en t.r u er en Technical Publication w w w .
1 Safety Safety, accident prevention and environmental protection instructions Product Summary en t.r u 2 Engine layout, technical data 3 Operation Task descriptions 4 Maintenance and Servicing 5 er Maintenance schedule Troubleshooting en Malfunctions, causes, measures w w w .
Safety 1-1 Safety, Accident Prevention and Environmental Protection Instructions These instructions must be read and followed by every person involved in operation, maintenance or transportation of the machinery plant. General en t.r u In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory regulations regarding accident prevention must be observed.
1-2 Safety Transportation 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. Transport the engine only in the installation position. en t.r u In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the transport pallet or transport with equipment for heavy loads (forklift truck).
Safety 1-3 Maintenance and repair Compliance with maintenance and repair specifications is an important safety factor. Unless expressly permitted, no maintenance or repair work is to be carried out with the engine running. Ensure the engine cannot be started unintentionally. On engines equipped with electrical starter, disconnect the starter battery. On engines equipped with air starter, close the shut-off valve of the compressed-air system and vent the compressed-air line.
1-4 Safety When working high on the engine, always use suitable ladders and work platforms. Make sure components are placed on stable surfaces. In order to prevent back injuries when lifting heavy components adults, depending on age and sex, should only lift weights between max. 10 kg and 30 kg, therefore: Use lifting gear or seek assistance. Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that hooks are correctly positioned.
Safety 1-5 On completion of the maintenance and repair work, any cables which have become loose must be correctly connected and secured. Always tighten connectors with connector pliers. On completion of all repair work, the component and system must be subjected to a function check. Separate testing of the repaired component without system integration is insufficient. en t.
1-6 Safety Auxiliary materials Use only fluids and lubricants that have been tested and approved by MTU. Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions applicable to the product. Take care when handling hot, chilled or caustic materials. When using inflammable materials, avoid sparks and do not smoke.
Safety 1-7 Liquid nitrogen Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numbing. Protective clothing (including gloves and closed shoes) and protective goggles! Avoid all knocks and jars to the containers, fixtures or workpieces. Compressed air en t.
1-8 Safety Warning signs Before putting the engine into service and before working on the engine, read and follow all warning signs. Do not paint on warning signs. Replace illegible signs. Warning notices DANGER WARNING CAUTION In event of immediate danger. Consequences: Death or serious injury. In event of dangerous situations. Consequences: Death or serious injury. en t.
Product Summary 2-1 Engine layout w .g Crankcase and externally mounted components Gear train Running gear Cylinder head Valve gear Fuel system (high pressure) Fuel system (low pressure) Exhaust turbocharger Intercooler Air intake / air supply 140 170 180 200 210 230 250 500 Exhaust system Starting system Lube oil system Cooling system Power supply Mounting / support PTO systems, driving end and free end Monitoring, control and regulation system, general electr.
2-2 Product Summary 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. The numbering of engine components is also from the driving end, starting with No. 1. en t.
Product Summary 2-3 Engine transport 8/12/16V 4000 G Use only the transport and lifting equipment approved by MTU. Transport the engine only in the installation position. en t.r u Lift only the engine by the lifting eyes provided. Lifting eyes are designed only for the weight of the engine. w w w .g en er For further transportation instructions, see chapter Safety.
2-4 Product Summary Basic data - engines for stationary power supply 8V 4000 G61/81 - 12V 4000 G21/41/61/81 - 16V 4000 G21/41/61/81 Basic Design Firing order 12V en Firing order 16V er en t.
Product Summary 2-5 Genset engines for stationary power generation with liquid-cooled chargeair cooling - Engine power Standby power at variable load < 85 % Continuous operation with limited operating time 3C Standby power at variable load < 75 % Prime power at variable load < 75 % Prime power at 100% load 100 % max. 500 max.
2-6 Product Summary Acoustics Sound pressure level acc.
Product Summary 2-7 Sound pressure level acc.
2-8 Product Summary Operational data The operational data of the engine acceptance-test protocol are binding reference values. All data are referenced to the engine running at operating temperature and nominal load. Please address any questions regarding the operational data to your MTU contact person, indicating the engine model and number. Unit Coolant temperature at engine outlet Pressure loss in the external cooling system, max.
Product Summary 2-9 Charge Air Unit Charge-air pressure before cylinder Reference value Optimized fuel consumption Optimized exhaust emission TA-Luft EPA 8V 4000 G61 bar ABS 3.4 -- -- standby power 8V 4000 G81 bar ABS -- -- 3.5 bar ABS 3.0 -- -- 12V 4000 G61 en t.r u Application group 3D, bar ABS 3.0 3.5 -- 16V 4000 G21 bar ABS 2.7 3.1 -- 16V 4000 G61 bar ABS 2.9 3.3 -- Application group 3B, 8V 4000 G61 bar ABS 3.1 3.
2 - 10 Product Summary Oil capacity 8V 4000 G approx. 145 lit. approx. 85 lit. approx. 115 lit. 12V 4000 G Initial filling Oil dipstick mark, "min." Oil dipstick mark, "max." en t.r u Initial filling Oil dipstick mark, "min." Oil dipstick mark, "max." approx. 260 lit. approx. 160 lit. approx. 200 lit. 16V 4000 G Initial filling Oil dipstick mark, "min." Oil dipstick mark, "max." approx. 290 lit. approx. 160 lit. approx. 230 lit.
Table of Contents Operation 3.1 Putting the engine into operation after extended out-of-service periods (>3 months) . . . 3 1 3.2 Putting the engine into operation after scheduled out-of-service-period ............. 3 2 ........................................... 3 2 ............................................. 3 3 ........................................................ 3 4 3.3 Starting the engine in manual mode 3.4 Emergency start (override mode) 3.5 Operational checks 3.
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Operation 3.1 1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions en t.r u Engine is stopped and starting disabled. MTU Fluids and Lubricants Specification (A001061/..) is available.
2 Operation 3.2 Putting the engine into operation after scheduled out-of-service-period Preconditions Putting the engine into operation en t.r u Engine is stopped and starting disabled. Item Task Lube oil system Check oil level ( Cooling system Check engine coolant level ( Page 6 41); Check charge-air coolant level ( Page 6 48). Cooling system Preheat coolant with preheating unit. Fuel prefilter Drain ( Monitoring equipment Carry out lamp test (see manufacturer s documentation).
Operation 3 Starting the engine Task Switching cabinet, control panel etc. (depending on manufacturer) If coolant temperature is > 40 C (with preheating pump), or > 10 C (60 Hz generator, without preheating pump), or > 5 C (50 Hz generator, without preheating pump): Press start button. Automatic starting procedure is performed; Tachometer indicates increasing crankshaft speed; After the starting procedure is completed, engine is running at rated speed. en t.
4 Operation Connecting the generator to network Task Switching cabinet, control panel etc. (depending on manufacturer) If generator is not connected to network: Close the generator circuit breaker. Engine Run at rated power. 3.5 en t.r u Item Operational checks WARNING Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors. Operational checks er DANGER Unguarded rotating and moving engine components.
Operation 5 3.6 Stopping the engine in manual mode Preconditions Generator is not connected to network. Engine is running in manual mode. CAUTION en t.r u 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.
6 Operation After emergency stop from LOP Task Switching cabinet, control panel etc. (depending on manufacturer) Press button for alarm acknowledgement. Audible and visual signalization stops. 3.8 After stopping the engine ready for operation en t.r u Item engine remains After stopping the engine Item Task Engine/generator control system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION. After stopping the engine putting the engine out of service er 3.
Table of Contents Maintenance 4.1 Maintenance and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 1 1 4.2 Maintenance Schedule Application Groups 3C and 3D . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Maintenance and Servicing 1 4.1 Maintenance and Servicing 4.1.1 Maintenance and servicing en t.r u Low operating and maintenance costs as well as operational reliability and availability depend on maintenance and servicing being carried out in compliance with our specifications and instructions. The overall system, of which the engine is an integral part, must be maintained in such a way as to ensure trouble-free engine operation.
Maintenance Schedule 4.2 Maintenance Schedule 4.2.1 Maintenance schedule Application Groups 3C and 3D Application Groups 3C and 3D Application group 3C: Continuous operation, limited (peak-shaving) 3D: Standby operation MTU maintenance levels en t.
Maintenance Schedule Application Groups 3C and 3D 4 3 Item Task W3 Engine coolant cooler Check cooler elements for external contamination (see manufacturer s documentation). W3 Charge-air coolant cooler Check cooler elements for external contamination (see manufacturer s documentation). W3 Battery Check (see manufacturer s information). W4 HP pump Check relief bore for oil and fuel discharge and obstructions ( Page 6 14).
4 Maintenance Schedule Maintenance Schedule 4.3.1 Maintenance schedule Application Group 3B Application group 3B: Continuous operation with variable load MTU maintenance levels en t.r u 4.
Maintenance Schedule Application Group 3B 4 5 Item Task W3 LT coolant pump Check relief bore for oil and water discharge and obstructions ( Page 6 49). W3 Engine coolant cooler Check cooler elements for external contamination (see manufacturer s documentation). W3 Charge-air coolant cooler Check cooler elements for external contamination (see manufacturer s documentation). W3 Coupling Check condition (see manufacturer s documentation). W3 Battery Check (see manufacturer s information).
6 Maintenance Schedule Maintenance Schedule 4.4.1 Maintenance schedule Application Group 3A Application group 3A: Continuous operation with 100% load, unrestricted MTU maintenance levels en t.r u 4.
Maintenance Schedule Application Group 3A 4 7 Item Task W3 LT coolant pump Check relief bore for oil and water discharge and obstructions ( Page 6 49). W3 Engine coolant cooler Check cooler elements for external contamination (see manufacturer s documentation). W3 Charge-air coolant cooler Check cooler elements for external contamination (see manufacturer s documentation). W3 Coupling Check condition (see manufacturer s documentation). W3 Battery Check (see manufacturer s information).
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Table of Contents 5 I Troubleshooting 5.1 Troubleshooting 5 1 ............................................................... 5 4 w w w .g en er en t.r u 5.2 ECU alarms ...........................................................
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Troubleshooting 5.1 1 Troubleshooting Engine does not turn when starter is actuated Probable Cause Task Battery Low or defective Charge or replace (see manufacturer s documentation). Cable connections defective en t.r u Component Check if cable connections are properly secured (see manufacturer s documentation). Starter Engine wiring or starter defective Check if cable connections are properly secured, contact Service.
2 Troubleshooting Engine does not reach nominal speed Component Probable Cause Task Fuel supply Fuel prefilter clogged Replace filter element ( Fuel filter clogged Replace ( Air supply Air filter clogged Check signal ring position of service indicator ( Page 6 31). Fuel injection equipment Injector defective Engine wiring Defective Engine Overloaded Page 6 22). en t.r u Replace ( Check ( Page 6 15). Page 6 55). Contact Service.
Troubleshooting 3 Exhaust gas black Component Probable Cause Task Air supply Air filter clogged Check signal ring position of service indicator ( Page 6 31). Fuel injection equipment Injector defective Replace ( Engine Overloaded Component Probable Cause Engine oil Too much oil in engine Oil separator of crankcase breather contaminated Task Drain engine oil ( Page 6 34). Replace filter element ( Page 6 7). Contact Service. er Defective Exhaust gas white en t.r u Contact Service.
4 Troubleshooting 5.2 ECU alarms er en t.r u The ECU generates alarms which are indicated in different ways depending on the equipment configuration: as four-digit code on a PIM as alarm text on a display as four-digit code on a dialog PC .
Troubleshooting 5 Fault code Alarm text Meaning Task 023 L1 COOLANT LEVEL Engine coolant level too low Check coolant level and top up, if required ( Page 6 41) . 024 L2 COOLANT LEVEL Engine coolant level too low Check coolant level and top up, if required ( Page 6 41) . 030 ENGINE OVERSPEED Engine overspeed; automatic engine shutdown 044 L1 LEVEL INTERCOOLER Charge-air coolant level too low (1st limit) Check coolant level and top up, if required ( Page 6 48) .
6 Troubleshooting Alarm text Meaning Task 069 L1 T-EXTERN 1 Violation of first limit for external temperature channel 1 (Depending on the corresponding measuring point, which is read via CAN bus) 070 L2 T-EXTERN 1 Violation of second limit for external temperature channel 1 (Depending on the corresponding measuring point, which is read via CAN bus) 071 L1 T-EXTERN 2 Violation of first limit for external temperature channel 2 (Depending on the corresponding measuring point, which is read via
Troubleshooting 7 Alarm text Meaning Task 083 RAIL PRESSURE LOW Pressure in HP fuel system 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. Contact Service.
8 Troubleshooting Alarm text Meaning Task 104 OP HOURS1 NOT VALID Check sum error of hour meter data in EDM If fault occurs repeatedly: Contact Service. 105 OP HOURS2 NOT VALID Check sum error of hour meter data in IDM If fault occurs repeatedly: Contact Service. 106 ERR REC1 NOT VALID Check sum error of fault memory in EDM (redundant data record 1) If fault occurs repeatedly: Contact Service.
9 Alarm text Meaning Task 144 BANK2 ECU DEFECT Internal electronic fault; Engine does not start Contact Service. 145 15V_GOOD ECU DEFECT Electronic equipment defective; automatic engine shutdown Contact Service. 146 L1 AD-TEST1 SUPPLY A/D-converter supply voltage too low Contact Service. 147 AD-TEST1 ECU DEFECT Electronic equipment defective; automatic engine shutdown Contact Service. 148 L1 AD-TEST2 SUPPLY A/D-converter supply voltage too low Contact Service.
10 Troubleshooting Alarm text Meaning Task 187 CAN1 ERROR PASSIVE Light fault on Default CAN bus (e.g.shortage overload) (none) 188 CAN2 BUS OFF Severe fault on Redundant CAN bus; automatic change-over to Default CAN bus Contact Service. 189 CAN2 ERROR PASSIVE Light fault on Redundant CAN bus (e.g.
Troubleshooting 11 Alarm text Meaning 250 SD CAN SPEED DEMAND Sensor defect (CAN nominal speed demand) 1. Check speed transmitter. 2. Check wiring (CAN bus). 3. Contact Service. 266 SD SPEED DEMAND AN. Sensor defect (analog nominal speed demand) 1. Check speed transmitter. 2. Check wiring. 3. Contact Service. 267 SD SP.DEM.TEST BENCH Sensor defect (analog speed demand); NOTE: Only used in test-stand operation. 1. Check speed transmitter. 2. Check wiring. 3. Contact Service.
12 Troubleshooting Alarm text Meaning Task 307 TIMING CYLINDER A7 Injection timing fault cylinder A7 If fault occurs repeatedly: Contact Service. 308 TIMING CYLINDER A8 Injection timing fault cylinder A8 If fault occurs repeatedly: Contact Service. 309 TIMING CYLINDER A9 Injection timing fault cylinder A9 If fault occurs repeatedly: Contact Service. 310 TIMING CYLINDER A10 Injection timing fault cylinder A10 If fault occurs repeatedly: Contact Service.
Troubleshooting 13 Alarm text Meaning Task 326 WIRING CYLINDER A6 Faulty wiring to solenoid valve cylinder A6; Misfiring 1. Check wiring. 2. Contact Service. 327 WIRING CYLINDER A7 Faulty wiring to solenoid valve cylinder A7; Misfiring 1. Check wiring. 2. Contact Service. 328 WIRING CYLINDER A8 Faulty wiring to solenoid valve cylinder A8; Misfiring 1. Check wiring. 2. Contact Service. 329 WIRING CYLINDER A9 Faulty wiring to solenoid valve cylinder A9; Misfiring 1. Check wiring. 2.
14 Troubleshooting Alarm text Meaning Task 340 WIRING CYLINDER B10 Faulty wiring to solenoid valve cylinder B10; Misfiring 1. Check wiring. 2. Contact Service. 341 OPEN_LOAD CYL. A1 Disconnection in wiring to solenoid valve cylinder A1; Misfiring 1. Check wiring. 2. Contact Service. 342 OPEN_LOAD CYL. A2 Disconnection in wiring to solenoid valve cylinder A2; Misfiring 1. Check wiring. 2. Contact Service. 343 OPEN_LOAD CYL.
Troubleshooting 15 Alarm text Meaning 354 OPEN_LOAD CYL. B4 Disconnection in wiring to solenoid valve cylinder B4; Misfiring 1. Check wiring. 2. Contact Service. 355 OPEN_LOAD CYL. B5 Disconnection in wiring to solenoid valve cylinder B5; Misfiring 1. Check wiring. 2. Contact Service. 356 OPEN_LOAD CYL. B6 Disconnection in wiring to solenoid valve cylinder B6; Misfiring 1. Check wiring. 2. Contact Service. 357 OPEN_LOAD CYL.
16 Troubleshooting Alarm text Meaning Task 385 TRAN.OUT5 PLANT DEF Binary transistor output plant 5 defective Contact Service. 386 TRAN.OUT6 PLANT DEF Binary transistor output plant 6 defective Contact Service. w w w .g en er en t.
Table of Contents 6 I Task Description ................................................................... Engine barring manually ........................................... Engine barring with starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II Table of Contents 6 6 6 6 33 33 34 35 6.14 Oil Filtration / Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14.1 Engine oil filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14.2 Centrifugal oil filter cleaning and filter-sleeve replacement . . . . . . . . . . . . . . . . . . 6 6 6 36 36 37 6.15 Cooling System, General, HT Circuit . . . . . . . . . . . . . . . . . . . . . .
Engine 1 6.1 Engine 6.1.1 Engine barring manually Preconditions en t.r u Engine is stopped and starting disabled. Special tools Designation / Use Part No. Barring tool Qty. TC Ratchet TC 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. DANGER 6.1.2 w .g en er Barring engine manually 1. Remove protective plate. 2. Install barring tool (2). 3.
2 Engine 6.1.3 Engine test run er en t.r u Barring engine with starting system 1. Disengage the bayonet ring-nut (4) of connector X4 with connector pliers (2) and withdraw connector (3) from ECU. 2. Bar engine in unloaded condition: Press START button. 3. Let the crankshaft rotate until oil pressure is indicated. 4. Engine start is automatically interrupted when specified starting period is expired. If necessary, re-start the engine after approx. 20 seconds. 5.
Cylinder Liner 3 6.2 Cylinder Liner 6.2.1 Cylinder-liner endoscopic examination Preconditions en t.r u Engine is stopped and starting disabled. Special tools Designation / Use Part No. Rigid endoscope, max. diameter: 7 mm Qty. TC Preparatory steps 1. Remove cylinder-head cover ( Page 6 12). 2. Remove injector ( Page 6 15). Bringing the piston to BDC position 1. Use the barring tool to rotate the crankshaft until the crank pin of the cylinder to be inspected is at BDC position. 2.
4 Cylinder Liner w w w .g en er en t.r u Final steps 1. Install injector ( Page 6 15). 2. Install cylinder-head cover ( Page 6 12).
Cylinder Liner 6.2.2 5 Instructions and comments on endoscopic and visual examination of cylinder liner Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report. Light scoring can take place during the assembly of a new engine (honing products, particles, broken-off burrs). Removed cylinders clearly show such scoring on the running surface under endoscope magnification.
6 Cylinder Liner w w w .g en er en t.r u Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A definite opinion can first be made after a careful inspection and reference to the above criteria. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.
Crankcase Breather 7 6.3 Crankcase Breather 6.3.1 Crankcase breather oil separator replacement Preconditions en t.r u Engine is stopped and starting disabled. Material Designation / Use Part No. Ethanol, denatured Qty. FLS Spare parts Designation / Use Part No. Oil separator Qty. SPC w w w .g en er Crankcase breather oil separator replacement 1. Loosen clamps (1), push rubber sleeves (2) over tubes (3). 2.
8 Valve Gear 6.4 Valve Gear 6.4.1 Valve gear lubrication Preconditions en t.r u Engine is stopped and starting disabled. Material Designation / Use Part No. Engine oil Qty. FLS 6.4.2 .g en er Valve gear lubrication 1. Remove cylinder-head covers ( Page 6 12). 2. Fill oil chambers of valve bridges with oil. 3. Fill oil chambers of rocker arms and adjusting screws with oil. 4. Install cylinder-head covers ( Page 6 12).
Valve Gear 9 en t.r u 3. Rotate crankshaft with barring tool in engine direction of rotation until marking "OT-A1" and pointer are aligned. 3. Insert feeler gauge with determined value between valve bridge and valve-stem end (A). 4. At the opposite valve-stem end (B), a feeler gauge thicker by 0.05 mm should not fit, otherwise adjust valve bridge. w w w .g en er Checking valve-bridge balance 1. Prior to adjusting valve clearance, check valve-bridge balance on all valve bridges. 2.
10 Valve Gear en t.r u Valve-bridge balance adjustment 1. Hold valve bridge (1) firmly in position with open-end spanner and release locknut (2). 7. Tighten locknut (2) to 35 Nm + 5 Nm, holding valve bridge (1) in position with open-end spanner. 8. Check valve bridge adjustment again. w w w .g en er 2. Use feeler gauge to determine the distance between valve bridge and rocker arm. 3.
11 Cylinder A1 is in firing TDC Cylinder A1 is in overlap TDC Inlet valve Exhaust valve w w w .g 1 2 I X en er en t.r u Valve Gear M015403/00E 02-09 Adjusting valve clearance in two crankshaft positions 1. Check TDC position of piston in cylinder A1: If the rocker arms are unloaded on cylinder A, the piston is in firing TDC. If the rocker arms are loaded on cylinder A, the piston is in overlap TDC. 2. Check valve clearance with cold engine: Inlet valves (long rocker arm) = 0.
12 Valve Gear en t.r u Valve clearance adjustment 1. Release locknut (1). 2. Insert feeler gauge between valve bridge and rocker arm. 3. Using Allen key, set adjusting screw (2) so that the specified valve clearance is provided. 4. Feeler gauge must just pass through the gap. 5. Tighten locknut (1) to 90 + 9 Nm, holding adjusting screw (2) firm. 6. Replace or rectify adjusting screws and/or locknuts which do not move freely. 7. Check valve clearance. 6.4.3 er Final steps 1.
Valve Gear 13 w w w .g en er Cylinder-head cover installation 1. Clean mating faces. 2. Check condition of gasket, replace if necessary. 3. Place gasket and cylinder head cover on cylinder head. 4. Install screws and tighten to 42 Nm. en t.r u Cylinder-head cover removal 1. Clean very dirty cylinder head covers prior to removal. 2. Remove screws. 3. Remove cylinder head cover with gasket from cylinder head.
14 Injection pump / HP pump 6.5 Injection pump / HP pump 6.5.1 HP pump relief bore check WARNING Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors. en t.r u DANGER Unguarded rotating and moving engine components. Risk of serious injury danger to life! Take special care when working on a running engine. w w w .g en er HP pump relief bore check 1. Check relief bore for oil and fuel discharge by visual inspection. 2.
Fuel Injector 15 6.6 Fuel Injector 6.6.1 Injector replacement Spare parts Part No. Injector SPC Remove injector and install new one ( 6.6.2 Qty. en t.r u Designation / Use Page 6 15). Injector removal and installation Preconditions Engine is stopped and starting disabled. er Special tools Designation / Use Puller for injector removal Lever for force-in lever Injector installation jig Material Designation / Use Qty. TC TC TC TC TC TC TC Part No. Qty. FLS w Petroleum jelly .
16 Fuel Injector en t.r u Injector removal 1. Release the cable terminal threaded connection on the injector and remove cable terminals. 4. Install puller for injector removal. For this purpose, fit part (4) onto injector (1). 5. Slide part (2) over part (4) and turn to correct position - see next illustration. 6. Secure part (2) with nut (3). w w w .g en er 2. Remove screw (2) and take off hold-down clamp (1). 3. Remove HP fuel line (5).
Fuel Injector 17 en t.r u 7. Initial position of part (2) is position a. 8. End position is position b. 12. Remove sealing ring (1) from injector or use a self-made hook to take it out of the cylinder head. 13. Remove O-rings (2) from injector. 14. Cover all connections and bores, or seal with suitable plugs. w w w .g en er 9. Install puller bracket (2) for injector removal. 10. Turn nut (1) clockwise and withdraw injector. 11. Remove puller bracket from injector.
18 Fuel Injector en t.r u Injector installation 1. Prior to installation, remove all plugs. 2. Coat new O-rings (scope of supply of injector) with petroleum jelly and fit on injector. 3. Fit new sealing ring with petroleum jelly on injector, observe installation position of sealing ring. 7. Lock force-in lever (1) between pushrods. 8. Release palm grip (3) and move pressure element (2) to correct position of installation jig. 9.
Fuel Injector 19 en t.r u 11. Use slotted screwdriver to check thrust ring at both line ends for secure seating. 12. Tighten loose thrust ring to 10 Nm. 19. Fit cable terminals below the screws on injector and tighten to 1 Nm. w w w .g en er 13. Fit hold-down clamp (1) in correct position and install screw (2) by hand. 14. Tighten screw (2) with torque wrench, preliminary tightening torque: 5 Nm to 10 Nm. 15. Coat new O-rings (4) and (6) on with petroleum jelly and fit on HP fuel line (5). 16.
20 Fuel Injector Page 6 12). w w w .g en er en t.r u Final steps 1. Install cylinder-head cover ( 2. Open fuel supply to engine.
Fuel system 21 6.7 Fuel system 6.7.1 Fuel system venting Preconditions en t.r u Engine is stopped and starting disabled. Material Designation / Use Part No. Diesel fuel Qty. FLS Fuels are combustible. Risk of fire and explosion! Avoid naked flames, electrical sparks and ignition sources. Do not smoke. WARNING w w w .g en er LP fuel system venting 1. Loosen flushing/return line of HP pump at connection (1). 2. Unlock fuel priming pump (2), unscrew handle. 3.
22 Fuel Filter 6.8 Fuel Filter 6.8.1 Fuel filter replacement Preconditions en t.r u Engine is stopped and starting disabled. Special tools Designation / Use Part No. Strap wrench Qty. TC Material Designation / Use Part No. Diesel fuel Qty. FLS Spare parts er Designation / Use Easy-change filter Part No. Qty. SPC en Fuels are combustible. Risk of fire and explosion! Avoid naked flames, electrical sparks and ignition sources. Do not smoke. Fuel filter replacement 1.
Fuel Filter 23 6.8.2 Fuel prefilter cleaning Preconditions Engine is stopped and starting disabled. en t.r u Material Designation / Use Part No. Diesel fuel Qty. FLS Spare parts Designation / Use Part No. Sealing ring Qty. SPC Fuels are combustible. Risk of fire and explosion! Avoid naked flames, electrical sparks and ignition sources. Do not smoke. Fuel prefilter cleaning 1. Shut off fuel supply. 2. Remove nuts from filter head. 3.
24 Fuel Filter en t.r u Setting adjustable pointer of differential pressure gauge 1. After installation of a new filter element, align adjustable pointer (2) with pressure-indicating pointer (3) of pressure gauge (1). 2. Verify that differential pressure is within the limit. Fuel prefilter draining en 6.8.4 er Fuel prefilter checking differential pressure 1. With the engine running at full load or rated power, read off pressure at gauge (1). 2.
Fuel Filter 25 Left filter cut in Right filter cut in 2. Open vent plug (5) of the filter to be drained. 3. Unlock drain cock (6) by pressing toggle and open it. 4. Drain water and contaminants from the filter until pure fuel emerges. 5. Close drain cock (6). 6. Remove screws securing the cover and take off cover (2). 7. Fill filter housing with clean fuel. 8. Place new gasket in cover (2). 9. Fit cover with gasket and secure it with screws. 10. Cut the cut-out filter in again. 11.
26 Fuel Filter Unguarded rotating and moving engine components. Risk of serious injury danger to life! Take special care when working on a running engine. DANGER WARNING en t.r u Fuels are combustible. Risk of fire and explosion! Avoid naked flames, electrical sparks and ignition sources. Do not smoke. Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors. WARNING Left filter cut in Right filter cut in 2. Open vent plug (5) of the filter to be flushed. 3.
Fuel Filter 27 6.8.6 Fuel prefilter en t.r u 4. Place new gasket in cover (2). 5. Fit cover with gasket and secure it with screws. 6. Check differential pressure ( Page 6 23). Result: If flushing did not lead to an improvement of the differential pressure, replace filter element ( Page 6 27). filter element replacement Preconditions Engine is stopped and starting disabled. Material Designation / Use Part No. Diesel fuel Qty.
28 Fuel Filter w w w .g en er en t.r u 2. Open vent plug (5) of the contaminated filter. 3. Unlock drain cock (6) by pressing toggle and open it. 4. Drain water and contaminants from the filter. 5. Close drain cock (6). 6. Remove screws securing the cover and take off cover (2). 7. Remove spring (4) and filter element (3). 8. Insert new filter element (3) and spring (4). 9. Fill filter housing with clean fuel. 10. Place new gasket in cover (2). 11. Fit cover with gasket and secure it with screws.
Charge-Air Cooling, General, Left Side 6 6.9 Charge-Air Cooling, General, Left Side 6.9.1 Intercooler checking condensate drains for coolant discharge and obstructions WARNING Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors. en t.r u DANGER Unguarded rotating and moving engine components. Risk of serious injury danger to life! Take special care when working on a running engine. 29 Compressed air. Risk of injury! Do not direct compressed-air jet at persons.
30 Air Filter 6.10 Air Filter 6.10.1 Air filter replacement Spare parts Part No. Air filter SPC Remove air filter and install new one ( Page 6 30). Reset signal ring of service indicator ( Page 6 31). 6.10.2 Qty. en t.r u Designation / Use Air filter removal and installation Preconditions Engine is stopped and starting disabled. w w w .g en er Air filter removal and installation 1. Loosen clamp (2). 2. Remove air filter (3) and clamp (2) from flange of intake housing (1). 3.
Air Intake 31 6.11 Air Intake 6.11.1 Service indicator signal ring position check Preconditions en t.r u Engine is stopped and starting disabled. w w w .g en er Signal ring position check 1. If the signal ring is completely visible in the control window (2), replace air filter ( Page 6 30). 2. After installation of new filter, press reset button (1). Result: Engaged piston with signal ring moves back to initial position.
32 Starting System 6.12 Starting System 6.12.1 Starter condition check Preconditions en t.r u Engine is stopped and starting disabled. Starter condition check 1. Check starter securing screws for secure seating. 2. Tighten loose screw connections. 3. Check wiring ( Page 6 55). 6.12.2 Air starter manual operation WARNING Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors. er DANGER Unguarded rotating and moving engine components.
Lube Oil System 33 6.13 Lube Oil System 6.13.1 Engine-oil sample extraction and analysis Preconditions en t.r u MTU Fluids and Lubricants Specification (A001061/..) is available. Special tools Designation / Use Part No. MTU test kit Qty. TC Unguarded rotating and moving engine components. Risk of serious injury danger to life! Take special care when working on a running engine. DANGER WARNING Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
34 Lube Oil System 6.13.2 Engine oil change Preconditions en t.r u Engine is stopped and starting disabled. Engine is at operating temperature. MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Engine oil Qty. FLS Spare parts Designation / Use Part No. Sealing ring Qty. SPC Hot engine oil. Engine oil can contain combustion residues which are harmful to health.
Lube Oil System 6.13.3 35 Engine oil level check Preconditions Engine is stopped and starting disabled. er en t.r u Oil level check prior to engine start 1. Withdraw dipstick from guide tube and wipe it. 2. Insert dipstick into guide tube to stop, withdraw and check oil level. 3. Oil level must be between min. and max. marks. 4. If necessary, top up to max. mark. ( Page 6 34). 5. Insert dipstick into guide tube to stop. w w w .g en Oil level check after the engine is stopped 1.
36 Oil Filtration / Cooling 6.14 Oil Filtration / Cooling 6.14.1 Engine oil filter replacement Preconditions en t.r u Engine is stopped and starting disabled. Special tools Designation / Use Part No. Strap wrench Qty. TC Material Designation / Use Part No. Engine oil Qty. FLS Spare parts er Designation / Use Oil filter Part No. Qty. SPC en Hot engine oil. Engine oil can contain combustion residues which are harmful to health.
Oil Filtration / Cooling 6.14.2 37 Centrifugal oil filter cleaning and filter-sleeve replacement Preconditions Engine is stopped and starting disabled. en t.r u Special tools Designation / Use Part No. Strap wrench TC Material Designation / Use Part No. Cleaner Hakutex 60 Qty. FLS Spare parts Designation / Use Part No. Filter sleeve Sealing ring Qty. er SPC SPC Sealing ring SPC Hot engine oil. Engine oil can contain combustion residues which are harmful to health.
38 Oil Filtration / Cooling w w w .g en er en t.r u 12. Move standpipe (12) over rotor lower section (13). 13. Insert new filter sleeve (9) with stiffener plate (10) into rotor cap (8) and fit on standpipe (12). 14. Install knurled nut (7) and tighten. 15. Place rotor (5) in housing (6) and check for ease of movement. 16. Fit new sealing ring (4) on housing (6). 17. Fit cover (2). 18. Tighten Tommy nut (1) by hand. 19. Install clamp (3) and tighten. 20. Tighten Tommy nut (1).
Cooling System, General, HT Circuit 39 6.15 Cooling System, General, HT Circuit 6.15.1 Engine coolant system filling Preconditions en t.r u Engine is stopped and starting disabled. MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Coolant Qty. FLS Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask.
40 Cooling System, General, HT Circuit en t.r u Filling coolant with pump 1. Connect appropriate pump with hose to drain valve. 2. Open drain valve and pump treated coolant into engine, until coolant level reaches lower edge of cast-in eye or marking plate on filler neck. 3. Close drain valve. 4. Disconnect pump and hose. er Filling coolant through filler neck 1. Alternatively: Fill coolant though filler neck on coolant expansion tank until level reaches cast-in eye or marking plate. 2.
Cooling System, General, HT Circuit 41 Engine coolant change er 6.15.3 Material Designation / Use Drain engine coolant ( Part No. Qty. FLS en Coolant Page 6 40). Fill engine coolant system ( Page 6 39). Engine coolant-level check Preconditions .g 6.15.4 en t.r u Engine coolant draining 1. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape. 2. Continue to turn breather valve counterclockwise and remove. 3.
42 Cooling System, General, HT Circuit en t.r u Coolant-level check at filler neck: 1. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape. 2. Continue to turn breather valve counterclockwise and remove. 3. Check coolant level (coolant must be visible at the lower edge of the cast-in eye). .g en er Coolant-level check at external cooler: 1. Check coolant level (coolant must be visible at marking plate). 2.
Cooling System, General, HT Circuit 43 Unguarded rotating and moving engine components. Risk of serious injury danger to life! Take special care when working on a running engine. DANGER WARNING en t.r u Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask. Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors. WARNING HT cooling pump relief bore check .g 6.15.
44 Cooling System, General, HT Circuit w w w .g en er en t.r u HT cooling pump relief bore check 1. Check relief bore for oil and water discharge. 2. Stop engine ( Page 3 5)and disable engine start. 3. Clean the relief bore with a wire if it is dirty. Permissible water discharge: up to 10 drops per hour; Permissible oil discharge: up to 5 drops per hour. 4. If discharge exceeds the specified limits: Contact Service.
Cooling System, LT Circuit 45 6.16 Cooling System, LT Circuit 6.16.1 Charge-air coolant filling Preconditions en t.r u Engine is stopped and starting disabled. MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Charge-air coolant Qty. FLS Spare parts Designation / Use Part No. Sealing ring Qty. SPC CAUTION Cold coolant in hot engine can cause thermal stress. Formation of cracks in components! Fill / top up coolant only into cold engine.
46 Cooling System, LT Circuit en t.r u Charge-air coolant filling 1. Pour treated coolant via the filling points on the coolant lines from and to the intercooler and via the filler neck of the expansion tank until coolant is visible at the marking plate. 2. Install plugs with new sealing rings at the filling points. 3. Check proper condition of breather valve, clean sealing faces if required. 4. Set breather valve onto filler neck and close it. 6.16.2 er Final steps 1.
Cooling System, LT Circuit 47 en t.r u Charge-air coolant draining 1. Provide an appropriate container to drain the coolant into. 2. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape. 3. Continue to turn breather valve counterclockwise and remove. 4. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck. 5.
48 6.16.4 Cooling System, LT Circuit Charge-air coolant level check Preconditions Engine is stopped and starting disabled. MTU Fluids and Lubricants Specification (A001061/..) is available. en t.r u 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 en er Charge-air coolant level check at filler neck: 1.
Cooling System, LT Circuit 49 Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors. WARNING 6.16.6 LT cooling pump er en t.r u Charge-air coolant sample extraction and analysis 1. With the engine running, open drain valve. 2. Flush sample-extraction point by draining approx. 1 liter coolant. 3. Drain approx. 1 liter coolant into a clean container. 4. Close drain valve. 5.
50 Battery-Charging Generator 6.17 Battery-Charging Generator 6.17.1 Battery-charging generator drive drive belt condition check Preconditions en t.r u Engine is stopped and starting disabled. 6.17.2 en er Belt condition check 1. Remove guard cover. 2. Check belt for contamination by oil, cracks, wear, and signs of overheating. 3.
Battery-Charging Generator 51 en t.r u Belt tension check 1. Remove guard cover. 2. Place belt-tension tester onto drive belt midway between the belt pulleys. 3. Press button uniformly down onto drive-belt surface until spring disengagement can be heard and felt. 4. Do not press any further, otherwise the reading is not exact. 5. Take off belt-tension tester without changing the position of the indication arm. 6. Read off measuring value at the intersection of indication arm and "KG" scale. 7.
52 Battery-Charging Generator Battery-charging generator Preconditions Engine is stopped and starting disabled. condition check er 6.17.4 en t.r u Battery-charging generator drive drive belt replacement 1. Remove guard cover. 2. Loosen locknut (2) and screws (1). 3. Release drive belt with tensioning nut (3) and take off belt. 4. Check belt pulleys for cleanliness, remove dirt, if any. 5. Fit new drive belt. 6. Tension drive belt with tensioning nut (3) and check belt tension ( Page 6 50). 7.
Engine Mounts 53 6.18 Engine Mounts 6.18.1 Engine/generator mounting security check Preconditions en t.r u Engine is stopped and starting disabled. 6.18.2 en er Engine/generator mounting security check 1. Check securing screws (1), (2) and (3) of engine mounting for secure seating. 2. Check securing screws (2) and (3) of generator mounting for secure seating. 3. Tighten loose screw connections.
54 Engine Mounts en t.r u Engine/generator mounting resilient elements check 1. Wipe rubber surface with dry cloth, do not use organic detergents. 2. Check resilient elements for crack formation and deformation by visual inspection. 3. Have cracked elements replaced, contact Service. w w w .g en er Setting dimension check 1. Measure dimension (a) with Vernier caliper. 2. If dimension (a) is less than 57 mm, resilient elements must be replaced. Contact Service.
General Wiring, Engine / Gearbox / Plant 6 6.19 General Wiring, Engine / Gearbox / Plant 6.19.1 Engine wiring check 55 Preconditions en t.r u Engine is stopped and starting disabled. Material Designation / Use Part No. Isopropyl alcohol Qty. FLS w w w .g en er Engine wiring check 1. Check securing screws of cable clamps on the engine and tighten loose screw connections. 2. Make certain that cables are securely seated in clamps and cannot move freely. 3.
56 Engine Governor (Electronic) / Control System 6.20 Engine Governor (Electronic) / Control System 6.20.1 ECU and connectors cleaning Preconditions en t.r u Engine is stopped and starting disabled. Special tools Designation / Use Part No. Connector pliers Qty. TC Material Designation / Use Part No. Isopropyl alcohol Qty. FLS w w w .g en er ECU and connectors cleaning 1. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. 2.
Engine Governor (Electronic) / Control System 6.20.2 ECU 6 57 checking plug-in connections Preconditions Engine is stopped and starting disabled. en t.r u Special tools Designation / Use Part No. Connector pliers Qty. TC w w w .g en er ECU checking plug-in connections 1. Use connector pliers (3) to make certain that all plug-in connections of ECU are securely seated. 2. Tighten loose bayonet union nuts (2) with connector pliers (3) by turning them clockwise until they lock into place. 3.
Engine Governor (Electronic) / Control System w w w .g en er en t.
Table of Contents 7 I Annex 7.1 Abbreviations 7 1 .................................................................... 7 3 w w w .g en er en t.r u 7.2 Index .............................................................
Table of Contents w w w .g en er en t.
Annex 1 7.1 Abbreviations Abbreviation Meaning A/D Analog-to-Digital AL Alarm ANSI American National Standards Institute ATL Abgasturbolader Turbocharger BR Baureihe Engine Series CAN Controller Area Network DIN Deutsches Institut für Normung e. V.
2 Annex Meaning Explanation RL Redundancy Lost Alarm: Redundant CAN bus failure SAE Society of Automotive Engineers U.S. standardization organization SD Sensor Defect Alarm: Sensor failure SS Safety System Alarm initiated by safety system SPC Spare Parts Catalog T-xyz Temperature-xyz TC Tools Catalog TD Transmitter Deviation UT Unterer Totpunkt en t.r u Abbreviation Temperature measuring point xyz w w w .
Annex Index Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . After stopping the engine engine remains ready for operation . . . . . . . . . . . . . . . . . . . . . After stopping the engine putting the engine out of service . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air filter removal and installation . . . . . . Air filter replacement . . . . . . . . . . . . . . . Air filter removal and installation . . . . . . . .
4 Annex F 6 53 6 6 6 6 6 6 53 34 36 35 2 55 6 53 6 53 6 33 6 6 I Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection pump / HP pump . . . . . . . . . . . . . . . . HP pump relief bore check . . . . . . . . . Injector removal and installation . . . . . . . . . . . Injector replacement . . . . . . . . . . . . . . . . . . . . Instructions and comments on endoscopic and visual examination of cylinder liner . . . . . . . . .
Annex 5 T 31 32 32 32 32 2 5 2 2 2 2 Troubleshooting ....................... V Valve clearance check and adjustment . . . . . . Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder-head cover removal and installation . . . . . . . . . . . . . . . . . . . . . . . Valve clearance check and adjustment . . . . . . . . . . . . . . . . . . . . . . Valve gear lubrication . . . . . . . . . . . . . . Valve gear lubrication . . . . . . . . . . . . . . . . . . .
er en .g w w w en t.
