

speed)

2. Contact Service.

231

SD CAMSHAFT

Sensor defect (camshaft

1. Check wiring.

SPEED

speed)

2. Contact Service.

240

SD P-FUEL

Sensor defect (fuel pressure)

1. Check wiring.

2. Contact Service.

245

SD POWER

Sensor defect (engine gover-

Contact Service.

SUPPLY

nor operating voltage)

246

SD T-ELEC-

Sensor defect (temperature in

Contact Service.

TRONIC

engine governor)

250

SD CAN SPEED

Sensor defect (CAN nominal

1. Check speed transmitter.

DEMAND

speed demand)

2. Check wiring (CAN bus).

3. Contact Service.

266

SD SPEED DE-

Sensor defect (analog nomi-

1. Check speed transmitter.

MAND AN.

nal speed demand)

2. Check wiring.

3. Contact Service.

267

Sensor defect (analog speed

1. Check speed transmitter.

SP.DEM.TEST

demand);

2. Check wiring.

BENCH

3. Contact Service.

NOTE:

Only used in test-stand opera-

tion.

270

SD SPEED DE-

Sensor defect (frequency in-

1. Check speed transmitter.

MAND FI1

put for speed demand);

2. Check wiring.

3. Contact Service.

271

SD T-EXTERN 1

External device defective

Contact Service.

(CAN T-EXTERN 1)

272

SD T-EXTERN 2

External device defective

Contact Service.

(CAN T-EXTERN 2)

273

SD P-EXTERN 1

External device defective

Contact Service.

(CAN P-EXTERN 1)

274

SD P-EXTERN 2

External device defective

Contact Service.

(CAN P-EXTERN 2)

MS150064/01E 2011-11 | Troubleshooting | 57

Fault

Alarm text

Meaning

Task

code

275

SD EXT.COOL-

External coolant-level monitor-

Contact Service.

ANT LEVEL

ing defective (CAN)

276

SD INTERCOOL-

External charge-air coolant-

Contact Service.

ER LEVEL

level monitoring defective

(CAN)

277

SD BIN-EXTERN

External device defective

Contact Service.

(CAN BIN-EXTERN 3)

278

SD BIN-EXTERN

External device defective

Contact Service.

(CAN BIN-EXTERN 4)

301

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER A1

ice.

302

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER A2

ice.

303

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER A3

ice.

304

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER A4

ice.

305

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER A5

ice.

306

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER A6

ice.

307

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER A7

ice.

308

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER A8

ice.

309

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER A9

ice.

310

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER A10

A10

ice.

311

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER B1

ice.

312

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER B2

ice.

313

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER B3

ice.

314

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER B4

ice.

315

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER B5

ice.

316

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER B6

ice.

317

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER B7

ice.

318

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER B8

ice.

319

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER B9

ice.

58 | Troubleshooting |

MS150064/01E 2011-11

Fault

Alarm text

Meaning

Task

code

320

TIMING CYLIN-

Injection timing fault cylinder

If fault occurs repeatedly: Contact Serv-

DER B10

B10

ice.

321

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER A1

cylinder A1;

2. Contact Service.

Misfiring

322

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER A2

cylinder A2;

2. Contact Service.

Misfiring

323

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER A3

cylinder A3;

2. Contact Service.

Misfiring

324

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER A4

cylinder A4;

2. Contact Service.

Misfiring

325

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER A5

cylinder A5;

2. Contact Service.

Misfiring

326

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER A6

cylinder A6;

2. Contact Service.

Misfiring

327

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER A7

cylinder A7;

2. Contact Service.

Misfiring

328

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER A8

cylinder A8;

2. Contact Service.

Misfiring

329

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER A9

cylinder A9;

2. Contact Service.

Misfiring

330

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER A10

cylinder A10;

2. Contact Service.

Misfiring

331

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER B1

cylinder B1;

2. Contact Service.

Misfiring

332

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER B2

cylinder B2;

2. Contact Service.

Misfiring

333

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER B3

cylinder B3;

2. Contact Service.

Misfiring

MS150064/01E 2011-11 | Troubleshooting | 59

Fault

Alarm text

Meaning

Task

code

334

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER B4

cylinder B4;

2. Contact Service.

Misfiring

335

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER B5

cylinder B5;

2. Contact Service.

Misfiring

336

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER B6

cylinder B6;

2. Contact Service.

Misfiring

337

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER B7

cylinder B7;

2. Contact Service.

Misfiring

338

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER B8

cylinder B8;

2. Contact Service.

Misfiring

339

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER B9

cylinder B9;

2. Contact Service.

Misfiring

340

WIRING CYLIN-

Faulty wiring to solenoid valve

1. Check wiring.

DER B10

cylinder B10;

2. Contact Service.

Misfiring

341

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. A1

enoid valve cylinder A1;

2. Contact Service.

Misfiring

342

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. A2

enoid valve cylinder A2;

2. Contact Service.

Misfiring

343

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. A3

enoid valve cylinder A3;

2. Contact Service.

Misfiring

344

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. A4

enoid valve cylinder A4;

2. Contact Service.

Misfiring

345

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. A5

enoid valve cylinder A5;

2. Contact Service.

Misfiring

346

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. A6

enoid valve cylinder A6;

2. Contact Service.

Misfiring

347

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. A7

enoid valve cylinder A7;

2. Contact Service.

Misfiring

60 | Troubleshooting | MS150064/01E 2011-11

Fault

Alarm text

Meaning

Task

code

348

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. A8

enoid valve cylinder A8;

2. Contact Service.

Misfiring

349

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. A9

enoid valve cylinder A9;

2. Contact Service.

Misfiring

350

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. A10

enoid valve cylinder A10;

2. Contact Service.

Misfiring

351

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. B1

enoid valve cylinder B1;

2. Contact Service.

Misfiring

352

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. B2

enoid valve cylinder B2;

2. Contact Service.

Misfiring

353

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. B3

enoid valve cylinder B3;

2. Contact Service.

Misfiring

354

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. B4

enoid valve cylinder B4;

2. Contact Service.

Misfiring

355

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. B5

enoid valve cylinder B5;

2. Contact Service.

Misfiring

356

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. B6

enoid valve cylinder B6;

2. Contact Service.

Misfiring

357

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. B7

enoid valve cylinder B7;

2. Contact Service.

Misfiring

358

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. B8

enoid valve cylinder B8;

2. Contact Service.

Misfiring

359

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. B9

enoid valve cylinder B9;

2. Contact Service.

Misfiring

360

OPEN_LOAD

Disconnection in wiring to sol-

1. Check wiring.

CYL. B10

enoid valve cylinder B10;

2. Contact Service.

Misfiring

361

POWER STAGE

Defect in engine governor

Contact Service.

FAIL 1

(solenoid valve power stage)

362

POWER STAGE

Defect in engine governor

Contact Service.

FAIL 2

(solenoid valve power stage)

MS150064/01E 2011-11 | Troubleshooting | 61

Fault

Alarm text

Meaning

Task

code

363

STOP POWER

Solenoid valve or wiring or en-

1. Check wiring.

STAGE 1

gine governor defective

2. Try to re-start the engine

(→ Page 39).

automatic engine shutdown

3. Contact Service.

364

STOP POWER

Solenoid valve or wiring or en-

1. Check wiring.

STAGE 2

gine governor defective

2. Try to re-start the engine

(→ Page 39).

automatic engine shutdown

3. Contact Service.

365

STOP MV-WIR-

Solenoid-valve wiring faulty;

1. Check wiring.

ING

2. Try to re-start the engine

automatic engine shutdown

(→ Page 39).

3. Contact Service.

381

TRAN.OUT1

Binary transistor output

Contact Service.

PLANT DEF

plant 1 defective

382

TRAN.OUT2

Binary transistor output

Contact Service.

PLANT DEF

plant 2 defective

383

TRAN.OUT3

Binary transistor output

Contact Service.

PLANT DEF

plant 3 defective

384

TRAN.OUT4

Binary transistor output

Contact Service.

PLANT DEF

plant 4 defective

385

TRAN.OUT5

Binary transistor output

Contact Service.

PLANT DEF

plant 5 defective

386

TRAN.OUT6

Binary transistor output

Contact Service.

PLANT DEF

plant 6 defective

62 | Troubleshooting | MS150064/01E 2011-11

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 - Danger to life!

• Before barring the engine, ensure that nobody is in the danger zone.

Engine - Barring manually

Remove guard plate.

Engage barring device (2) with ring gear (3)

and install on flywheel housing.

Place ratchet (1) onto barring device (2).

Rotate crankshaft in engine direction of ro-

tation. Apart from the normal compression

resistance, there should be no further re-

sistance.

For barring device removal, follow reverse

sequence of working steps.

MS150064/01E 2011-11 | Task Description | 63

7.1.2

Engine - Barring with starting system

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Connector pliers

0135315483

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.

Engine - Barring with starting

system

Disengage the bayonet coupling (4) of con-

nector X4 with connector pliers (2) and

withdraw connector (3) from engine gover-

nor.

Bar engine in unloaded condition: Press

START button.

Let the crankshaft rotate until oil pressure is

indicated.

Engine start is automatically interrupted

when specified starting period is expired. If

necessary, re-start the engine after approx.

20 seconds.

Plug connector X4 (3) and use connector

pliers (2) to secure the bayonet coupling (4)

by turning it clockwise until it latches into

place.

64 | Task Description | MS150064/01E 2011-11

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.

Rigid endoscope

Y20097353

Preparatory steps

Remove cylinder head cover (→ Page 75).

Remove injector (→ Page 78).

Positioning crankshaft at BDC

Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached

BDC.

Insert endoscope into cylinder liner through injector seat.

Endoscopic examination of cylinder liner

Findings

Measure

• Thin carbon coating on circumference of carbon scraper ring

No action required

• Slight localized additive deposits at top edge

• Localized smooth areas at bottom edge

• Carbon deposits on circumference in clearance between top piston

ring and bottom edge of carbon scraper ring

• First signs of marks left by top piston ring

• Bright mark on entire circumference

• Consistent honing pattern without objections

• First signs of marks left by lower cooling bores

• Running pattern seems darker

• Dark areas with even or varying degrees of discoloration

Further endoscopic examina-

• Beginning and end of the discoloration are not sharply defined and

tion required as part of main-

do not cover the entire stroke area

tenance work

• Dark areas in the upper section of the cooling bore, remaining cir-

cumference without objections

• Piston rings without objections

• On the entire circumference, apart from light areas of discoloration

Cylinder liner must be re-

(that do not impair operation) clearly darker stripes that start at the

placed; Service must be con-

top piston ring

tacted

• Heat discoloration in the direction of stroke and honing pattern dam-

age

• Heat discoloration of piston rings

Compile endoscopic report using the table.

Use technical terms for description of the liner surface (→ Page 68).

Depending on findings:

• Do not take any action or

• carry out a further endoscopic examination as part of maintenance work or

• contact Service; cylinder liner must be replaced.

66 | Task Description | MS150064/01E 2011-11

7.2.2

Cylinder liner - Instructions and comments on endoscopic and visual

examination

Terms used for endoscopic examination

Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami-

nation report.

Findings

Measure

Minor dirt scores

Minor dirt scores can occur during the assembly of a new engine (honing prod-

ucts, particles, broken-off burrs). Removed cylinders clearly show such scoring

on the running surface under endoscope magnification. Cannot be felt with the

fingernail.

Findings not critical.

Single scores

Clearly visible scores caused by hard particles. They usually start in the TDC

area and cross through the hone pattern in the direction of stroke.

Findings not critical.

Scored area

These areas consist of scores of different length and depth next to one anoth-

er. In most cases, they are found at the 6-o'clock and 12-o'clock positions (in-

let/exhaust) along the transverse engine axis.

Findings not critical.

Smoothened area

Smoothened areas are on the running surface but almost the whole honing

pattern is still visible. Smoothened areas appear brighter and more brilliant

than the surrounding running surface.

Findings not critical.

Bright area

Bright areas are on the running surface and show local removal of the honing

pattern. Grooves from honing process are not visible any more.

Discoloration

This is caused by oxidation (surface discoloration through oil or fuel) and tem-

perature differences around the liner. It appears rather darker within the honed

structure in contrast to the bright metallic running surface. The honing pattern

is undisturbed. Discolorations extend in stroke direction and may be interrupt-

ed.

Findings not critical.

Corrosion fields / spots

Corrosion fields / spots result from water (condensed water) with the valves in

the overlap (open) position. They are clearly visible due to the dark color of the

honing groove bottom.

This corrosion is not critical unless there is corrosion pitting.

Black lines

Black lines are a step towards heat discoloration. They are visible as a clear

discoloration from TDC to BDC in the running surface and the start of localized

damage to the honing pattern.

Cylinder liners with a large number of black lines around the running surface

have limited service life and should be replaced.

68 | Task Description | MS150064/01E 2011-11

Findings

Measure

Burn mark

This is caused by a malfunction in the liner / ring tribosystem. Usually they run

over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and

becoming more visible from the second TDC-ring 2 onwards and less pro-

nounced from TDC-ring 1. The honing pattern is usually no longer visible and

displays a clearly defined (straight) edge to the undisturbed surface. The dam-

aged surface is usually discolored. The circumferential length varies.

Liners with burn marks, or heat discoloration, starting in TDC ring 1 have to be

replaced.

Seizure marks, scuff-

Irregular circumference lengths and depths. Can be caused either by the pis-

ing

ton skirt or the piston crown. Material deposits on the liner (smear), heavy dis-

coloration. Severe, visible scoring.

Replace liner.

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 fur-

ther operation of the engine.

MS150064/01E 2011-11 | Task Description | 69

7.3

Crankcase Breather

7.3.1

Crankcase breather - Oil separator 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 adapter

F30027340

Engine oil

Filter element

(→ Spare Parts Catalog)

Diaphragm

(→ Spare Parts Catalog)

Seal

(→ Spare Parts Catalog)

WARNING

Hot oil.

Oil can contain combustion residues which are harmful to health.

Risk of injury and poisoning!

• Wear protective clothing, gloves, and goggles / safety mask.

• Avoid contact with skin.

• Do not inhale oil vapor.

Replacing oil separator

Remove cover (2) with O-ring (3).

Remove filter element (1) from housing (4).

Insert new filter element in housing (4).

Fit cover (2) with new O-ring.

Use torque wrench to tighten the screws of cover (2) to the specified torque.

Name

Size

Type

Lubricant

Value/Standard

Screw

Tightening torque

(Engine oil)

6 Nm +2 Nm

Replace further oil separator elements in the same way.

70 | Task Description | MS150064/01E 2011-11

7.4.2

Valve clearance - Check and adjustment

Preconditions

☑ Engine is stopped 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

Y20010128

Torque wrench, 60-320 Nm

F30047446

Allen key

F30002817

Socket wrench, 24 mm

F30039526

Engine oil

Preparatory steps

Remove cylinder head cover (→ Page 75).

Install barring tool (→ Page 63).

Rotate crankshaft with barring tool in en-

gine direction of rotation until marking "OT-

A1" and pointer are aligned.

MS150064/01E 2011-11 | Task Description | 73

Checking valve clearance at two

crankshaft positions

Check TDC position of piston in cylinder

A1:

• If the rocker arms are unloaded on cylin-

der A1, the piston is in firing TDC.

• If the rocker arms are under load on cyl-

inder A1, the piston is in overlap TDC.

Check valve clearance with cold engine:

• Inlet valves (long rocker arm) = 0.2 mm

• Exhaust valves (short rocker arm) =

0.5 mm

Check all valve clearances in two crank-

shaft positions (firing TDC and overlap TDC

of cylinder A1) as per diagram.

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

0.1 mm, adjust valve clearance.

Adjusting valve clearance

Release locknut (1).

Insert feeler gauge between valve bridge

and rocker arm.

Using Allen key, set adjusting screw (2) so

that the specified valve clearance is provid-

ed.

Feeler gauge must just pass through the

gap.

Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2)

to prevent it from turning.

Name

Size

Type

Lubricant

Value/Standard

Locknut

M16 x 1.5

Tightening torque

(Engine oil)

90 Nm +9 Nm

Replace or rectify adjusting screws and/or locknuts which do not move freely.

Check valve clearance.

Final steps

Remove barring tool (→ Page 63).

Install cylinder head cover (→ Page 75).

74 | Task Description | MS150064/01E 2011-11

7.4.3

Cylinder head cover - Removal and installation

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Gasket

(→ Spare Parts Catalog)

Removing cylinder head cover

Clean cylinder head covers prior to removal

if they are heavily soiled.

Remove screws.

Remove cylinder head cover with gasket

from cylinder head.

Installing cylinder head cover

Clean mating face.

Check condition of gasket, replace if necessary.

Place gasket and cylinder head cover on cylinder head.

Install cylinder head cover.

MS150064/01E 2011-11 | Task Description | 75

7.5

Injection Pump / HP Pump

7.5.1

HP 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!

• Wear ear protectors.

Checking HP pump relief bore

Check relief bore for oil and fuel discharge

by visual inspection.

If relief bore is contaminated, stop the en-

gine, disable engine start, and clean relief

bore.

Note the following in case of fluid dis-

charge:

• Heavy discharge means continuous dis-

charge of fluids (leakage). Contact Serv-

ice.

• Minor discharge of fluids up to 10 drops

per day is normal (moistening) and not

considered a leakage.

76 | Task Description | MS150064/01E 2011-11

7.6.2

Injector - Removal and installation

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Installation and removal tool for injector

F6790161

Milling cutter

F30452739

Slotted nut screwdriver

F30452578

Torque wrench, 0.5-5 Nm

0015384230

Torque wrench, 10-60 Nm

F30510423

Torque wrench, 60-320 Nm

F30047446

Assembly paste (Optimoly Paste White T)

40477

Grease (Kluthe Hakuform 30-10/emulsifier)

X00058060

Engine oil

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

CAUTION

Removal of all injectors.

Damage to component!

• Ensure that the high-pressure fuel accumulator is secured on the engine through two HP lines.

CAUTION

Cable damage during operation.

Fire hazard!

• Twist cables when installing.

• Ensure that cables do not touch components.

Preparatory steps

Shut off fuel inlet to engine.

Remove cylinder head cover (→ Page 75).

78 | Task Description | MS150064/01E 2011-11

Remove sealing ring (1) from injector or use

a self-made wire hook to extract it from the

cylinder head.

Remove O-rings (2) from injector.

Cover all connections and bores, or seal

with suitable plugs.

Installing injector

Remove all plugs before installing.

Coat nozzle retaining nut area of injector

with assembly paste.

Fit new O-rings on injector and coat with

grease.

Fit new sealing ring on injector with grease

ensuring correct installation position of seal-

ing ring.

Clean sealing surface on cylinder head and

protective sleeve with milling cutter.

Insert injector into cylinder head ensuring

that the HP line connection is aligned cor-

rectly.

Press in injector with installation/removal

device.

Remove installation/removal device.

80 | Task Description | MS150064/01E 2011-11

Use slotted screwdriver to check thrust ring

at both line ends for secure seating.

10.

Tighten loose thrust ring to the specified tightening torque.

Name

Size

Type

Lubricant

Value/Standard

Thrust ring

Tightening torque

5 Nm to 10 Nm

11.

Coat screw head mating face (2) and

thread with engine oil.

12.

Place hold-down clamp (1) in correct installation position. Tighten screw (2) with torque wrench to the

specified initial tightening torque.

Name

Size

Type

Lubricant

Value/Standard

Screw

M12

Preload torque

(Engine oil)

5 Nm to 10 Nm

13.

Fit O-rings (4) and (6) on high-pressure fuel line (5) and coat with grease.

14.

Tighten high-pressure fuel line (5) to the specified initial tightening torque.

Name

Size

Type

Lubricant

Value/Standard

HP line

Preload torque

(Engine oil)

5 Nm to 10 Nm

15.

Tighten screw (2) to specified torque using a torque wrench.

Name

Size

Type

Lubricant

Value/Standard

Screw

M12

Tightening torque

100 Nm + 10 Nm

MS150064/01E 2011-11 | Task Description | 81

16.

Tighten union nut of connecting piece (limiting valve) to specified torque using a torque wrench.

Name

Size

Type

Lubricant

Value/Standard

Union nut

Tightening torque

140 Nm + 10 Nm

17.

Tighten union nut of connecting piece (injector) to specified torque using a torque wrench.

Name

Size

Type

Lubricant

Value/Standard

Union nut

Tightening torque

120 Nm +10 Nm

18.

Twist cable several times.

19.

Insert cable terminals (arrows) underneath screws on injector and tighten screws to specified torque us-

ing a torque wrench.

Name

Size

Type

Lubricant

Value/Standard

Screw

Tightening torque

1.5 Nm

Final steps

Install cylinder head cover (→ Page 75).

Open up fuel inlet to engine.

82 | Task Description | MS150064/01E 2011-11

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.

• Do not smoke.

Venting LP fuel system

Loosen flushing/return line of HP pump at

connection (1).

Unlock fuel priming pump (2), screw out

handle.

Operate the fuel priming pump (2) with the

handle until bubble-free fuel comes out of

the connection (1).

Lock fuel priming pump (2), screw in han-

dle.

Verify that fuel priming pump (2) is locked:

Handle must be tightened.

Tighten connection (1) of flushing/return

line.

MS150064/01E 2011-11 | Task Description | 83

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!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Replacing fuel filter

Remove easy-change filter using filter

wrench.

Clean sealing surface on filter head.

Slightly lubricate seal on the easy-change

filter.

Screw on easy-change filter by hand until

the seal connects and tighten manually.

Vent fuel system (→ Page 83).

Replace other easy-change filters in the

same way.

84 | Task Description | MS150064/01E 2011-11

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!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Fuel prefilter cleaning

Shut off fuel supply.

Remove nuts from filter head.

Take off filter housing and drain fuel into

appropriate container.

Remove filter-element securing nut and re-

move filter element by pulling it downwards.

Wash filter element in clean fuel using a

smooth brush.

Wash filter housing with clean fuel.

Insert filter element into filter housing and

secure with nut.

Place new sealing ring into groove in filter

head.

Fit cover with seal and secure it with nuts

crosswise.

10.

Open fuel supply.

MS150064/01E 2011-11 | Task Description | 85

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!

• Wear ear protectors.

Adjusting differential pressure

gauge

When installing the new filter element: align

adjustable pointer (2) with pressure-indicat-

ing pointer (3) of pressure gauge (1).

Check differential pressure.

Checking differential pressure of fuel prefilter

With the engine running at full load or rated power, read off pressure at gauge (1).

If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating

pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 88).

86 | Task Description | MS150064/01E 2011-11

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!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Fuel prefilter - Draining

Cut out filter to be drained.

I Left filter cut in

II Right filter cut in

Open threaded vent plug (5) of filter to be

drained.

Unlock drain valve (6) by pressing toggle

and open it.

Drain water and contaminants from filter un-

til pure fuel emerges.

Close drain valve (6).

Remove screws for cover and take off cov-

er (2).

Fill filter housing with clean fuel.

Place new gasket in cover (2).

Fit cover with gasket and secure it with

screws.

10.

Cut in the cut-out filter again.

11.

Close threaded vent plug (5) when fuel

emerges.

MS150064/01E 2011-11 | Task Description | 87

7.8.5

Fuel prefilter - Flushing

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Diesel 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.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

Engine noise above 85 dB (A).

Risk of damage to hearing!

• Wear ear protectors.

Fuel prefilter - Flushing

Cut out clogged filter.

I Left filter cut in

II Right filter cut in

88 | Task Description | MS150064/01E 2011-11

Open threaded vent plug (5) of filter to be

flushed.

Unlock drain valve (6) by pressing 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).

Fuel prefilter - Topping up with fuel

Stop engine (→ Page 42) and disable engine start.

Remove screws for cover and take off cover (2).

Fill filter housing with clean fuel.

Place new gasket in cover (2).

Fit cover with gasket and secure it with screws.

Check differential pressure (→ Page 86).

Result:

If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefil-

ter (→ Page 90).

MS150064/01E 2011-11 | Task Description | 89

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).

Insert new filter element (3) and spring

housing (4).

Fill filter housing with clean fuel.

10.

Place new gasket in cover (2).

11.

Fit cover with gasket and secure it with

screws.

12.

Cut in the cut-out filter again.

13.

Close threaded vent plug (5) when fuel

emerges.

14.

Adjust the differential pressure gauge

(→ Page 86).

MS150064/01E 2011-11 | Task Description | 91

7.9

Charge-Air Cooling

7.9.1

Intercooler - Check drain for coolant leakage and obstruction

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!

• Wear ear protectors.

WARNING

Compressed air

Risk of injury!

• Do not direct compressed-air jet at persons.

• Wear protective goggles / safety mask and ear protectors.

Intercooler - Check drain for

coolant leakage and obstruction

Verify that air emerges from condensate

drain bore(s) on left and right engine sides

at driving end when engine is running. If no

air emerges:

• Clean drain bore(s)

• Blow out with compressed air

If a large amount of coolant is continuously

discharged, the intercooler is leaking. Con-

tact Service.

Emergency measures prior to engine start with a leaking intercooler

Remove injectors (→ Page 78).

Bar engine manually (→ Page 63).

Crank engine on starting system to blow out combustion chambers (→ Page 64).

Install injectors (→ Page 78).

92 | Task Description | MS150064/01E 2011-11

7.13

Lube Oil System, Lube Oil Circuit

7.13.1

Engine oil level - Check

Preconditions

☑ Engine shut down and starting disabled.

Checking oil level prior to engine

start

Withdraw oil dipstick from guide tube and

wipe it.

Insert oil dipstick into guide tube up to 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 fil-

ter or heat exchanger back to the oil pan.

The oil level must reach mark (1) or exceed

mark (1) by up to 2 cm.

Top up with oil to mark (1) as necessary

(→ Page 99).

Insert oil dipstick into guide tube up to the

stop.

Checking oil level after the engine is stopped

5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.

Insert oil dipstick into guide tube up to stop, withdraw after approx. 10 seconds and check oil level.

Oil level must be between marks (1) and (2).

Top up with oil to mark (1) as necessary (→ Page 99).

Insert oil dipstick into guide tube up to the stop.

98 | Task Description | MS150064/01E 2011-11

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

F30027337

Ratchet adapter

F30027341

Engine oil

Sealing ring

(→ Spare Parts Catalog)

WARNING

Hot oil.

Oil can contain combustion residues which are harmful to health.

Risk of injury and poisoning!

• Wear protective clothing, gloves, and goggles / safety mask.

• Avoid contact with skin.

• Do not inhale oil vapor.

Oil change without semirotary hand pump: Draining engine oil at drain plug(s) on oil

pan

Provide a suitable container in which to collect the engine oil.

Remove drain plug(s) and drain engine oil.

Install drain plug(s) with new sealing ring.

Oil change with semirotary hand pump: Extracting engine oil

Provide a suitable container in which to collect the engine oil.

Extract all engine oil from oil pan using the semirotary hand pump.

Draining residual oil from

equipment carrier (only with

unscheduled engine oil change)

Provide a suitable container in which to col-

lect the engine oil.

Remove drain plug (1) and drain engine oil

from engine oil heat exchanger and from

engine oil filter.

Remove drain plugs (2) and (3) and drain

engine oil.

Replace engine oil filter (→ Page 102).

Install drain plug(s) with new sealing ring.

MS150064/01E 2011-11 | Task Description | 99

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.

Risk of serious injury - danger to life!

• Take special care when working on a running engine.

WARNING

Hot oil.

Oil can contain combustion residues which are harmful to health.

Risk of injury and poisoning!

• Wear protective clothing, gloves, and goggles / safety mask.

• Avoid contact with skin.

• Do not inhale oil vapor.

WARNING

Engine noise above 85 dB (A).

Risk of damage to hearing!

• Wear ear protectors.

Engine oil sample extraction and

analysis

With the engine running at operating tem-

perature, open screw on flange of centrifu-

gal oil filter by 1 to 2 rotations.

Drain approx. 2 liters engine oil to flush out

the oil sludge.

Drain approx. 1 liter engine oil into a clean

container.

Close screw.

Using the equipment and chemicals of the

MTU test kit, examine oil for:

• Dispersing capacity (spot test);

• Water content;

• Fuel dilution.

MS150064/01E 2011-11 | Task Description | 101

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.

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.

Replacing engine oil filter

Remove oil filter using filter wrench.

Clean sealing surface on connecting piece.

Check condition of new oil filter sealing ring

and coat it with engine oil.

Screw on and tighten new engine oil filter

by hand.

Replace other engine oil filters in the same

way.

Crank engine on starting system after every

oil change and filter replacement

(→ Page 64).

Check engine oil level (→ Page 98).

102 | Task Description | MS150064/01E 2011-11

7.14.2

Centrifugal oil filter - Cleaning and filter sleeve replacement

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Filter wrench

F30379104

Torque wrench, 6-50 Nm

F30027336

Ratchet adapter

F30027339

Cold cleaner (Hakutex 60)

50602

Grease (Kluthe Hakuform 30-10/emulsifier)

X00029933

Filter sleeve

(→ Spare Parts Catalog)

Sealing ring

(→ Spare Parts Catalog)

Sealing ring

(→ Spare Parts Catalog)

WARNING

Hot oil.

Oil can contain combustion residues which are harmful to health.

Risk of injury and poisoning!

• Wear protective clothing, gloves, and goggles / safety mask.

• Avoid contact with skin.

• Do not inhale oil vapor.

WARNING

Compressed air

Risk of injury!

• Do not direct compressed-air jet at persons.

• Wear protective goggles / safety mask and ear protectors.

MS150064/01E 2011-11 | Task Description | 103

Cleaning centrifugal oil filter and

replacing filter sleeve

Undo screw (1) and remove.

Remove clamp (3) and take off hood (2).

Carefully remove rotor (5) from housing.

Hold rotor assembly (5) firmly in position

with filter wrench and undo knurled nut (7).

Take off rotor cap (8).

Remove filter sleeve (9), stiffener plate (10)

and sealing ring (11).

Measure thickness of oil residues on filter

sleeve.

If maximum layer thickness of oil residues

exceeds 30 mm, shorten maintenance in-

terval.

Remove standpipe (12) from lower rotor

section (13).

10.

Wash hood (2), rotor cap (8), stiffener

plate, (10) standpipe (12), rotor lower sec-

tion (13) and nozzles (14) with cold cleaner

and blow out with compressed air. Do not

use sharp objects for cleaning.

11.

Check nozzles (14) for obstructions.

12.

Press standpipe (12) onto rotor lower sec-

tion (13).

13.

Insert new filter sleeve (9) with stiffener

plate (10) into rotor cap (8), ensuring that

smooth surface of filter sleeve (9) faces ro-

tor cap (8).

14.

Check sealing ring (11), replace if necessa-

ry. Coat sealing ring with grease and insert

in groove of rotor cap (8).

15.

Place rotor cap (8) onto standpipe (12).

16.

Hold rotor assembly (5) firmly in position

with filter wrench and tighten knurled

nut (7).

17.

Lubricate bearings of rotor (5) with oil, in-

sert into housing (6) and check for ease of

movement.

18.

Check sealing ring (4), replace if necessary.

Fit sealing ring on housing (6).

19.

Fit hood (2).

20.

Tighten screw (1) by hand.

21.

Install clamp (3) and tighten to specified torque using a torque wrench.

Name

Size

Type

Lubricant

Value/Standard

Clamp

Tightening torque

6 Nm + 1 Nm

22.

Tighten screw (1) to specified torque using a torque wrench.

Name

Size

Type

Lubricant

Value/Standard

Screw

Tightening torque

6 Nm + 1 Nm

104 | Task Description | MS150064/01E 2011-11

7.15

Coolant Circuit, General, High-Temperature Circuit

7.15.1

Coolant level - Check

Preconditions

☑ Engine shut down 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.

• Wear protective clothing, gloves, and goggles / safety mask.

Checking coolant level at filler neck:

Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to

escape.

Continue to turn breather valve counterclockwise and remove.

Check coolant level (coolant must be visible at the lower edge of the cast-in eye).

Checking coolant level at remote

cooler:

Check coolant level (coolant must be visible

at marking plate).

Top up coolant if necessary (→ Page 108).

Check and clean breather valve.

Place breather valve on filler neck and

close.

Coolant level check by means of level sensor:

Switch on engine control system and check readings on the display.

Top up coolant if necessary (→ Page 108).

MS150064/01E 2011-11 | Task Description | 105

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.

Switch off preheating unit.

Engine coolant - Draining

Turn breather valve of filler neck on coolant

expansion tank counterclockwise to first

stop and allow pressure to escape.

Continue to turn breather valve counter-

clockwise and remove.

Draw off separated corrosion inhibitor oil in

expansion tank through the filler neck.

Open drain valves and/or drain plugs and

drain coolant at the following points:

• At preheating unit;

• At HT coolant pump elbow;

• On crankcase, left and right side.

Close all open drain points.

Set breather valve onto filler neck and close

it.

MS150064/01E 2011-11 | Task Description | 107

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.

Risk of injury and scalding!

• Let the engine cool down.

• Wear protective clothing, gloves, and goggles / safety mask.

CAUTION

Cold coolant in hot engine can cause thermal stress.

Formation of cracks in components!

• Fill / top up coolant only into cold engine.

Preparatory steps

Turn breather valve of coolant expansion

tank counterclockwise until the first stop

and allow pressure to escape.

Continue to turn breather valve counter-

clockwise and remove.

108 | Task Description | MS150064/01E 2011-11

Filling with coolant using a pump

Connect suitable pump and hose to engine

coolant pump drain valve (arrowed) or drain

and filling line between engine and radiator.

Undo screw connection (arrowed) of the

vent line on the distributor.

Open drain valve and pump coolant into en-

gine with a pressure of at least 0.5 bar until

coolant escapes from the open connection.

Tighten connection (arrowed).

Fill coolant expansion tank until coolant lev-

el reaches the bottom edge of the filler

neck.

Close drain valve.

Check proper condition of breather valve

and clean sealing faces if required.

Fit breather valve and close it.

Start engine (→ Page 39).

10.

After 10 seconds of running the engine

without load, shut down the engine

(→ Page 42).

11.

Turn breather valve of coolant expansion

tank counterclockwise until the first stop

and allow pressure to escape.

12.

Continue to turn breather valve counter-

clockwise and remove.

13.

Check coolant level (→ Page 105) and top

up engine coolant as required:

a) Add coolant via filler neck on expansion

tank until the coolant level at bottom

edge of filler neck remains constant.

b) Check proper condition of breather

valve and clean sealing faces if re-

quired.

c) Fit breather valve and close it.

14.

Repeat the steps from "Start engine"

(→ Step 8) until coolant is no longer needed

to be topped up.

15.

Disconnect pump and hose.

MS150064/01E 2011-11 | Task Description | 109

Alternatively: Filling with coolant

through filler neck

Undo screw connection (arrowed) of the

vent line on the distributor.

Fill in coolant via filler neck on expansion

tank until the coolant level at bottom edge

of filler neck remains constant.

Tighten connection (arrowed).

Check proper condition of breather valve

and clean sealing faces if required.

Fit breather valve and close it.

Start engine (→ Page 39).

After 10 seconds of running the engine

without load, shut down the engine

(→ Page 42).

Turn breather valve of coolant expansion

tank counterclockwise until the first stop

and allow pressure to escape.

Turn breather valve counterclockwise and

remove.

10.

Check coolant level (→ Page 105) and top

up with coolant through the filler neck if re-

quired:

a) Add coolant via filler neck on expansion

tank until the coolant level at bottom

edge of filler neck remains constant.

b) Check proper condition of breather

valve and clean sealing faces if re-

quired.

c) Fit breather valve and close it.

11.

Repeat the steps from "Start engine"

(→ Step 6) until coolant is no longer needed

to be topped up.

Final steps

Start the engine and run it without load for some minutes.

Check coolant level (→ Page 105) and top up engine coolant as required.

110 | Task Description | MS150064/01E 2011-11

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!

• Wear ear protectors.

Checking relief bore on engine

coolant pump

Checking relief bore for oil and coolant dis-

charge.

Stop engine (→ Page 42) and disable en-

gine start, observe general safety instruc-

tions for maintenance and repair.

Clean the relief bore with a wire if it is dirty.

• Permissible coolant discharge: up to 10

drops per hour.

• Permissible oil discharge: up to 5 drops

per hour.

If discharge exceeds the specified limits:

Contact Service.

MS150064/01E 2011-11 | Task Description | 111

7.15.6

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.

Risk of serious injury - danger to life!

• Take special care when working on a running engine.

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.

WARNING

Engine noise above 85 dB (A).

Risk of damage to hearing!

• Wear ear protectors.

Coolant sample extraction and

analysis

With the engine running, open drain valve

(1).

Flush sample-extraction point by draining

approx. 1 liter coolant.

Drain approx. 1 liter coolant into a clean

container.

Close drain valve (1).

Using the equipment and chemicals of the

MTU test kit, check the coolant for:

• Antifreeze concentration

• Corrosion inhibitor concentration

• pH value.

For coolant change intervals, see (→ MTU

Fluids and Lubricants Specifications.)

112 | Task Description | MS150064/01E 2011-11

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.

• Wear protective clothing, gloves, and goggles / safety mask.

Checking charge-air coolant level

at filler neck:

Turn breather valve on coolant expansion

tank counterclockwise to the first stop and

allow pressure to escape.

Continue to turn breather valve counter-

clockwise and remove.

Check coolant level (coolant must be visible

at marking plate).

Top up coolant if necessary (→ Page 116).

Check proper condition of breather valve,

clean sealing faces if required.

Fit breather valve and close it.

Checking charge-air coolant level by means of level sensor:

Switch on engine control system and check display (coolant level is automatically monitored by engine

control system).

Top up coolant if necessary (→ Page 116).

MS150064/01E 2011-11 | Task Description | 113

7.16.3

Charge-air coolant - Draining

Preconditions

☑ Engine is stopped and starting disabled.

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!

• Let the engine cool down.

• Wear protective clothing, gloves, and goggles / safety mask.

Charge-air coolant - Draining

Provide an appropriate container to drain

the coolant into.

Turn breather valve of coolant expansion

tank counterclockwise until the first stop

and allow pressure to escape.

Continue to turn breather valve counter-

clockwise and remove.

Draw off precipitated corrosion inhibitor oil

from the expansion tank through filler neck.

Open drain cocks and drain plugs and drain

coolant at the following points:

• at the LT cooling pump

• at the coolant lines to and from the inter-

cooler

Draining of residual coolant:

• at the intercooler

Close all drain valves and install drain plugs

with new sealing rings.

Set breather valve onto filler neck and close

it.

MS150064/01E 2011-11 | Task Description | 115

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.

Charge-air coolant

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.

CAUTION

Cold coolant in hot engine can cause thermal stress.

Formation of cracks in components!

• Fill / top up coolant only into cold engine.

Preparatory steps

Turn breather valve of coolant expansion

tank counterclockwise until the first stop

and allow pressure to escape.

Continue to turn breather valve counter-

clockwise and remove.

116 | Task Description | MS150064/01E 2011-11

Filling with charge-air coolant using

a pump

Connect suitable pump and hose to charge-

air coolant pump drain valve (arrowed) or

drain and filling line between engine and ra-

diator.

Undo plug screws (1) on coolant lines to

and from intercooler and connection (2) of

the vent line on the distributor.

Open drain valve and pump coolant into en-

gine with a pressure of at least 0.5 bar until

coolant escapes from the open connec-

tions.

Tighten plug screws (1) and connection (2)

in sequence from top to bottom.

Fill coolant expansion tank until coolant lev-

el reaches the bottom edge of the filler

neck.

Close drain valve.

Check proper condition of breather valve

and clean sealing faces if required.

Install and close breather valve.

Start engine (→ Page 39).

10.

After the engine has run at unloaded condi-

tion for 10 seconds, stop engine

(→ Page 42).

11.

Turn breather valve of coolant expansion

tank counterclockwise until the first stop

and allow pressure to escape.

12.

Continue to turn breather valve counter-

clockwise and remove.

13.

Check coolant level (→ Page 113) and top

up if required:

a) Add coolant via filler neck on expansion

tank until the coolant level at bottom

edge of filler neck remains constant.

b) Check proper condition of breather

valve and clean sealing faces if re-

quired.

c) Install and close breather valve.

14.

Repeat the steps from "Start engine"

(→ Step 8) until coolant no longer needs to

be topped up.

15.

Disconnect pump and hose.

MS150064/01E 2011-11 | Task Description | 117

Alternatively: Filling with coolant

through filler neck

Undo plug screws (1) on coolant lines to

and from intercooler and connection (2) of

the vent line on the distributor.

Fill in coolant via filler neck on expansion

tank until the coolant level at bottom edge

of filler neck remains constant.

Tighten plug screws (1) and connection (2)

in sequence from top to bottom.

Check proper condition of breather valve

and clean sealing faces if required.

Install and close breather valve.

Start engine (→ Page 39).

After the engine has run at unloaded condi-

tion for 10 seconds, stop engine

(→ Page 42).

Turn breather valve of coolant expansion

tank counterclockwise until the first stop

and allow pressure to escape.

Turn breather valve counterclockwise and

remove.

10.

Check coolant level (→ Page 113) and top

up if required:

a) Add coolant via filler neck on expansion

tank until the coolant level at bottom

edge of filler neck remains constant.

b) Check proper condition of breather

valve and clean sealing faces if re-

quired.

c) Install and close breather valve.

11.

Repeat the steps from "Start engine"

(→ Step 6) until coolant no longer needs to

be topped up.

Final steps

Start the engine and operate it at unloaded condition for some minutes.

Check coolant level (→ Page 113) and top up if required.

118 | Task Description | MS150064/01E 2011-11

7.16.5

Charge-air 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

(→ Tools 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

Coolant is hot and under pressure.

Risk of injury and scalding!

• Let the engine cool down.

• Wear protective clothing, gloves, and goggles / safety mask.

WARNING

Engine noise above 85 dB (A).

Risk of damage to hearing!

• Wear ear protectors.

Charge-air coolant - Sample

extraction and analysis

With the engine running, open drain valve.

Flush sample-extraction point by draining

approx. 1 liter coolant.

Drain approx. 1 liter coolant into a clean

container.

Close drain valve.

Using the equipment and chemicals of the

MTU test kit, examine coolant for:

• antifreeze concentration;

• corrosion inhibitor concentration;

• pH value.

Change charge-air coolant according to the

intervals specified in the MTU Fluids and

Lubricants Specifications (→ Page 114).

MS150064/01E 2011-11 | Task Description | 119

7.16.6

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!

• Wear ear protectors.

Charge-air coolant pump - Relief

bore check

Check relief bore for oil and coolant dis-

charge.

Stop engine (→ Page 42) and disable en-

gine start, observe general safety instruc-

tions for maintenance and repair.

Clean the relief bore with a wire if it is dirty.

• Permissible coolant discharge: up to 10

drops per hour.

• Permissible oil discharge: up to 5 drops

per hour.

If discharge exceeds the specified limits:

Contact Service.

120 | Task Description | MS150064/01E 2011-11

7.18.2

Battery-charging generator drive - Drive belt tension check

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Belt tension tester

Y4345711

Preparatory steps

Remove guard cover.

Check belt condition visually (→ Page 121).

Checking drive belt tension

Fit measuring head (2) on belt-tension tester (3) and hit drive belt (1) with a suitable tool.

Hold belt tension tester over belt drive until the measured value is displayed. For specifications, refer to

table below.

Application

Value for new drive belt

Value for used drive belt

Series 4000

92 Hz to 96 Hz

80 Hz to 84 Hz

If the measured values deviate from the specifications above, adjust drive belt tension (→ Page 122).

MS150064/01E 2011-11 | Task Description | 123

7.18.3

Battery-charging generator drive - Drive belt replacement

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Drive belt

(→ Spare Parts Catalog)

Note:

In the event of drive belt failure during engine operation fit a new drive belt as quickly as possible. Non-

compliance with these instructions may lead to severe consequential damage to drive unit and gear train,

since pretension by the drive belt is no longer provided. Therefore, engine operation without drive-belt

connection is not allowed.

Battery-charging generator drive -

Drive belt replacement

Remove guard cover.

Loosen locknut (2) and screws (1).

Release drive belt with tensioning nut (3)

and take off belt.

Clean belt pulleys.

Fit new drive belt.

Tension drive belt with tensioning nut (3)

and check belt tension (→ Page 122).

Tighten locknut (2).

Tighten screws (1).

Install guard cover.

10.

Check belt tension after 30 minutes and

again after 8 hours engine runtime.

124 | Task Description | MS150064/01E 2011-11

7.19

Wiring (General) for Engine/Gearbox/Unit

7.19.1

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.

Check that cable ties are firm, tighten loose cable ties.

Replace faulty cable ties.

Visually inspect the following electrical line components for damage:

• connector housings;

• contacts;

• sockets;

• cables and terminals;

• plug-in contacts.

(→ Contact Service) if cable conductors are damaged.

Note:

Close male connectors that are not plugged in with the protective cap supplied.

Clean dirty connector housings, sockets and contacts with isopropyl alcohol.

Ensure that all sensor connectors are securely engaged.

MS150064/01E 2011-11 | Task Description | 125

7.20

Accessories for (Electronic) Engine Governor / Control

System

7.20.1

Engine control unit and connectors - Cleaning

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Connector pliers

0135315483

Isopropyl alcohol

46181

Cleaning engine control unit and

connectors

Remove heavy soiling from housing surface

with isopropyl alcohol.

Remove dirt from surface of connectors (1),

connector sockets and shrink-formed com-

ponents (2) using a cloth moistened with

isopropyl alcohol.

Check legibility of cable labels. Clean or re-

place illegible labels.

Cleaning heavily soiled connectors

on engine control unit

Use connector pliers (2) to disengage bayo-

net union nut (4) and withdraw connector

(3).

Clean connector housings, connector sock-

et housings (1) and all contacts with iso-

propyl alcohol.

When connectors, sockets and all contacts

are dry: Fit connectors and check engine

control unit plug connections (→ Page 127).

126 | Task Description | MS150064/01E 2011-11

7.20.2

Engine control unit plug connections - Check

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Connector pliers

0135315483

Checking engine control unit plug

connections

Use connector pliers (3) to make certain

that all plug connections on engine control

unit are securely seated.

Tighten loose bayonet union nuts (2) with

connector pliers (3) by turning them clock-

wise until they latch into place.

Make sure that unassigned sockets are

closed off with cover caps.

If bayonet union nuts are defective, contact

Service.

MS150064/01E 2011-11 | Task Description | 127

8 Appendix A

8.1

Abbreviations

Abbreviation

Meaning

Explanation

A/D

Analog/Digital

Transformer: transforms sensor voltages into

numeric values

ADEC

Advanced Diesel Engine Controller

Engine management system

AFRS

Air Filter Restriction Sensor

ANSI

American National Standards Institute

Association of American standardization or-

ganizations

ATL

Abgasturbolader

Exhaust turbocharger (ETC)

ATS

Air Temperature Sensor

Baureihe

Series

Betriebsstoffvorschrift

MTU Fluids and Lubricants Specifications,

Publication No. A01061/..

CAN

Controller Area Network

Data bus system, bus standard

CDC

Calibration Drift Compensation

Setting of drift compensation in engine gov-

ernor with DiaSys

CEL

Stop Engine Light

1st function: Warning lamp (rectify fault as

soon as possible)

2nd function: Read out fault codes

CKT

Circuit

CLS

Coolant Level Sensor

Monitors coolant level

CPS

Coolant Pressure Sensor

Monitors coolant pressure

CTS

Coolant Temperature Sensor

Monitors coolant temperature

DDEC

Detroit Diesel Electronic Controls

Engine control system made by Detroit Die-

sel

DDL

Diagnostic Data Link

Diagnostic lines

DDR

Diagnostic Data Reader

Diagnostic unit

DIN

Deutsches Institut für Normung e. V.

At the same time identifier of German stand-

ards (DIN = “Deutsche Industrie-Norm”)

Default Lost

Alarm: Default CAN bus failure

DOC

Diesel Oxidation Catalyst

Oxidation catalyst upstream of the diesel

particulate filter

DPF

Diesel Particulate Filter

Diagnostic Tool

Diagnostic unit

ECM

Electronic Control Module

Electronic control unit of the DDEC system

ECU

Engine Control Unit

Engine governor

EDM

Engine Data Module

Memory module for engine data

EEPROM

Electrically Erasable Programmable

Read Only Memory

EFPA

Electronic Foot Pedal Assembly

128 | Appendix A | MS150064/01E 2011-11

Abbreviation

Meaning

Explanation

EGR

Exhaust Gas Recirculation

EMU

Engine Monitoring Unit

ETK

Ersatzteilkatalog

Spare Parts Catalog (SPC)

EUI

Electronic Unit Injector

FPS

Fuel Pressure Sensor

Monitors fuel pressure

FRS

Fuel - Differential Pressure Sensor

FTS

Fuel Temperature Sensor

Monitors fuel temperature

FWCP

Fire Water Control Panel

Control cabinet

GND

Ground

Hochdruck

High Pressure (HP)

High

Alarm: Measured value exceeds 1st maxi-

mum limit

HIHI

High High

Alarm: Measured value exceeds 2nd maxi-

mum limit value

High Temperature

IDM

Interface Data Module

Memory module for interface data

INJ

Injector

ISO

International Organization for Stand-

International umbrella organization for all na-

ardization

tional standardization institutes

KGS

Kraftgegenseite

Engine free end in accordance with DIN ISO

1204

Kraftseite

Engine driving end in accordance with DIN

ISO 1204

LED

Light Emitting Diode

Low

Alarm: Measured value lower than 1st mini-

mum limit value

LOLO

Low Low

Alarm: Measured value lower than 2nd mini-

mum limit value

LSG

Limiting Speed Governor

N/A

Not Applicable

Low Pressure

OEM

Original Equipment Manufacturer

Optimized Idle

OLS

Oil Level Sensor

Monitors oil level

OPS

Oil Pressure Sensor

Monitors oil pressure

OTS

Oil Temperature Sensor

Monitors oil temperature

Oberer Totpunkt

Top Dead Center (TDC)

PAN

Panel

Control panel

PIM

Peripheral Interface Module

PWM

Modulated signal

P-xyz

Pressure-xyz

Pressure measuring point, xyz specifies the

measuring point designation

Redundancy Lost

Alarm: Redundant CAN bus failure

MS150064/01E 2011-11 | Appendix A | 129

Abbreviation

Meaning

Explanation

SAE

Society of Automotive Engineers

U.S. standardization organization

Sensor Defect

Alarm: Sensor failure

SEL

Stop Engine Light

1st function: Warning lamp (stop engine and

rectify fault)

2nd function: Read out fault codes

SID

System Identifier

SRS

Synchronous Reference Sensor

TDC cylinder 1

Safety System

Safety system alarm

TBS

Turbocharger Boost Sensor

Monitors charge-air pressure

TCI

Turbo Compressor Inlet

TCO

Turbo Compressor Outlet

Transmitter Deviation

Alarm: Deviation in transmitter values

TPS

Throttle Position Sensor

TRS

Timing Reference Sensor

T-xyz

Temperature-xyz

Temperature measuring point, xyz specifies

the measuring point designation

Unterer Totpunkt

Bottom Dead Center (BDC)

VNT

Variable Nozzle Turbine

VSG

Variable-Speed Governor

VSS

Vehicle Speed Sensor

WZK

Werkzeugkatalog

Tool Catalog (TC)

130 | Appendix A | MS150064/01E 2011-11

8.2

MTU contacts/service partners

Service

Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service

centers ensures fast and direct support on site and the high availability of our products.

Local support

Experienced and qualified specialists place their knowledge and expertise at your disposal.

For locally available support, go to the MTU internet site: http://www.mtu-online.com

24h hotline

With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you

- either during operation, for preventive maintenance, corrective work in case of malfunction or changed

operating conditions, or for spare parts supply.

Your contact at Headquarters:Service-support@mtu-online.com

Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare

part at the right time at the right place.

With this aim in mind, we can call on a globally networked spares logistics system

- a central depot at Headquarters, as well as decentralized depots among our subsidiaries, representa-

tives and contractual workshops.

Your contact at Headquarters:

E-mail: spare.parts@mtu-online.com

Phone: +49 7541 908555

Fax: +49 7541 908121

MS150064/01E 2011-11 | Appendix A | 131

9 Appendix B

9.1

Special Tools

Allen key

Part No.:

F30002817

Qty.:

Used in:

7.4.2 Valve clearance - Check and adjustment (→ Page 73)

Barring device

Part No.:

F6555766

Qty.:

Used in:

7.1.1 Engine - Barring manually (→ Page 63)

Belt tension tester

Part No.:

Y4345711

Qty.:

Used in:

7.18.2 Battery-charging generator drive - Drive belt tension check (→ Page 123)

Connector pliers

Part No.:

0135315483

Qty.:

Used in:

7.1.2 Engine - Barring with starting system (→ Page 64)

Qty.:

Used in:

7.20.1 Engine control unit and connectors - Cleaning (→ Page 126)

Qty.:

Used in:

7.20.2 Engine control unit plug connections - Check (→ Page 127)

Feeler gauge

Part No.:

Y20010128

Qty.:

Used in:

7.4.2 Valve clearance - Check and adjustment (→ Page 73)

Filter wrench

Part No.:

F30379104

Qty.:

Used in:

7.8.1 Fuel filter - Replacement (→ Page 84)

Qty.:

Used in:

7.14.1 Engine oil filter - Replacement (→ Page 102)

Qty.:

Used in:

7.14.2 Centrifugal oil filter - Cleaning and filter sleeve replacement (→ Page 103)

Installation and removal tool for injector

Part No.:

F6790161

Qty.:

Used in:

7.6.2 Injector - Removal and installation (→ Page 78)

132 | Appendix B | MS150064/01E 2011-11

Milling cutter

Part No.:

F30452739

Qty.:

Used in:

7.6.2 Injector - Removal and installation (→ Page 78)

MTU test kit

Part No.:

5605892099/00

Qty.:

Used in:

7.13.3 Engine oil - Sample extraction and analysis (→ Page 101)

Qty.:

Used in:

7.15.6 Coolant - Sample extraction and analysis (→ Page 112)

MTU test kit

Part No.:

Qty.:

Used in:

7.16.5 Charge-air coolant - Sample extraction and analysis (→ Page 119)

Ratchet adapter

Part No.:

F30027340

Qty.:

Used in:

7.3.1 Crankcase breather - Oil separator replacement, diaphragm check and replace-

ment (→ Page 70)

Ratchet adapter

Part No.:

F30027341

Qty.:

Used in:

7.13.2 Engine oil - Change (→ Page 99)

Ratchet adapter

Part No.:

F30027339

Qty.:

Used in:

7.14.2 Centrifugal oil filter - Cleaning and filter sleeve replacement (→ Page 103)

Ratchet with extension

Part No.:

F30006212

Qty.:

Used in:

7.1.1 Engine - Barring manually (→ Page 63)

Rigid endoscope

Part No.:

Y20097353

Qty.:

Used in:

7.2.1 Cylinder liner - Endoscopic examination (→ Page 66)

Slotted nut screwdriver

Part No.:

F30452578

Qty.:

Used in:

7.6.2 Injector - Removal and installation (→ Page 78)

MS150064/01E 2011-11 | Appendix B | 133

Socket wrench, 24 mm

Part No.:

F30039526

Qty.:

Used in:

7.4.2 Valve clearance - Check and adjustment (→ Page 73)

Steam jet cleaner

Part No.:

Qty.:

Used in:

4.10 Plant - Cleaning (→ Page 46)

Torque wrench, 0.5-5 Nm

Part No.:

0015384230

Qty.:

Used in:

7.6.2 Injector - Removal and installation (→ Page 78)

Torque wrench, 10-60 Nm

Part No.:

F30510423

Qty.:

Used in:

1.4 Crankshaft transport locking device (→ Page 10)

Qty.:

Used in:

7.6.2 Injector - Removal and installation (→ Page 78)

Torque wrench, 40-200 Nm

Part No.:

F30027337

Qty.:

Used in:

7.13.2 Engine oil - Change (→ Page 99)

Torque wrench, 6-50 Nm

Part No.:

F30027336

Qty.:

Used in:

7.3.1 Crankcase breather - Oil separator replacement, diaphragm check and replace-

ment (→ Page 70)

Torque wrench, 6-50 Nm

Part No.:

F30027336

Qty.:

Used in:

7.14.2 Centrifugal oil filter - Cleaning and filter sleeve replacement (→ Page 103)

Torque wrench, 60-320 Nm

Part No.:

F30047446

Qty.:

Used in:

1.4 Crankshaft transport locking device (→ Page 10)

Qty.:

Used in:

7.4.2 Valve clearance - Check and adjustment (→ Page 73)

Qty.:

Used in:

7.6.2 Injector - Removal and installation (→ Page 78)

134 | Appendix B | MS150064/01E 2011-11

9.2

Index

12V 4000 engine data, continuous operation, variable

Engine

3B, emissions optimized (TA-Luft) 31

- Barring manually

12V 4000 engine data, continuous operation, variable

– Main dimensions

3B, emissions optimized w/o certificate 27

– Test run

12V 4000 engine data, continuous operation, variable

– Wiring check

125

3B, optimized fuel consumption 23

Engine control unit

- plug connections check

127

Engine control unit and connectors

Abbreviations 128

- Cleaning

126

After stopping the engine - Engine remains ready for op-

Engine coolant

eration 44

- Change

106

After stopping the engine - putting the engine out of

– Draining

107

service 45

Engine coolant pump

Air filter

- Relief bore check

111

- Removal and installation

Engine layout 22

– Replacement

Engine oil

Air starter - Manual operation 96

- Change

- Sample extraction and analysis

101

Engine oil filter

Centrifugal oil filter

- Replacement

102

- Cleaning and filter sleeve replacement

103

Engine oil level

Charge-air coolant

- Check

- Change

114

Engine side and cylinder

– Filling

116

- Designations

– Level check

113

Engine wiring

Charge-air coolant level

- Check

125

- Check

113

Charge-air coolant pump

- Relief bore check

120

Fault messages on engine governor 51

Contacts 131

Final compression pressure 34

Contamination indicator

Fire prevention and environmental protection 18

- Signal ring position check

Firing order 35

Coolant

Fluids and lubricants 18

- Sample extraction and analysis

112

Fuel

Coolant - charge air

- prefilter

- Level check

113

- Flushing

Coolant - charge-air

Fuel filter

- Change

114

- Replacement

Coolant level

Fuel prefilter

- Check

105

- Differential pressure gauge

Crankshaft transport locking device

- Check and adjustment

- Removal/installation

– Draining

Cylinder head cover

– Filter element

- Removal and installation

- Replacement

Cylinder liner

– Flushing

- Endoscopic examination

Fuel prefilter cleaning 85

– Instructions and comments on endoscopic and visual

examination

General conditions 7

Drive belt

- Condition check

121

HP pump

- Relief bore check

Emergency stop 43

MS150064/01E 2011-11 | Appendix B | 135

Injector

- Removal and installation

– Replacement

Inspection port cover

- Explosion hazard

Intercooler

- Drain, coolant leakage

Maintenance and repair work

- Safety regulations

MTU contact persons 131

Operational checks 41

Personnel and organizational requirements 8

Plant

- Cleaning

Putting the engine into operation after extended out-of-

service periods (>3 months) 37

Putting the engine into operation after scheduled out-of-

service-period 38

Safety instructions 20

Service partners 131

Start engine in manual mode (testing mode) 39

Starter

- Condition check

Starting the engine in emergency situations (override

mode) 40

Startup and operation

- Safety regulations

Stop engine in manual mode (testing mode) 42

Transport 9

Troubleshooting 48

Valve clearance

- Check and adjustment

Valve gear

- Lubrication

Wiring - engine

- Check

125

136 | Appendix B | MS150064/01E 2011-11