Operating Instructions Diesel engine 20 V 4000 G23 with 6 exhaust turbochargers 20 V 4000 G43 with 6 exhaust turbochargers 20 V 4000 G63 with 6 exhaust turbochargers 20 V 4000 G63L with 6 exhaust turbochargers 20 V 4000 G83 with 6 exhaust turbochargers 20 V 4000 G83L with 6 exhaust turbochargers MS150093/01E
Printed in Germany © 2012 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐ filming and storage or processing on electronic systems including data bases and online services.
Table of Contents 1 Safety 1.1 1.2 1.3 1.4 1.5 General conditions Personnel and organizational requirements Transport Crankshaft transport locking device Explosion hazard when removing inspection port cover on engine 1.6 Safety regulations for maintenance and repair work 1.7 Auxiliary materials, fluids and lubricants, fire prevention and environmental protection 1.8 Conventions for safety instructions in the text 5 6 7 8 11 3.7 Stop engine in manual mode (testing mode) 3.8 Emergency stop 3.
6.8 Fuel Filter 6.8.1 Fuel filter – Replacement 6.8.2 Fuel prefilter cleaning 6.8.3 Fuel prefilter – Differential pressure gauge check and adjustment 6.8.4 Fuel prefilter – Draining 6.8.5 Fuel prefilter ‒ Flushing 6.8.6 Fuel prefilter – Filter element replacement 6.9 Charge-Air Cooling 6.9.1 Intercooler – Checking condensate drain for coolant discharge and obstructions 6.10 Air Filter 6.10.1 Air filter – Replacement 6.10.2 Air filter – Check 6.10.3 Air filter – Removal and installation 6.
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.
1.2 Personnel and organizational requirements Personnel requirements All work on the engine shall be carried out by trained and qualified personnel only. The specified legal minimum age must be observed. The operator must specify the responsibilities of the operating, maintenance and repair personnel. Organizational measures This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐ tion.
1.3 Transport Transport Always use the lifting eyes on the engine and generator/gearbox when transporting gensets. Always use the lifting eyes on the engine when transporting an engine separately. Only use transport and lifting devices approved by MTU. The engine/genset must only be transported in installation position: maximum permissible diagonal pull 10°. Remove any loose parts on the genset. Raise the engine/genset slowly.
1.4 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 1 Torque wrench, 60-320 Nm F30047446 1 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: 1. 2. 3. 4. 5. 6.
Fitting the transport locking device on driving end (KS) Note: 1. 2. 3. Note: 4. 5. 6. Attach plates (2) only to the upper part of the openings. 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.
Installing guard plates and engine mounting brackets (if applicable) on driving end (KS) Note: 1. TIM-ID: 0000004010 - 008 2. Always use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure them on the engine. Install engine mounting brackets (2) on both sides with guard plates (1) washers (3), and screws (4). Tighten screws (4).
1.5 Explosion hazard when removing inspection port cover on engine DANGER Explosion hazard due to oil vapors. Risk of serious injury – danger to life! • Allow the engine to cool down before opening the crankcase! • Avoid open flames, electrical sparks and ignition sources. Safety instructions Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion due to oil vapors).
1.6 Safety regulations for maintenance and repair work 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.
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.
TIM-ID: 0000000879 - 023 For conducting light-beam procedures and measurement work, only the following laser devices must be used: • Laser devices of classes 1, 2 or 3A. • Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
1.7 Auxiliary materials, 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.
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.
1.8 Conventions for safety instructions in the text DANGER WARNING CAUTION NOTICE Note: In the event of immediate danger. Consequences: Death or serious injury • Remedial action In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action In the event of dangerous situations. Consequences: Minor injury or material damage • Remedial action In the event of a situation involving potentially adverse effects on the product. Consequences: Material damage.
2 Product Summary 2.
2.2 Overview of sensors, actuators and injectors 1 Temperature sensors for single exhaust gas B4.1 to B4.10 (engine side A) 2 Sensor B34 (P-Fuel after filter) 3 M8 (HP fuel pump ac‐ tuator) TIM-ID: 0000019859 - 001 The injectors (Y39.1 to Y39.10, engine side A) are underneath the cylinder head covers of the cylinder. Injector replacement and necessary activities (→ Page 119).
5 6 7 8 B07 (T lube oil) B01 (N camshaft) B48 (P fuel, rail) B43 (P charge-air cool‐ ant) 9 B26 (T charge-air cool‐ ant) 10 B06 (T coolant) TIM-ID: 0000019859 - 001 1 B50 (P crankcase) 2 B05.
1 Temperature sensors for single exhaust gas B4.11 to B4.20 (engine side B) 2 B16 (P coolant) 3 B10 (P charge air) 4 B09 (T charge air) TIM-ID: 0000019859 - 001 The injectors (Y39.11 to Y39.20, engine side B) are underneath the cylinder head covers of the cylinder.
TIM-ID: 0000019859 - 001 1 B13 (N crankshaft) 22 | Product Summary | MS150093/01E 2012-06
2.3 Engine – Main dimensions Engine – Main dimensions approx. 3560 mm Width (B) approx. 1660 mm Height (C) approx.
2.
2.
2.6 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
2.7 20V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized fuel consumption Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings).
Number of cylinders 20 20 20 20 20 Exhaust gas over‐ pressure 30 30 30 30 30 85 85 85 85 85 Number of cylin‐ ders 20 20 20 20 20 Number of cylin‐ ders 20 20 20 20 20 90 90 90 90 90 Exhaust gas over‐ pressure, max. A mbar MODEL-RELATED DATA (basic design) Cylinder arrange‐ ment: V-angle Degrees Bore mm 170 170 170 170 170 Stroke mm 210 210 210 210 210 Cylinder displace‐ ment Liters 4.77 4.77 4.77 4.77 4.77 Total displacement Liters 95.4 95.
COOLANT SYSTEM (LT circuit) Number of cylin‐ ders 20 20 20 20 20 Coolant tempera‐ A ture before inter‐ cooler (at engine in‐ let inlet from cool‐ ing system) °C 55 55 55 55 55 Coolant antifreeze content, max. % 50 50 50 50 50 bar 0.7 0.7 0.7 0.7 0.7 20 20 20 20 20 L Pressure loss in off- L engine cooling sys‐ tem, max.
GENERAL OPERATING DATA Number of cylin‐ ders Cold start capabili‐ ty: Air temperature (w/o start aid, w/o preheating) - (case A) 20 20 20 20 20 R °C 10 10 10 10 10 Coolant preheating: R preheating temper‐ ature (min.
ACOUSTICS Number of cylin‐ ders 20 20 20 20 20 dB(A) 104 104 106 106 110 Engine surface R noise with attenuat‐ ed intake noise (fil‐ ter) - DL (sound power level LW, ISO 6798, +2dB (A) tolerance) dB(A) 123 123 124 125 130 TIM-ID: 0000023524 - 001 Engine surface R noise with attenuat‐ ed intake noise (fil‐ ter) - DL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) MS150093/01E 2012-06 | Product Summary | 31
2.8 20V 4000 Gx3 engine data: Continuous operation, variable 3B, optimized exhaust emissions ("TA-Luft") Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings).
Number of cylinders 20 20 20 16.4 16.4 16.4 Inlet valves per cylinder 2 2 2 Exhaust valves per cylinder 2 2 2 20 20 20 3.1 3.4 3.
GENERAL OPERATING DATA Number of cylinders 20 20 20 Cold start capability: Air temperature (w/o start aid, w/o preheating) - (case A) R °C 10 10 10 Coolant preheating: preheating temperature (min.
2.9 20 V 4000 Gx3 engine data: Standby operation 3D, optimized fuel consumption, 6ETC Explanation: DL BL A G r L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings).
MODEL-RELATED DATA (basic design) Number of cylin‐ ders 20 20 20 20 20 20 Number of cylin‐ ders 20 20 20 20 20 20 90 90 90 90 90 90 Cylinder arrange‐ ment: V-angle Degrees Bore mm 170 170 170 170 170 170 Stroke mm 210 210 210 210 210 210 Cylinder dis‐ placement Liters 4.77 4.77 4.77 4.77 4.77 4.77 Total displace‐ ment Liters 95.4 95.4 95.4 95.4 95.4 95.4 16.4 16.4 16.4 16.4 16.4 16.
COOLANT SYSTEM (LT circuit) Number of cylin‐ ders 20 20 20 20 20 20 Coolant tempera‐ A ture before inter‐ cooler (at engine inlet inlet from cooling system) °C 55 55 55 55 55 55 Coolant anti‐ freeze content, max. % 50 50 50 50 50 50 bar 0.7 0.7 0.7 0.7 0.7 0.7 20 20 20 20 20 20 L Pressure loss in L off-engine cool‐ ing system, max.
FUEL SYSTEM Number of cylin‐ ders 20 20 20 20 20 20 Fuel pressure at engine inlet con‐ nection, min. (when engine is starting) L bar -0.1 -0.1 -0.1 -0.1 -0.1 -0.1 Fuel pressure at supply connec‐ tion to engine (when engine is starting), max. L bar 1.5 1.5 1.5 1.5 1.5 1.
Number of cylin‐ ders 20 20 20 20 20 20 Oil pan capacity L at dipstick mark “min.” (standard oil system) (op‐ tion: max. operat‐ ing inclinations) Liters 245 245 245 245 245 245 Oil pan capacity L at dipstick mark “max.” (standard oil system) (op‐ tion: max.
3 Operation 3.1 Putting the engine into operation after extended out-ofservice periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting into operation after long out-of-service periods (>3 months) Item Action Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..). Valve gear Lubricate valve gear every ≥ 6 months (→ Page 112). Lube oil system Check engine oil level (→ Page 142).
3.2 Putting the engine into operation after scheduled out-ofservice-period Preconditions ☑ Engine is stopped and starting disabled. Putting the engine into operation Item Task Lube oil system Check oil level (→ Page 142); Cooling system Check engine coolant level (→ Page 147); Check charge-air coolant level (→ Page 155). Cooling system Preheat coolant with preheating unit. Fuel prefilter Drain (→ Page 129). Monitoring equipment Carry out lamp test (see manufacturer's documentation).
3.3 Start engine in manual mode (testing mode) Preconditions ☑ Generator (if provided) not connected to network. ☑ External start interlock is not activated. DANGER WARNING 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. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors.
3.4 Safety system – Override CAUTION CAUTION Safety functions and engine shutdown alarms will be disregarded. Serious damage to plant! • Initiate emergency start only in emergency situations. Inadmissible operational condition. Major material damage! • Use override function only in hazardous situations to ensure full capability in case of engine mal‐ functions. Preparation Note: This function is only available when a pushbutton is provided.
3.5 Operational checks DANGER WARNING Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Operational checks Item Measure Control and display panels Check readings of operational data (speed, temperature, pressures).
3.6 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.
3.7 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.
3.8 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Task EMERGENCY STOP but‐ ton Press. • Engine is stopped by switching off power supply to ECU; • Signalization (e.g. by horn, flashing lamp) is released. After emergency stop from LOP Item Task Switching cabinet, control panel etc.
3.9 After stopping the engine – Engine remains ready for operation After stopping the engine Action Engine/generator/pump control Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
3.10 After stopping the engine – putting the engine out of service Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) is available.
3.11 Plant cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not present. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner - 1 30390 1 Cleaner (Hakupur 312) WARNING WARNING CAUTION NOTICE Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Water jet. Risk of injury and scalding! • Do not direct water jet at persons.
4 Maintenance 4.1 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. TIM-ID: 0000019908 - 002 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 142) W0501 Visually inspect engine for leaks and general condition.
5 Troubleshooting 5.1 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). Engine wiring or starter defective Check cable connections for secure seating, Starter (electric) Contact Service.
Engine does not reach nominal speed Component Probable cause Task Fuel supply Fuel prefilter clogged Replace (→ Page 132). Easy-change fuel filter clogged Replace (→ Page 126). Air supply Air filter clogged Check signal ring position of service in‐ dicator (→ Page 138). Fuel injection equip‐ ment Injector defective Replace (→ Page 119). Engine wiring Defective Check (→ Page 165). Engine Overloaded Contact Service.
Exhaust gas blue Component Probable cause Task Engine oil Too much engine oil in the engine Drain engine oil (→ Page 140). Oil separator of crankcase breather contaminated Replace (→ Page 111). Exhaust turbocharg‐ Defective er, cylinder head, pis‐ ton rings, cylinder lin‐ er Contact Service. Exhaust gas white Component Probable cause Task Engine Not at operating temperature Run engine to reach operating temper‐ ature. Fuel system Water in fuel Check fuel system on fuel prefilter.
5.2 Engine governor ADEC (ECU 7) for Series 4000 genset engines – Fault messages 003 – HI T-Fuel ZKP-Number: 2.0122.931 Limit value 1 Cause Corrective action Fuel temperature too high. u Contact Service. 004 – SS T-Fuel ZKP-Number: 2.0122.932 Limit value 2 Cause Corrective action Fuel temperature too high; engine shutdown. u Contact Service. 005 – HI T-Charge Air ZKP-Number: 2.0121.931 Limit value 1 Cause Corrective action Charge-air temperature too high. 1. Reduce power. 2. Check intercooler.
010 – SS T-Coolant Intercooler ZKP-Number: 2.0124.932 Limit value 2 Cause Coolant temperature in intercooler too high; engine shutdown. Corrective action u Reduce power. 015 – LO P-Lube Oil ZKP-Number: 2.0100.921 Limit value 1 Cause Lube oil pressure too low. Corrective action u Check oil level, top up as necessary (→ Page 142). 016 – SS P-Lube Oil ZKP-Number: 2.0100.922 Limit value 2 Cause Lube oil pressure too low; engine shutdown. Corrective action 1.
022 – SS T-Exhaust B ZKP-Number: 2.0127.932 Limit value 2 Cause Exhaust gas temperature (Bside) too high; engine shutdown. Corrective action 1. Check cabling (→ Page 165). 2. Contact Service. 023 – LO Coolant Level ZKP-Number: 2.0152.921 Limit value 1 Cause Coolant level too low. Corrective action u Check coolant level in expansion tank (→ Page 147). 025 – HI P-Diff. Lube Oil ZKP-Number: 2.0154.931 Limit value 1 Cause Oil filter differential pressure too high.
030 – SS Engine Speed ZKP-Number: 2.2510.932 Limit value 2 Cause Reduced fuel injection. Corrective action 1. Acknowledge alarm. 2. Attempt to restart engine. 031 – HI ETC 1 overspeed ZKP-Number: 2.3011.931 Limit value 1 Cause Speed of primary turbocharger too high. Corrective action u Contact Service. 032 – SS ETC 1 overspeed ZKP-Number: 2.3012.932 Limit value 2 Cause Speed of primary turbocharger too high. Corrective action 1. Automatic power reduction by engine control system. 2.
037 – SS ETC 2 Overspeed ZKP-Number: 2.3013.912 Limit value 2 Cause Corrective action Speed of first secondary turbocharger too high. 1. Reduce power. 2. Contact Service. 038 – AL ETC Speed Deviation ZKP-Number: 1.8004.205 Cause Corrective action Synchronization fault between primary turbocharger and one of the secondary turbochargers. 1. Reduce power. 2. Contact Service. 039 – AL ETC 2 Cutin Failure ZKP-Number: 1.8004.204 Cause ETC 2 failed to cut in. Corrective action 1. Reduce power. 2.
057 – LO P-Coolant ZKP-Number: 2.0101.921 Limit value 1 Cause Coolant pressure too low. Corrective action u Check coolant circuit. 058 – SS P-Coolant ZKP-Number: 2.0101.922 Limit value 2 Cause Coolant pressure too low; engine shutdown or reduction of fuel injection. Corrective action 1. Automatic engine shutdown. 2. Check coolant level (→ Page 147). 59 – SS T-Coolant L3 ZKP-Number: 20.120.933 Limit value 3 Cause Coolant temperature too high/ low Corrective action 1. Allow engine to cool down; 2.
064 – SS P-Crankcase ZKP-Number: 2.0106.932 Limit value 2 Cause Crankcase pressure too high; engine shutdown. Corrective action 1. Replace oil separator element (→ Page 111). 2. Contact Service. 065 – LO P-Fuel ZKP-Number: 2.0102.921 Limit value 1 Cause Fuel supply pressure too low. Corrective action 1. Check fuel lines for leaks. 2. Clean fuel prefilter (→ Page 127). 3. Flush fuel prefilter (→ Page 130). 4. Replace filter element of fuel prefilter (→ Page 132). 5. Replace fuel filter (→ Page 126).
081 – AL Rail Leakage ZKP-Number: 1.8004.046 Cause Pressure gradient in common rail too low during engine start or too high during engine stop; HP fuel system leaky, air in system. Corrective action u Contact Service. 082 – HI P-Fuel (Common Rail) ZKP-Number: 2.0104.931 Cause Rail pressure > set-point value; DBR reduction, start of injection moved to late; suction restrictor jamming or wiring of suction restrictor faulty. Corrective action u Contact Service. 083 – LO P-Fuel (Common Rail) ZKP-Number: 2.
090 – SS Starter Speed Not Reached ZKP-Number: 2.1090.925 Cause Idling speed was not attained. Corrective action u Contact Service. 091 – SS Release Speed Not Reached ZKP-Number: 2.1090.924 Cause Runup speed was not attained. Corrective action u Contact Service. 092 – SS Starter Speed Not Reached ZKP-Number: 2.1090.923 Cause Starter speed was not attained; termination of start sequence; starter rotates too low or not at all. Corrective action u Contact Service. 093 – SS T-Preheat ZKP-Number: 2.1090.
102 – AL Consumption Meter Faulty ZKP-Number: 1.8004.624 Cause Corrective action consumption meter faulty. u Contact Service. 104 – AL Eng Hours Counter Defect ZKP-Number: 1.8004.623 Cause Corrective action hour meter faulty. u Contact Service. 118 – LO ECU Supply Voltage ZKP-Number: 2.0140.921 Limit value 1 Cause Corrective action Supply voltage too low. 1. Check ECU supply voltage. 2. Contact Service. 119 – LOLO ECU Supply Voltage ZKP-Number: 2.0140.
122 – HI T-ECU ZKP-Number: 2.0132.921 Limit value 1 Cause Electronic unit temperature too high. Corrective action 1. Reduce power. 2. Improve engine room ventilation. 141 – AL Power too high ZKP-Number: 11.088.007 Cause This alarm is activated when the average power of the last 24 hours exceeded the maximum value set in PR1.1088.001. Corrective action u Reduce power. 142 – AL MCR exceeded 1 hour ZKP-Number: 1.1088.
180 – AL CAN1 Node Lost ZKP-Number: 2.0500.680 Cause Connection to one node on CAN bus 1 failed. Corrective action u Contact Service. 181 – AL CAN2 Node Lost ZKP-Number: 2.0500.681 Cause Connection to one node on CAN bus 2 failed. Corrective action u Contact Service. 182 – AL CAN Wrong Parameters ZKP-Number: 2.0500.682 Cause Incorrect parameter values entered in data record. Corrective action u Contact Service. 183 – AL CAN No PU-Data ZKP-Number: 2.0500.
187 – AL CAN1 Error Passive ZKP-Number: 2.0500.687 Cause Corrective action CAN controller 1 has signaled a warning. 1. Inspect CAN bus for short circuit and rectify short circuit as necessary. 2. Check shielding, improve as necessary. 3. Contact Service. 188 – AL CAN2 Bus Off ZKP-Number: 2.0500.688 Cause Corrective action CAN controller 2 is in “Bus-Off” status. => Automatic changeover to CAN 1; short circuit, massive interference or Baud rate incompatibility. 1.
203 – SD T-Charge Air ZKP-Number: 1.8004.571 Cause Charge-air temperature sensor faulty; short circuit or wire break. Corrective action u Check sensor and cabling (B9), replace as necessary. Error cleared after restarting the engine. 204 – SD Level Lube Oil ZKP-Number: 1.8004.602 Cause Lube-oil level sensor faulty; short circuit or wire break. Corrective action u Check sensor and cabling, replace as necessary. 205 – SD T-Coolant Intercooler ZKP-Number: 1.8004.
211 – SD P-Lube Oil ZKP-Number: 1.8004.563 Cause Lube-oil pressure sensor faulty; short circuit or wire break. Corrective action u Check sensor and cabling (B5), replace as necessary. Error cleared after restarting the engine. 212 – SD P-Coolant ZKP-Number: 1.8004.564 Cause Coolant pressure sensor faulty; short circuit or wire break. Corrective action u Check sensor and cabling (B16), replace as necessary. Error cleared after restarting the engine. 213 – SD P-Coolant Intercooler ZKP-Number: 1.8004.
219 – SD T-Intake Air ZKP-Number: 1.8004.573 Cause Corrective action Intake air temperature sensor faulty; short circuit or wire break. u Check sensor and cabling (B3), replace as necessary. Error cleared after restarting the engine. 220 – SD Coolant Level ZKP-Number: 1.8004.584 Cause Corrective action Coolant level sensor faulty; short circuit or wire break. u Check sensor and cabling (F33), replace as necessary. Error cleared after restarting the engine. 221 – HI P-Diff Lube Oil ZKP-Number: 1.
228 – SD P-Fuel before Filter ZKP-Number: 18.004.595 Cause Fuel pressure sensor faulty; short circuit or wire break. Corrective action u Check sensor and cabling (B5.3), replace as necessary. 229 – AL Stop Camshaft Sensor Defect ZKP-Number: 1.8004.562 Cause engine stop due to camshaft sensor fault (and a prior crankshaft sensor fault in the same operating cycle). Corrective action u Check connector and cabling to sensor B1, replace as necessary. Error cleared after restarting the engine.
239 – SD P-Diff Fuel ZKP-Number: 18.004.598 Cause Fuel differential pressure sensor faulty. This alarm occurs only in combination with the alarm SD P-Fuel before Filter or SD P-Fuel after Filter. Corrective action u Note further fault messages. 240 – SD P-Fuel ZKP-Number: 1.8004.565 Cause Fuel pressure sensor faulty; short circuit or wire break. Corrective action u Check sensor and cabling (B34), replace as necessary. Error cleared after restarting the engine. 241 – SD T-Umblasen ZKP-Number: 1.8004.
266 – SD Speed Demand ZKP-Number: 2.8006.586 Cause Analog speed demand signal faulty; short circuit or wire break. Corrective action 1. Check cabling. 2. Check speed demand signal. 268 – SD Spinning Value ZKP-Number: 28.006.591 Cause Analog wheel slip signal faulty; short circuit or wire break. Corrective action u Check sensor and cabling, replace as necessary. 269 – SD Loadp.Analog filt ZKP-Number: 2.8006.588 Cause Filtered analog load pulse signal missing; short circuit or wire break.
303 – AL Timing Cylinder A3 ZKP-Number: 1.8004.502 Cause Time-of-flight measuring fault of injector: time-of flight measured value extremely low or extremely high. Corrective action u Replace injector concerned if the fault message appears frequently (→ Page 119). 304 – AL Timing Cylinder A4 ZKP-Number: 1.8004.503 Cause Time-of-flight measuring fault of injector: time-of flight measured value extremely low or extremely high.
308 – AL Timing Cylinder A8 ZKP-Number: 1.8004.507 Cause Corrective action Time-of-flight measuring fault of injector: time-of flight measured value extremely low or extremely high. u Replace injector concerned if the fault message appears frequently (→ Page 119). 309 – AL Timing Cylinder A9 ZKP-Number: 1.8004.508 Cause Corrective action Time-of-flight measuring fault of injector: time-of flight measured value extremely low or extremely high.
313 – AL Timing Cylinder B3 ZKP-Number: 1.8004.512 Cause Time-of-flight measuring fault of injector: time-of flight measured value extremely low or extremely high. Corrective action u Replace injector concerned if the fault message appears frequently (→ Page 119). 314 – AL Timing Cylinder B4 ZKP-Number: 1.8004.513 Cause Time-of-flight measuring fault of injector: time-of flight measured value extremely low or extremely high.
318 – AL Timing Cylinder B8 ZKP-Number: 1.8004.517 Cause Corrective action Time-of-flight measuring fault of injector: time-of flight measured value extremely low or extremely high. u Replace injector concerned if the fault message appears frequently (→ Page 119). 319 – AL Timing Cylinder B9 ZKP-Number: 1.8004.518 Cause Corrective action Time-of-flight measuring fault of injector: time-of flight measured value extremely low or extremely high.
324 – AL Wiring Cylinder A4 ZKP-Number: 1.8004.523 Cause Corrective action Cabling fault in injector cabling to cylinder. Result: misfiring. 1. Check solenoid valve. 2. Contact Service. 325 – AL Wiring Cylinder A5 ZKP-Number: 1.8004.524 Cause Corrective action Cabling fault in injector cabling to cylinder. Result: misfiring. 1. Check solenoid valve. 2. Contact Service. 326 – AL Wiring Cylinder A6 ZKP-Number: 1.8004.525 Cause Corrective action Cabling fault in injector cabling to cylinder.
331 – AL Wiring Cylinder B1 ZKP-Number: 1.8004.530 Cause Cabling fault in injector cabling to cylinder. Result: misfiring. Corrective action 1. Check solenoid valve. 2. Contact Service. 332 – AL Wiring Cylinder B2 ZKP-Number: 1.8004.531 Cause Cabling fault in injector cabling to cylinder. Result: misfiring. Corrective action 1. Check solenoid valve. 2. Contact Service. 333 – AL Wiring Cylinder B3 ZKP-Number: 1.8004.532 Cause Cabling fault in injector cabling to cylinder. Result: misfiring.
338 – AL Wiring Cylinder B8 ZKP-Number: 1.8004.537 Cause Corrective action Cabling fault in injector cabling to cylinder. Result: misfiring. 1. Check solenoid valve. 2. Contact Service. 339 – AL Wiring Cylinder B9 ZKP-Number: 1.8004.538 Cause Corrective action Cabling fault in injector cabling to cylinder. Result: misfiring. 1. Check solenoid valve. 2. Contact Service. 340 – AL Wiring Cylinder B10 ZKP-Number: 1.8004.539 Cause Cabling fault in injector cabling to cylinder. Result: misfiring.
345 – AL Open Load Cylinder A5 ZKP-Number: 1.8004.544 Cause Disruption fault in injector cabling to cylinder. Result: misfiring. Corrective action 1. Check solenoid valve. 2. Contact Service. 346 – AL Open Load Cylinder A6 ZKP-Number: 1.8004.545 Cause Disruption fault in injector cabling to cylinder. Result: misfiring. Corrective action 1. Check solenoid valve. 2. Contact Service. 347 – AL Open Load Cylinder A7 ZKP-Number: 1.8004.546 Cause Disruption fault in injector cabling to cylinder.
352 – AL Open Load Cylinder B2 ZKP-Number: 1.8004.551 Cause Disruption fault in injector cabling to cylinder. Result: misfiring. Corrective action 1. Check solenoid valve. 2. Contact Service. 353 – AL Open Load Cylinder B3 ZKP-Number: 1.8004.552 Cause Disruption fault in injector cabling to cylinder. Result: misfiring. Corrective action 1. Check solenoid valve. 2. Contact Service. 354 – AL Open Load Cylinder B4 ZKP-Number: 1.8004.553 Cause Disruption fault in injector cabling to cylinder.
359 – AL Open Load Cylinder B9 ZKP-Number: 1.8004.558 Cause Disruption fault in injector cabling to cylinder. Result: misfiring. Corrective action 1. Check solenoid valve. 2. Contact Service. 360 – AL Open Load Cylinder B10 ZKP-Number: 1.8004.559 Cause Disruption fault in injector cabling to cylinder. Result: misfiring. Corrective action 1. Check solenoid valve. 2. Contact Service. 361 – AL Power Stage Low ZKP-Number: 1.8004.496 Cause Internal electronic fault (electronics possibly faulty: start ITS).
365 – AL Stop MV-Wiring Ground ZKP-Number: 1.8004.561 Cause Injector cabling fault. If bit “1.1020.021” (Power Stage Failure: stop engine) is set, engine will be shut down as additional measure. 1. Short circuit of positive connection of one or more injectors to ground 2. Short circuit of negative connection of one or more injectors to ground . Corrective action 1. Check cabling. 2. Attempt to restart engine. 371 – AL Wiring TO 1 ZKP-Number: 1.8004.
381 – AL Wiring TOP 1 ZKP-Number: 2.8006.638 Cause Short circuit or wire break on transistor output, plant-side 1 (TOP 1). Corrective action u Check cabling to plant. 382 – AL Wiring TOP 2 ZKP-Number: 2.8006.639 Cause Short circuit or wire break on transistor output, plant-side 2 (TOP 2). Corrective action u Check cabling to plant. 383 – AL Wiring TOP 3 ZKP-Number: 2.8006.640 Cause Short circuit or wire break on transistor output, plant-side 3 (TOP 3). Corrective action u Check cabling to plant.
393 – SS T-Coolant Red ZKP-Number: 2.0129.932 Limit value 2 Cause Redundant coolant temperature reading too high; engine shutdown. Corrective action 1. Check cabling and sensor. 2. Contact Service. 394 – LO P-Lube Oil Red ZKP-Number: 2.0112.921 Limit value 1 Cause Redundant lube oil pressure reading too low. Corrective action 1. Check cabling and sensor. 2. Contact Service. 395 – SS P-Lube Oil Red ZKP-Number: 2.0112.922 Limit value 2 Cause Redundant lube oil pressure reading too low.
401 – AL Open Load Digital Input 2 ZKP-Number: 2.8006.626 Cause Open circuit at digital input 2; cabling faulty or no resistance across the switch. Corrective action 1. Check cabling. 2. Check input of target device. 3. Contact Service. 402 – AL Open Load Digital Input 3 ZKP-Number: 2.8006.627 Cause Open circuit at digital input 3; cabling faulty or no resistance across the switch. Corrective action 1. Check cabling. 2. Check input of target device. 3. Contact Service.
407 – AL Open Load Digital Input 8 ZKP-Number: 2.8006.632 Cause Open circuit at digital input 8; cabling faulty or no resistance across the switch. Corrective action 1. Check cabling. 2. Check input of target device. 3. Contact Service. 408 – AL Open Load Emerg. Stop Input ESI ZKP-Number: 2.8006.633 Cause Open circuit at input for emergency stop; cabling faulty or no resistance across the switch. Corrective action 1. Check cabling. 2. Check input of target device. 3. Contact Service.
413 – HIHI U-PDU ZKP-Number: 2.0141.932 Limit value 2 Cause Corrective action Injector voltage too high. 1. Check cabling. 2. Check power supply. 3. Contact Service. 414 – HI Water Level Fuel Prefilter ZKP-Number: 2.0156.931 Limit value 1 Cause Corrective action Water level in fuel prefilter too high. u Drain water (→ Page 129). 415 – LO P-Coolant Intercooler ZKP-Number: 2.0107.921 Limit value 1 Cause Corrective action Coolant pressure in intercooler too low. u Top up coolant (→ Page 158).
420 – AL L1 Aux 1 ZKP-Number: 2.0160.921 Limit value 1 Cause Input signal of Aux 1 has exceeded/not attained limit value 1, depending on configuration. Corrective action u Determine and rectify reason for limit value violation. 421 – AL L2 Aux 1 ZKP-Number: 2.0160.922 Limit value 2 Cause Input signal of Aux 1 has exceeded/not attained limit value 2, depending on configuration. Corrective action u Determine and rectify reason for limit value violation. 428 – AL L1 T-Aux 1 ZKP-Number: 2.0130.
434 – HI T-Coolant before Engine ZKP-Number: 20.173.931 Limit value 1 Cause Coolant temperature too high. Corrective action u Check coolant circuit. 435 – SS T-Coolant before Engine ZKP-Number: 20.173.932 Limit value 2 Cause Coolant temperature too high. Corrective action u Check coolant circuit. 440 – AL L1 P-Aux 1 ZKP-Number: 2.0110.921 Limit value 1 Cause Pressure signal of Aux 1 has exceeded / not attained limit value 1, depending on configuration.
448 – HI P-Charge Air ZKP-Number: 2.0103.931 Limit value 1 Cause Charge-air pressure too high. Corrective action u Contact Service. 449 – SS P-Charge Air ZKP-Number: 2.0103.932 Limit value 2 Cause Charge-air pressure too high. Corrective action u Contact Service. 450 – SD Idle/End-Torque Input [%] ZKP-Number: 2.8006.592 Cause Input signal for idle/end torque faulty; short circuit or wire break. Corrective action u Check signal transmitter and cabling, replace as necessary.
460 – HI T-Exhaust EMU ZKP-Number: 2.8006.652 Limit value 1 Cause EMU exhaust gas temperature value too high. Corrective action 1. Check cabling. 2. Contact Service. 461 – LO T-Exhaust EMU ZKP-Number: 2.8006.653 Limit value 1 Cause EMU exhaust gas temperature value too low. Corrective action 1. Check cabling. 2. Contact Service. 462 – HI T-Coolant EMU ZKP-Number: 2.8006.654 Limit value 1 Cause EMU coolant temperature value too high / low. Corrective action u Check configuration with DiaSys.
469 – SD AUX 1 ZKP-Number: 1.8004.590 Cause Corrective action Analog input signal for Aux 1 faulty; short circuit or wire break. u Check signal transmitter and cabling, replace as necessary. Error cleared after restarting the engine. 470 – SD T-ECU ZKP-Number: 1.8004.587 Cause Corrective action Temperature sensor for ECU faulty; short circuit or wire break. u Check sensor and cabling, replace as necessary. Error cleared after restarting the engine. 471 – SD Coil Current ZKP-Number: 1.8004.
475 – AL CR Trigger Engine Stop ZKP-Number: 1.8010.009 Cause Tripped by crash recorder triggering due to engine shutdown. Corrective action u Determine and rectify cause of triggering / engine shutdown. 476 – AL Crash Rec. Init. Error ZKP-Number: 1.8010.007 Cause Crash recorder initialization error. Corrective action u Check setting with DiaSys. 478 – AL Comb. Alarm Yel (Plant) ZKP-Number: 2.8006.001 Cause Combined alarm YELLOW from plant. Corrective action u Note further fault messages.
483 – SD T-Exhaust D ZKP-Number: 18.004.597 Cause Exhaust temperature sensor on A-side faulty; short circuit or wire break. Corrective action u Check sensor and cabling (B4.24), replace as necessary. 484 – HI T-Exhaust C ZKP-Number: 20.133.931 Limit value 1 Cause Exhaust gas temperature (Cside) too high. Corrective action 1. Reduce power. 2. Contact Service. 485 – SS T-Exhaust C ZKP-Number: 20.133.932 Limit value 2 Cause Exhaust gas temperature (Cside) too high. Corrective action 1. Reduce power. 2.
489 – SS ETC3 Overspeed ZKP-Number: 23.014.932 Limit value 2 Cause Speed of second secondary turbocharger too high. Corrective action u Reduce power. 490 – HI ETC4 Overspeed ZKP-Number: 23.015.931 Limit value 1 Cause Speed of third secondary turbocharger too high. Corrective action u Reduce power. 491 – SS ETC4 Overspeed ZKP-Number: 23.015.932 Limit value 2 Cause Speed of third secondary turbocharger too high. Corrective action u Reduce power. 492 – AL ETC4 CutIn Failure ZKP-Number: 18.004.
501 – AL Wiring POM Starter 2 ZKP-Number: 14.500.901 Cause Corrective action A wiring fault was detected in the connection of starter 2 of the CPM. The root cause might be a missing consumer, a wire break or a short circuit. u Check connection between POM and starter. 502 – AL Open Load POM Alternator ZKP-Number: 14.500.902 Cause Corrective action An open circuit was detected at the battery-charging generator connection of the POM. u Check connection between POM and battery-charging generator.
508 – AL Wrong POM-ID ZKP-Number: 14.500.908 Cause Corrective action POM transmits a different ID No. than expected. u Check POM wiring harness. 510 – AL Override applied ZKP-Number: 27.002.010 Cause Corrective action Override was activated. u Deactivate Override pushbutton. 515 – AL Starter Not Engaged ZKP-Number: 21.090.926 Cause Starter on CPM / POM could not be engaged.The starting sequence will be terminated when the number of automatic start attempts defined in PR 2.1090.134 is exhausted.
524 – SS Engine Overspeed Mid Val ZKP-Number: 20.480.089 Limit value 2 Cause Average engine overspeed value from three sources is too high. Corrective action 1. Acknowledge alarm. 2. Attempt to restart engine. 525 – SD P-Lube Oil (R2) ZKP-Number: 18.004.638 Cause Redundant lube oil pressure sensor faulty; short circuit or wire break. Corrective action u Check sensor and cabling, replace as necessary. 526 – SD T-Coolant (R2) ZKP-Number: 18.004.
530 – SS P-Lube Oil Red2 ZKP-Number: 20.480.295 Limit value 2 Cause Corrective action Second redundant lube-oil pressure too high. u Check oil level, top up as necessary . 543 – AL Multiple FDH Slaves ZKP-Number: 20.555.005 Cause There is more than one unit activated as backup medium for FDH. Corrective action u Contact Service. 544 – AL Configuration Changed ZKP-Number: 20.555.003 Cause This alarm is activated if the system configuration was changed, e.g. due to an exchange of the ECU or SAM.
551 – SS Engine Overspeed Camshaft ZKP-Number: 22.510.933 Limit value 2 Cause Camshaft overspeed. Corrective action 1. Acknowledge alarm. 2. Attempt to restart engine. 555 – AL Call MTU Field Service ZKP-Number: 20.555.001 Cause This alarm is activated if the ECU feature Field Data Handling (FDH) has carried out a maintenance job which led to a change of the engine parameters.
579 – AL MD CAN Request Idle Speed ZKP-Number: 21.063.511 Cause MD forced idle demand => node failure (node 3,4 or 5) Corrective action u 580 – AL MD CAN Speed Limitation ZKP-Number: 21.063.513 Cause MD speed limitation demand => node failure (node 3,4 or 5) Corrective action u 581 – AL MD CAN Stop ZKP-Number: 21.063.
6 Task Description 6.1 Engine 6.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use DANGER Part No. Qty. Barring device F6555766 1 Ratchet with extension F30006212 1 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 1. 2. 3. 4. TIM-ID: 0000000917 - 007 5.
6.1.2 DANGER Engine – Barring with starting system 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 1. 2. 3. 4. 5. TIM-ID: 0000000918 - 004 6. Release latch of connector X4. Remove connector from engine governor.
6.1.3 DANGER WARNING Engine – Test run 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. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Engine – Test run Start engine (→ Page 42). Perform test run not below 1/3 load and at least until steady-state temperature is reached. Carry out operational checks (→ Page 44). Stop engine (→ Page 46).
6.2 Cylinder Liner 6.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 1 Preparatory steps 1. 2. Remove cylinder head cover (→ Page 117). Remove injector (→ Page 120). Positioning crankshaft at BDC 1. 2. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC.
Final steps Install injector (→ Page 120). Install cylinder head cover (→ Page 117). TIM-ID: 0000000015 - 013 1. 2.
6.2.2 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.
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.
6.3 Crankcase Breather 6.3.1 Crankcase breather – Oil mist fine separator replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Engine oil Oil mist fine separator (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) Qty. 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.
6.4 Valve Drive 6.4.1 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication 1. 2. 3. TIM-ID: 0000000921 - 008 4. Remove cylinder head covers (→ Page 117). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjust‐ ing screws with oil. Install cylinder head covers (→ Page 117).
6.4.2 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 Y20098771 1 Torque wrench, 60-320 Nm F30452768 1 Box wrench socket, 24 mm F30039526 1 Ratchet adapter F30027341 1 Engine oil Preparatory steps Remove cylinder head cover (→ Page 117). Install barring device (→ Page 104). 3.
4. Rotate crankshaft with barring device in di‐ rection of engine rotation until TDC-A1 marking and pointer are aligned.
Diagram for 16V engines (two crankshaft positions) 1 2 I X Cylinder A1 is in firing TDC Cylinder A1 is in overlap TDC Inlet valve Exhaust valve Diagram for 20V engines (two crankshaft positions) 1 2 I X Cylinder A1 is in firing TDC Cylinder A1 is in overlap TDC Inlet valve Exhaust valve Checking valve clearance at two crankshaft positions 1. 2. TIM-ID: 0000000922 - 008 3. 4. 5. Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
Adjusting valve clearance 1. 2. 3. 4. 5. 6. 7. Release locknut (1). Insert feeler gauge between valve bridge and rocker arm. Use Allen key to set adjusting screw (2) so that the specified valve clearance is estab‐ lished. 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 Locknut M16 x 1.
6.4.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Grease (Kluthe Hakuform 30-10/Emulgier) Qty. X00058061 O-ring (→ Spare Parts Catalog) Removing cylinder head cover 1. 2. 3. Clean very dirty cylinder head covers (3) prior to removal. Remove screws (1) and washers (2). Take off cylinder head cover (3) with Oring (4) from cylinder head (5).
6.5 Injection Pump / HP Pump 6.5.1 HP pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING WARNING CAUTION Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Oils/oil vapors are combustible. Risk of fire! • No open flames, no electric sparks. Do not smoke. Avoid ignition sources.
6.6 Injection Valve / Injector 6.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Injector Qty. (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 120).
6.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal tool F6789889 1 Milling cutter F30452739 1 Torque wrench, 0.
2. 3. Note: 4. 5. 6. 7. 8. 9. 10. The injector accumulator will be emptied when removing the adapter. Remove adapter (3). Remove screw (2) and take off hold-down clamp (1). Install installation/removal tool on cylinder head. Remove injector with installation/removal tool. Remove installation/removal tool. Remove sealing ring (4) from injector or use a self-made hook to take it out of the cylin‐ der head. Remove O-rings (3), O-ring (2) and damper ring (1) from injector.
Installing injector 1. 2. 3. Remove plug before installing the injec‐ tor. (Do not remove the plug from the HP line before installing the adapter.) Coat injector with assembly paste at the seat of the nozzle clamping nut. Fit new sealing ring (4) (included in the scope of supply of the injector) with grease on injector, observe installation position of sealing ring (4). 4.
9. 10. Note: 11. 12. Coat screw head mating face (2) and thread with engine oil. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the specified initial tightening torque. Name Size Type Lubricant Value/Standard Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm Ensure special cleanness. Coat thread and sealing cone of adapter (3) with engine oil. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
18. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening sequence: 1 Adapter (4) 2 Rail (6) Name Size Union nut / thrust screw 19. Type Tightening torque Lubricant Value/Standard 40 Nm + 5 Nm Fit cable connector onto injector. Final steps Install cylinder head cover (→ Page 117). Open fuel supply to engine. TIM-ID: 0000000925 - 006 1. 2.
6.7 Fuel System 6.7.1 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 1. 2. 3. Note: 4. Collect fuel in a suitable container. Operate the pump with the handle (1) until bubble-free fuel emerges from the vent valve (2).
6.8 Fuel Filter 6.8.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Filter wrench Engine oil Easy-change filter WARNING Part No. Qty. F30379104 1 (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Replacing the fuel filter 1. 2. 3. 4. 5. TIM-ID: 0000004907 - 001 6.
6.8.2 Fuel prefilter cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Diesel fuel Sealing ring WARNING Qty. (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Fuel prefilter cleaning 1. 2. 3. 4. 5. 6. 7. 8. 9. TIM-ID: 0000004936 - 001 10. Shut off fuel supply. Remove nuts from filter head.
6.8.3 DANGER WARNING Fuel prefilter – Differential pressure gauge check and adjustment Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Adjusting differential pressure gauge 1. 2. When installing the new filter element: align adjustable pointer (2) with pressure-indicat‐ ing pointer (3) of pressure gauge (1).
6.8.4 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Diesel fuel Gasket WARNING Qty. (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Fuel prefilter – Draining 1. Cut out filter to be drained. I Left filter cut in II Right filter cut in 2. Open threaded vent plug (5) of filter to be drained.
6.8.5 Fuel prefilter ‒ Flushing Special tools, Material, Spare parts Designation / Use Fuel Gasket DANGER WARNING WARNING Part No. Qty. (→ Spare Parts Catalog) Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Engine noise above 85 dB (A).
2. 3. Result: 4. Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing valve toggle, open it and drain fuel. 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 46) and disable engine start. Remove screws for cover and take off cover (2). Fill filter housing with clean fuel.
6.8.6 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) Qty. Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Replacing filter element Cut out filter to be drained.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. TIM-ID: 0000004944 - 004 14. 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. Place new gasket in cover (2).
6.9 Charge-Air Cooling 6.9.1 DANGER WARNING WARNING Intercooler – Checking condensate drain for coolant discharge and obstructions Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors.
6.10 Air Filter 6.10.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Air filter Part No. Qty. (→ Spare Parts Catalog) Air filter – Replacement Remove air filter and install new one (→ Page 137). Reset signal ring of service indicator (→ Page 138). TIM-ID: 0000000903 - 004 1. 2.
6.10.2 Air filter – Check Special tools, Material, Spare parts Designation / Use Air filter Part No. Qty. (→ Spare Parts Catalog) Air filter – Check Check entire circumference of air filter for damage. Fit new air filter if damaged (→ Page 137). TIM-ID: 0000005430 - 003 1. 2.
6.10.3 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Removing and installing air filter 1. 2. 3. 4. TIM-ID: 0000005457 - 006 5. Release clamp (2). Remove air filter (3) and clamp (2) from connecting flange of intake housing (1). Verify that there are no objects in the con‐ necting flange of the intake housing (1) and clean it. Place new air filter (3) with clamp (2) onto intake housing (1). Tighten clamp (2).
6.11 Air Intake 6.11.1 Contamination indicator – Signal ring position check (optional) Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position 1. 2. TIM-ID: 0000005484 - 007 Result: If the signal ring is completely visible in the observation window (2), replace air filter (→ Page 135). After installation of new filter, press reset button (1). Engaged piston with signal ring moves back to initial position.
6.12 Starting Equipment 6.12.1 DANGER WARNING Air starter – Manual operation 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. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Air starter – Manual operation 1. 2. TIM-ID: 0000006076 - 003 3. Press pushbutton for manual start and hold it.
6.13 Lube Oil System, Lube Oil Circuit 6.13.1 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 1 Ratchet adapter F30027341 1 Engine oil Sealing ring WARNING (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
Draining residual oil from equipment carrier (only with unscheduled engine oil change) 1. 4. 5. 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 144). Install drain plug(s) with new sealing ring. 6. Tighten drain plugs (2) and (3) with torque wrench to specified tightening torque. 2. 3.
6.13.2 Engine oil level – Check Preconditions ☑ Engine shut down and starting disabled. Checking oil level prior to engine start 1. 2. Note: 3. 4. 5. 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. 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.
6.13.3 Engine oil – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use MTU test kit DANGER WARNING WARNING Part No. Qty. 5605892099/00 1 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Hot oil. Oil can contain combustion residues which are harmful to health.
6.14 Oil Filtration / Cooling 6.14.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Filter wrench Engine oil Oil filter WARNING Part No. Qty. F30379104 (→ Spare Parts Catalog) 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.
6.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Qty. Torque wrench, 6-50 Nm F30027336 1 Cold cleaner (Hakutex 60) X00056750 1 Filter sleeve (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
Centrifugal oil filter cleaning and filter sleeve replacement 16. Remove clamp (14). Release cover screw (2) and take off cov‐ er (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3). Take off rotor cover (4). Remove filter sleeve (6). Measure thickness of oil residues on filter sleeve (6). If maximum layer thickness of oil residues exceeds 45 mm, shorten maintenance in‐ terval.
6.15 Coolant Circuit, General, High-Temperature Circuit 6.15.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Coolant-level check at remote cooler: 1. 2. 3. 4. Check coolant level (coolant must be visible at marking plate).
6.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 149). Fill with engine coolant (→ Page 150). TIM-ID: 0000000036 - 030 1. 2.
6.15.3 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 1. 2. Provide an appropriate container to drain the coolant into. Switch off preheating unit. Engine coolant – Draining 1. 2. 3. 4. TIM-ID: 0000000960 - 002 5. 6.
6.15.4 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 CAUTION Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Cold coolant in hot engine can cause thermal stress.
Filling coolant with pump 1. Connect appropriate pump with hose to the drain valve of the engine coolant pump (ar‐ row). 2. 3. Open venting point at distributor (arrow). Open drain valve and pump coolant into en‐ gine at 0.5 bar minimum. Close venting point when coolant emerges. Fill expansion tank until overflow edge is reached. Close drain valve. Check proper condition of breather valve on coolant expansion tank, clean sealing faces if required. Fit breather valve and close it.
Alternatively: Filling coolant through filler neck 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Open venting point at distributor (arrow). Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. Close venting point when coolant emerges. Check proper condition of breather valve on coolant expansion tank, clean sealing faces if required. Fit breather valve and close it. Start engine (→ Page 42).
6.15.5 DANGER WARNING Engine coolant pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Engine coolant pump – Relief bore check 1. 2. 3. TIM-ID: 0000000939 - 002 4. Check relief bore for oil and coolant dis‐ charge.
6.15.6 Engine coolant – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use MTU test kit DANGER WARNING WARNING Part No. Qty. 5605892099/00 1 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
6.16 Low-Temperature Circuit 6.16.1 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: 1. 2. 3. 4. 5. 6.
6.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 157). Fill with charge-air coolant (→ Page 158). TIM-ID: 0000000041 - 011 1. 2.
6.16.3 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Sealing ring WARNING Qty. (→ Spare Parts Catalog) Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Draining charge-air coolant 1. 2. 3. 4. 5. 6. 7.
6.16.4 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 CAUTION Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Cold coolant in hot engine can cause thermal stress.
Filling coolant with pump 1. Connect a suitable pump with a hose to the drain valve (arrowed). 2. Undo the vent line union at the distributor piece (arrowed). Open drain valve and pump coolant into en‐ gine at 0.5 bar minimum. Tighten the union (arrowed) if coolant leaks out at the loose union. Fill expansion tank until overflow edge is reached. Close drain valve. Check proper condition of breather valve and clean sealing faces if required. Set breather valve onto filler neck and close it.
Alternatively: Filling coolant through filler neck 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Undo the vent line union at the distributor piece (arrowed). Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. Tighten the union (arrowed) if coolant leaks out at the loose union. Check proper condition of breather valve on coolant expansion tank, clean sealing faces if required. Fit breather valve and close it. Start engine (→ Page 42).
6.16.5 DANGER WARNING Charge-air coolant pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Charge-air coolant pump – Relief bore check 1. 2. 3. TIM-ID: 0000000943 - 002 4. Check relief bore for oil and coolant dis‐ charge.
6.17 Belt Drive 6.17.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed.
6.18 Battery-Charging Generator 6.18.1 Battery-charging generator drive – Drive belt tension adjustment Preconditions ☑ Engine is stopped and starting disabled. WARNING Spring/circlip/tensioning roller preload. Risk of injury! • Only use specified tool and equipment. Adjusting belt tension 1. 2. Result: 3. 4. Tighten screw (2) with torque wrench to the specified tightening torque. Name Size Type Screw M10x1.
6.18.2 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Drive belt WARNING Qty. (→ Spare Parts Catalog) Spring/circlip/tensioning roller preload. Risk of injury! • Only use specified tool and equipment. Battery-charging generator drive – Drive belt replacement 4. 5. 6. 7. Result: 8. 9. 10. 11. Remove protective cover. Slacken screws (1) and (2) by half a turn.
6.19 Wiring (General) for Engine/Gearbox/Unit 6.19.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 1 Engine wiring – Check 1. 2. 3. 4. 5. 6. Close male connectors that are not plugged in with the protective cap supplied. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. Ensure that all sensor connectors are securely engaged.
6.20 Engine Mounting / Support 6.20.1 Engine mounting – Check Engine mounting – Check Item Findings Action Visually inspect mounts.
6.21 Accessories for (Electronic) Engine Governor / Control System 6.21.1 CDC parameters – Reset with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Resetting CDC parameters (DiaSys® is available) Note: u The CDC parameters must be reset, otherwise the emission certification of the engine is no longer appli‐ cable. Reset the CDC parameters with DiaSys® (→ Manufacturer's documentation).
6.21.2 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Note: Designation / Use Part No. Qty. Isopropyl alcohol X00058037 1 Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Engine governor and connectors – Cleaning 1. 2. 3. Remove coarse dirt from housing surface with isopropyl alcohol.
6.21.3 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Checking plug-in connections on engine governor Check all plug-in connections for secure seating. Latch connectors if loose. TIM-ID: 0000000048 - 005 1. 2.
6.21.4 ECU 7 engine governor – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. CAUTION Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed. Removing engine governor from engine 1. 2. 3. 4. 5. 6. Note or mark assignment of cables and connectors. Remove all screws (2). Undo latches (3) of the connectors. Remove all connectors. Remove screws (1).
7 Appendix A 7.
Abbreviation Meaning EGR Exhaust Gas Recirculation EMU Engine Monitoring Unit ETK Ersatzteilkatalog EUI Electronic Unit Injector FPS Fuel Pressure Sensor FRS Fuel - Differential Pressure Sensor FTS Fuel Temperature Sensor Monitors fuel temperature FWCP Fire Water Control Panel Control cabinet GND Ground HD Hochdruck High Pressure (HP) HI High Alarm: Measured value exceeds 1st maxi‐ mum limit HIHI High High Alarm: Measured value exceeds 2nd maxi‐ mum limit value HT High Temper
Abbreviation Meaning Explanation SAE Society of Automotive Engineers U.S.
7.2 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.
8 Appendix B 8.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 1 6.1.1 Engine – Barring manually (→ Page 104) Part No.: F30039526 Qty.: Used in: 1 6.4.2 Valve clearance – Check and adjustment (→ Page 113) Part No.: Y20098771 Qty.: Used in: 1 6.4.2 Valve clearance – Check and adjustment (→ Page 113) Part No.: F30379104 Qty.: Used in: 1 6.8.1 Fuel filter – Replacement (→ Page 126) Qty.: Used in: 6.14.
Installation/removal tool Part No.: F6789889 Qty.: Used in: 1 6.6.2 Injector – Removal and installation (→ Page 120) Part No.: F30452739 Qty.: Used in: 1 6.6.2 Injector – Removal and installation (→ Page 120) Part No.: 5605892099/00 Qty.: Used in: 1 6.13.3 Engine oil – Sample extraction and analysis (→ Page 143) Qty.: Used in: 1 6.15.6 Engine coolant – Sample extraction and analysis (→ Page 154) Part No.: F30027341 Qty.: Used in: 1 6.4.
Ratchet with extension Part No.: F30006212 Qty.: Used in: 1 6.1.1 Engine – Barring manually (→ Page 104) Part No.: Y20097353 Qty.: Used in: 1 6.2.1 Cylinder liner – Endoscopic examination (→ Page 107) Part No.: - Qty.: Used in: 1 3.11 Plant cleaning (→ Page 50) Part No.: 0015384230 Qty.: Used in: 1 6.6.2 Injector – Removal and installation (→ Page 120) Rigid endoscope Steam jet cleaner DCL-ID: 0000005896 - 002 Torque wrench, 0.
Torque wrench, 10-60 Nm Part No.: F30510423 Qty.: Used in: 1 1.4 Crankshaft transport locking device (→ Page 8) Part No.: F30452769 Qty.: Used in: 1 6.6.2 Injector – Removal and installation (→ Page 120) Part No.: F30027337 Qty.: Used in: 1 6.13.1 Engine oil – Change (→ Page 140) Part No.: F30027336 Qty.: Used in: 1 6.14.
Torque wrench, 60-320 Nm Part No.: F30047446 Qty.: Used in: 1 1.4 Crankshaft transport locking device (→ Page 8) Part No.: F30452768 Qty.: Used in: 1 6.4.2 Valve clearance – Check and adjustment (→ Page 113) Qty.: Used in: 1 6.6.
8.
Fuel – prefilter – Flushing 130 Fuel filter – Replacement 126 Fuel prefilter – Differential pressure gauge – Check and adjustment 128 – Draining 129 – Filter element – Replacement 132 – Flushing 130 Fuel prefilter cleaning 127 Stop engine in manual mode (testing mode) 46 G W General conditions 5 Wiring - engine – Check 165 H Hotline 174 HP pump – Filling with engine oil T Transport 7 Troubleshooting 52 V Valve clearance – Adjustment 113 – Check 113 Valve gear – Lubrication 112 118 I Injector – Remo
