M015241 03e

Operating Instructions
Diesel engine 16 V 4000 E20
M015241/03E
Printed in Germany 2011 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. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments.
Commissioning Note
Important
Please complete and return the Commissioning Note card below to MTU Friedrichshafen GmbH. The Commissioning Note information serves as a basis for the contractually agreed logistic support (war ranty, spare parts, etc.).
Table of Contents
1 Safety 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 General conditions Personnel and organizational requirements Transport Crankshaft transport locking device Safety regulations for startup and operation Explosion hazard when removing inspection port cover on engine Safety regulations for maintenance and repair work Fluids and lubricants, fire prevention and environmental protection Engine Barring with starting system Conventions for safety instructions in the text 7 8 9 10 12 13 14 17 19 20 6 Troubleshooting 6.1 Troubleshooting 6.2 DDEC alarms 41 44
7 Task Description 7.1 Engine

7.1.1 Engine Barring manually 7.1.2 Engine Barring with starting system 7.2.1 Cylinder liner Endoscopic examination 7.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners 7.3.1 Crankcase breather Oil separator check 7.3.2 Crankcase breather Filter element replacement 7.3.3 Crankcase breather (open-circuit crankcase ventilation) Filter element cleaning 7.4.1 Valve gear Lubrication 7.4.2 Valve clearance Check and adjustment 7.4.3 Cylinder head cover Removal and installation 7.5.1 HP pump Relief bore check 7.6.1 Injector Replacement 7.6.2 Injector Removal and installation 7.7.1 Fuel system Venting 7.8.1 Fuel filter Replacement 7.8.2 Fuel prefilter Draining 7.8.3 Edge-type fuel filter Draining 7.9.1 Intercooler Check drain for coolant leakage and obstruction
64
64 66 67 69
7.2 Cylinder Liner
67
7.3 Crankcase Breather
71
71 72 74
2 General Information 2.1 Engine layout 2.2 Engine side and cylinder designations 2.3 Sensors and actuators Overview 21 25 26
7.4 Valve Drive
75
75 76 80
3 Technical Data 3.1 16V 4000 E20 engine data 3.2 Firing order 28 32
7.5 Injection Pump / HP Pump 7.6 Injection Valve / Injector
81 82
81 82 83 88 89 90 91
4 Operation 4.1 Putting the engine into operation after extended out-of-service periods (>3 months) 4.2 Putting the engine into operation after scheduled out-of-service-period 4.3 Engine Start in manual mode 4.4 Operational checks 4.5 Engine Shutdown in manual mode 4.6 After stopping the engine 4.7 Plant Cleaning
7.7 Fuel System 33 34 35 36 37 38 39 7.8 Fuel Filter
88 89
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7.9 Charge-Air Cooling
92
92
7.10 Air Intake 5 Maintenance 5.1 Maintenance task reference table [QL1] 40
7.10.1 Service indicator Check 7.11.1 Starter Condition check 7.11.2 Cold start system with ether injection Check
93 94
93 94 95
7.11 Starting Equipment
7.12 Lube Oil System, Lube Oil Circuit
96
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7.12.1 Engine oil level Check 7.12.2 Engine oil Change 7.12.3 Engine oil Sample extraction and analysis
96 97 99
7.13 Oil Filtration / Cooling
7.13.1 Engine oil filter Replacement 7.13.2 Centrifugal oil filter Cleaning and filter sleeve replacement
100
7.17.4 Battery-charging generator drive Drive belt and belt tensioner replacement 7.17.5 Battery-charging generator drive Drive belt tension adjustment
122 123
100 101
7.18 Fan Drive
7.18.1 Fan drive belt Tension check / adjustment 7.18.2 Fan drive Drive belt replacement 7.19.1 Engine wiring Check
124
124 126 127
7.14 Coolant Circuit, General, HighTemperature Circuit

7.14.1 7.14.2 7.14.3 7.14.4 7.14.5 7.14.6 7.15.1 7.15.2 7.15.3 7.15.4 7.15.5
Coolant level - Check Engine coolant Change Engine coolant Draining Engine coolant Filling Engine coolant pump Relief bore check Coolant Sample extraction and analysis Charge-air coolant Level check Charge-air coolant Change Charge-air coolant Draining Charge-air coolant Filling Charge-air coolant pump Relief bore check
103
7.19 Wiring (General) for Engine/Gearbox/Unit 7.20 Accessories for (Electronic) Engine Governor / Control System
127
103 104 105 106 108 109 110 111 112 113 116 117 118 119 120
7.20.1 DDEC and connectors Cleaning 7.20.2 DDEC Checking plug-in connections
128
128 130
7.15 Low-Temperature Circuit
110
8 Appendix A 8.1 Abbreviations 8.2 MTU contacts/service partners 131 134
7.16 Belt Drive
7.16.1 Drive belt Condition check 7.17.1 Battery-charging generator Condition check 7.17.2 Battery-charging generator Check 7.17.3 Battery-charging generator Removal and installation
117 118
7.17 Battery-Charging Generator
9 Appendix B 9.1 Special Tools 9.2 Index 135 139
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1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com pulsory regulations regarding accident prevention and environmental protection must be observed. This state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may nevertheless present a risk of injury or damage in the following cases: Incorrect use Operation, maintenance and repair by unqualified personnel Modifications or conversions Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user alone. Correct use also includes observation of and compliance with the operating instructions and mainte nance and repair specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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1.2 Personnel and organizational requirements

Personnel requirements
Work on the engine must only be carried out by appropriately qualified and instructed personnel. Observe the minimum legal age. Responsibilities of the operating, maintenance and repair personnel must be specified by the operating company.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta tion. Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and transport personnel at all times. Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person nel must have read and understood the safety-relevant instructions. This is especially important for personnel who work on the engine only on an occasional basis. These persons shall receive repeated instruction. Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.
Working clothes and protective equipment

Wear proper protective clothing for all work. Depending on the kind of work, use the necessary personal protective equipment.
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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. Transport the engine/genset in the installation position only, maximum admissible inclination is 10. Remove any loose parts on the genset. Hoist the engine/genset slowly ensuring that lifting cables/chains do not touch the engine or any of its component parts. Readjust lifting device as necessary. Pay attention to the center of gravity of the engine/genset. When specially wrapped in aluminum foil, suspend the engine/genset by the lifting eyes on the bearing pedestal or transport by means of handling equipment (forklift truck) capable of bearing the load. Fit the crankshaft shipping lock on the engine and fit the engine mount locking devices prior to transport.
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Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip ping and tipping when driving up or down inclines and ramps.
Placement after transport

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

This locking device protects the crankshaft bearings from shocks and vibration damage during engine transport. For removal of the transport locking device, observe the following: The transport locking device should remain installed as long as possible during engine installation in order to avoid damage. Starting or barring the engine is allowed only with the transport locking device removed. If the genera tor is already mounted on the engine, ensure that the transport locking device of the generator is re moved. Prior to every engine transport (without generator), this transport locking device must be reinstalled according to the instructions.
Removing the transport locking device from driving end (KS)

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Release the locknuts (6) on both sides of the flywheel housing, remove screws (5) and take off the two locks (4). Remove screws (2), washers (3), cover plate (8) with label (7) and plates (1). Store the removed parts of the transport locking device carefully for possible reuse!
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Fitting the transport locking device on driving end (KS)

Secure the two plates (1) with screws (5) and nuts (6) together with cover plate (8) at the bores on both sides of the flywheel housing. Tightening torque: 250 Nm + 25 Nm, lubricant: engine oil. Screw nut (6) onto screws (5) up to the end of the thread. Fit the locks (4) through the openings of plates (1) and fasten with the screws (5). Tighten screws (5) in alternating steps on both sides. Tightening torque : 30 Nm + 3 Nm, lubricant: en gine oil. Screw on nuts (6) of both screws (5) at plates (1) and secure. Mark the engine as "Fitted with transportation locking device".
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1.5 Safety regulations for startup and operation

Safety requirements for initial operation
Prior to initial operation of the unit, install the assembly or unit according to the specifications and check the installation according to the MTU specifications. Before putting the device or plant into operation, always ensure: that all maintenance and repair work is completed, that all loose parts have been removed from rotating machine components, that nobody is in the danger area of moving machine parts. Immediately after putting the device or plant into operation, make sure that all control and display instru ments as well as the signaling and alarm systems work properly.
Safety requirements for operators

The procedures for cases of emergency must be practiced regularly. The operator must be familiar with the control and display elements. The operator must be familiar with the consequences of any operations performed. During operation, the display instruments and monitoring units must be permanently observed with re gard to present operating status, violation of limit values and warning or alarm messages. The following steps must be taken if a malfunction of the system is recognized or reported by the system: inform supervisor(s) in charge, analyze the message, if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine: Wear ear protection. Ensure that the engine room is well ventilated. Do not inhale engine exhaust gases. Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere. Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent. Protect battery terminals, battery-charger terminals and cables against accidental contact. When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live. Observe the safety instructions for these devices.
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1.6 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
u Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion due to oil vapors).
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1.7 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. Cover the screw or plug with a rag to prevent fluids escaping under pressure. Take special care when draining hot fluids Risk of injury. When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated. Allow the engine / system to cool down before starting to work. Observe the maintenance and repair instructions. Never carry out maintenance and repair work with the engine running unless expressly instructed to do so. Secure the engine against accidental starting. Disconnect the battery when electrical starters are fitted. Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic starters are fitted. Disconnect the control equipment from the assembly or system. Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly. Carry out work only on assembles and/or units which are properly secured. Never use lines for climbing. Keep fuel injection lines and connections clean. Always seal connections with caps or covers if a line is removed or opened. Take care not to damage lines, in particular fuel lines, during maintenance and repair work. Ensure that all retainers and dampers are installed correctly. Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con tact with other components. Do not place fuel or oil lines near hot components. Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper ly protected. Note cooling time for components which are heated for installation or removal Risk of burning. When working high on the engine, always use suitable ladders and work platforms. Make sure compo nents are placed on stable surfaces. Observe special cleanness when conducting maintenance and repair work on the assembly or system. After completion of maintenance and repair work, make sure that no loose objects are in/on the assem bly or system. Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards have been reinstalled and that all tools and loose parts have been removed after working on the engine. The following additional instructions apply to starters with beryllium copper pinion: Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de vice as an additional measure. 14 | Safety | M015241/03E 2011-12
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Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when welding in its vicinity. Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system. Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devices for hydraulic removal/installation procedures. Observe the max. permissible push-on pressure specified for the equipment. Do not attempt to bend or apply force to lines. Before starting work, pay attention to the following: Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs). For hydraulic installation, screw on the tool with the piston retracted. For hydraulic removal, screw on the tool with the piston extended. For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft end until correct sealing is established. During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the component to be installed/removed.
Working on electrical/electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during operation by contact with sharp objects, by rubbing against other components or by a hot surface. Do not secure cables on lines carrying fluids. Do not use cable binders to secure cables. Always use connector pliers to tighten connectors. Subject the device or system to a function check on completion of all repair work. Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
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Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles Heavily focused ra diation. Laser equipment must be fitted with the protective devices necessary for safe operation according to type and application.
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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.
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1.8 Fluids and lubricants, fire prevention and environmental protection

Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit. Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid. When starting the engine with an external power source, connect the ground lead last and remove it first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the ground lead of the engine or to the ground terminal of the starter. Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating danger are drowned. Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal

Modification or removal of mechanical or electronic components or the installation of additional compo nents as well as the execution of calibration processes that might affect the emission characteristics of the engine are prohibited by emission regulations. Emission control units/systems may only be main tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act and involves the termination of the operating license by the emission authorities. MTU does not accept any liability for violations of the emission regulations. MTU will provide assistance and advice if emissionrelevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili ty and performance of MTU engines and must be complied with over the entire life cycle of the engine. Use only fuel of prescribed quality to comply with emission limit values. Dispose of used fluids, lubricants and filters in accordance with local regulations. Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are subjected to proper recycling procedures.
Fluids and lubricants

Use only fluids and lubricants that have been tested and approved by MTU. Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions that apply to the product. Take special care when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do not smoke.
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Used oil
Used oil contains harmful combustion residues. Rub barrier cream into hands. Wash hands after contact with used oil.
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Lead
When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. Adopt suitable measures to avoid the formation of lead dust. Switch on extraction system. Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air: Pay special attention to the pressure level in the compressed air network and pressure vessel. Assemblies and equipment to be connected must either be designed for this pressure, or, if the per mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose couplings and connections must be securely attached. Wear goggles when blowing off components or blowing away chips. Provide the snout of the air nozzle with a protective disk (e.g. rubber disk). First shut off compressed air lines before compressed air equipment is disconnected from the supply line, or before equipment or tool is to be replaced. Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers, results in a risk of explosion. Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying purposes or to check for leaks, results in a risk of bursting. Carry out leak test in accordance with the specifications.
Painting
When carrying out painting work outside the spray stands provided with fume extraction systems, en sure that the area is well ventilated. Make sure that neighboring work areas are not impaired. No open flames. No smoking. Observe fire prevention regulations. Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. Avoid body contact (eyes, hands). Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask. Make sure that working area is well ventilated. Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids and alkaline solutions

When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing. If such solutions are spilled onto clothing, remove the affected clothing immediately. Rinse injured parts of the body thoroughly with clean water. Rinse eyes immediately with eyedrops or clean tap water.
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1.9 Engine Barring with starting system

Preconditions
External pushbutton Bar engine without starting is provided.
DANGER
Unguarded rotating and moving engine components. Risk of serious injury danger to life! before barring or starting the engine, ensure that nobody is in the danger zone. After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.
Engine Barring with starting system

1. 2. 3. Press pushbutton Bar engine without starting and keep depressed. Let the crankshaft rotate until oil pressure is indicated, but not longer than 10 seconds. Repeat this procedure after approx. 20 seconds if required.
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1.10 Conventions for safety instructions in the text

DANGER
In the event of immediate danger. Consequences: Death or serious injury Remedial action
WARNING
In the event of potentially dangerous situations. Consequences: Death or serious injury Remedial action
CAUTION
In the event of dangerous situations. Consequences: Minor injury or material damage Remedial action
Note:
This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
1. 2. Read and familiarize yourself with all safety notices before starting up or repairing the product. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
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2 General Information
2.1 Engine layout
Engine version with closed-circuit crankcase ventilation
1 Engine lifting eyes 2 Cylinder-head cover, cyl inder head 3 Coolant inlet 4 Intercooler
5 6 7 8 9
Main PTO Charge-air coolant outlet Charge-air coolant inlet Coolant pump, LT circuit Coolant pump, HT circuit
10 Engine oil dipstick 11 Engine oil filler neck 12 Starter, engine right-hand side
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1 2 3 4 5 6 7
Engine lifting eyes Coolant outlet Fan drive Centrifugal oil filter Engine oil filter HP fuel pump Vibration damper
8 Oil drain plugs 9 Engine oil pan 10 Battery-charging genera tor drive 11 Starter, engine left-hand side 12 Inspection port cover
13 DDEC electronic engine control system 14 Fuel duplex filter (easychange filter) 15 Compressor
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1 Battery-charging genera tor 2 Combustion-air inlet 3 Exhaust turbocharger
4 Crankcase breather of closed-circuit crankcase ventilation (oil separator) 5 Exhaust outlet
6 Engine oil heat exchang er
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Engine version with open-circuit crankcase ventilation
1 Crankcase breather, A side 2 Crankcase breather, B side
3 Crankcase breather mounted on cylinder head cover 4 Cylinder head cover
5 Vent line to atmosphere
Engine model designation

Key to the engine model designation 16V 4000 E20 16 V 4000 E 2 0 Number of cylinders Cylinder arrangement: V engine Series Application: E=Excavator Application segment Design index
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2.2 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 of the engine. Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
1 KGS = Free end 2 Right engine side
3 KS = Driving end 4 Left engine side
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2.3 Sensors and actuators Overview

Sensors, actuators
1 Sensor (oil pressure) 2 Sensor (oil temperature) 3 Sensor (crankcase pres sure) 4 Sensor (charge-air cool ant temperature)
5 Sensor (reference mark TDC cylinder 1) 6 Sensor (LP fuel) 7 Sensor (fuel temperature) 8 Sensor (HP fuel)
9 Sensor (charge-air cool ant pressure) 10 Sensor (coolant pres sure) 11 DDEC
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1 Sensor (coolant tempera ture) 2 Connector power supply / interface to vehicle
3 Sensor (crankshaft angle sensor for injection timing of any cylinder)
4 Sensor (charge-air tem perature) 5 Sensor (charge-air pres sure)
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3 Technical Data
3.1 16V 4000 E20 engine data
Explanation: DL BL A G R L N X Ref. value: Continuous power (CP) Ref. value: Fuel stop power (FSP) Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable
REFERENCE CONDITIONS
Engine model Application group Intake air temperature Charge-air coolant temperature Raw water inlet temperature Barometric pressure Site altitude above sea level C C C mbar m 16V 4000 5A 25 55 1000 100
POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders Engine rated speed Net brake power (without fan) (fuel stop power ISO 3046) A A rpm kW 16V 4000 1800 1600
GENERAL CONDITIONS (for maximum power)

Number of cylinders Intake air depression (new filter) Intake air depression Exhaust backpressure Exhaust backpressure, max. Fuel temperature at fuel feed connection A L A L R mbar mbar mbar mbar C 16V 4000 25 50 30 30
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50
CONSUMPTION
Number of cylinders Specific fuel consumption (be) 100% BL (+5%; EN 590; 42.8MJ/kg) G Lube oil consumption after 100 h operation, average (B = fuel con sumption per hour) R g/kWh % of B 16V 4000 194 0.3
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MODEL-RELATED DATA (basic design)

Number of cylinders Number of cylinders Cylinder configuration: V angle Bore Stroke Cylinder displacement Total displacement Number of inlet valves, per cylinder Number of exhaust valves, per cylinder degrees mm mm liter liter 16V 4000 16 90 165 190 4.06 65.0 2 2
COMBUSTION AIR / EXHAUST GAS

Number of cylinders Charge-air pressure before cylinder (abs.) Exhaust temperature after turbocharger R R bar ABS C 16V 4000 2.7 410
COOLING SYSTEM (HT circuit)

Number of cylinders Coolant temperature (at engine outlet to cooling equipment; with max. 40% antifreeze) Coolant temperature after engine, alarm Coolant temperature after engine, shutdown Coolant antifreeze content, max. permissible Coolant pump: inlet pressure, min. Coolant pump: inlet pressure, max. Thermostat, starts to open Thermostat, fully open A R L L L L R R C C C % bar bar C C 16V 4000 92 95 97 40 0.2 2.2 77 85
COOLING SYSTEM (LT circuit)

Number of cylinders Coolant temperature (at engine outlet to cooling equipment) Coolant temperature before intercooler (with max. 40% antifreeze) Coolant temperature differential after/before intercooler, max. Coolant antifreeze content, max. permissible
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16V 4000 R A L L R R C C C % C C 65 55 15 40 32 44
Thermostat, starts to open Thermostat, fully open
LUBE OIL SYSTEM

Number of cylinders Lube oil operating temperature before engine, from Lube oil operating temperature before engine, to Lube oil operating pressure before engine, from R R R C C bar 16V 4000 88 93 5.0
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Number of cylinders Lube oil operating pressure before engine, to Lube oil pressure before engine, alarm Lube oil pressure before engine, shutdown Lube oil fine filter (main circuit) differential pressure, max. R R L L bar bar bar bar
16V 4000 6,0 4.5 4.0 1.0
FUEL SYSTEM
Number of cylinders Fuel pressure at supply connection to engine (when engine is start L ing), min. admissible Fuel pressure at supply connection to engine (when engine is start L ing), max. admissible Fuel pressure before injection pump, from (H.P. pump) Fuel pressure before injection pump, to (H.P. pump) Fuel pressure before injection pump, min. (H.P. pump) R bar 3.5 R bar 6.0 R bar bar bar 16V 4000 0.1 1.5 4.0
GENERAL OPERATING DATA

Number of cylinders Coolant preheating: preheating temperature (min.) R C 16V 4000 40
INCLINATIONS STANDARD OIL SYSTEM (Ref.: waterline)

Number of cylinders Longitudinal inclination, continuous max., driving end down (Option: max. operating inclinations) Longitudinal inclination, continuous max., driving end up (Option: max. operating inclinations) L degrees 10 L degrees 16V 4000 22.5
CAPACITIES
Number of cylinders Engine coolant capacity (without cooling equipment) Engine oil capacity, initial filling (standard oil system) (Option: max. operating inclinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. operating inclinations) R R L L liter liter liter liter 16V 4000 210 520 360 460
TIM-ID: 0000002641 - 001
WEIGHTS / MAIN DIMENSIONS

Number of cylinders Engine dry weight (basic engine) R kg 16V 4000 7490
FREE-FIELD SOUND PRESSURE LEVEL

Number of cylinders Exhaust noise, unsilenced, 1m distance R db(A) 16V 4000 118
TIM-ID: 0000002641 - 001
M015241/03E 2011-12 | Technical Data | 31
3.2 Firing order

Firing order
Number of cylin ders 8V 12V 16 V 20 V Firing order A1-B4-A4-A2-B3-A3-B2-B1 A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
TIM-ID: 0000002794 - 004
4 Operation
4.1 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 Engine Valve gear Lube oil system Fuel prefilter Fuel system Coolant circuit Action Depreserve ( MTU Fluids and Lubricants Specifications A001061/..). Lubricate valve gear every 6 months ( Page 75). Check engine oil level ( Page 96). Fill with fuel ( Page 90)( Page 91). Vent ( Page 88). If engine is out of service for more than one year, change engine coolant ( Page 104). Change charge-air coolant ( Page 111). Coolant circuit Coolant circuit DDEC Check engine coolant level ( Page 103); Check charge-air coolant level ( Page 110). Preheat coolant with preheating unit, if fitted. Check plug-in connections ( Page 130).
TIM-ID: 0000002201 - 002
M015241/03E 2011-12 | Operation | 33
4.2 Putting the engine into operation after scheduled out-ofservice-period

Preconditions
Engine is stopped and starting disabled.
Startup
Item Lube oil system Coolant circuit Coolant circuit Engine control system Action Check engine oil level ( Page 96). Check engine coolant level ( Page 103); Check charge-air coolant level ( Page 110). Preheat coolant with coolant preheating unit (if applicable). Put into operation.
34 | Operation | M015241/03E 2011-12
TIM-ID: 0000002683 - 005
4.3 Engine Start in manual mode

Preconditions
Engine with no load. External start interlock is not activated.
DANGER
Unguarded rotating and moving engine components. Risk of serious injury danger to life! Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING
Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
Preparation
Item Operating mode switch (if applicable) Coolant preheating unit (if applicable). Measure Switch to manual mode. Switch on.
Starting the engine

Item Switch cabinet, operator station etc. (depending on manufacturer). Measure If coolant temperature is > 40 C (with coolant preheating unit, if applicable) press start button. Automatic starting sequence is executed Engine speed display instrument indicates increasing speed After the starting sequence is completed, engine is running at idle speed.
TIM-ID: 0000002233 - 003
M015241/03E 2011-12 | Operation | 35
4.4 Operational checks

DANGER
Unguarded rotating and moving engine components. Risk of serious injury danger to life! Take special care when working on a running engine.
WARNING
Operational checks
Item Control and display panels Engine operation Action Check readings of operational data (speed, temperature, pressures). Check engine visually for leaks and general condition; Check for abnormal running noise, exhaust discoloration and vibrations ( Page 41). HP pump Fuel prefilter Check relief bore ( Page 81). Drain water and contaminants via drain cock on fuel prefilter ( Page 90)( Page 91). ( Page 90)Check reading on differential pressure gage of fuel prefilter (if fitted). Engine coolant pump Charge-air coolant pump Check relief bore ( Page 108). Check relief bore ( Page 116).
36 | Operation | M015241/03E 2011-12
TIM-ID: 0000002264 - 002
4.5 Engine Shutdown in manual mode

Preconditions
Engine is not under load Engine 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.
Preparation
Item Engine Measure Operate engine at idling speed for approx. 5 minutes.
Shutting the engine down

Item Switch cabinet, operator station etc. (depending on manufacturer) Measure Press stop button. Automatic stopping sequence is executed.
TIM-ID: 0000002291 - 003
M015241/03E 2011-12 | Operation | 37
4.6 After stopping the engine

Preconditions
MTU Fluids and Lubricants Specification (A001061/..) is available.
After stopping the engine

Item Coolant circuit Task Drain coolant ( Page 105)( Page 112)if freezing temperatures are ex pected and: the engine is to remain out of service for an extended period and cool ant has no antifreeze additive; the coolant is not maintained at a suitable temperature; antifreeze concentration is 50 % and outside temperature is below -40C. Switch OFF.
Engine control system
Air intake and exhaust sys Out-of-service-period > 1 week: tem Seal engine's air and exhaust sides. Out-of-service-period > 1 month: Preserve engine ( MTU Fluids and Lubricants Specifications A001061/.. ).
38 | Operation | M015241/03E 2011-12
TIM-ID: 0000002321 - 001
4.7 Plant Cleaning

Preconditions
Engine is stopped and starting disabled. Operating voltage is not applied.
Special tools, Material, Spare parts

Designation / Use Steam jet cleaner Cleaner (Hakupur 312)
WARNING
Part No. 30390
Qty. 1 1
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. Wear protective clothing, gloves, and goggles / safety mask. Excessive reaction time of cleaning agents on components. Damage to component! Observe manufacturer's instructions. Wear protective clothing, gloves, and goggles / safety mask. There is a risk of damaging sensors with compressed air.
WARNING
CAUTION
Note:
Plant Cleaning
1. 2. 3. 4. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro tection). Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit carefully and observe the safety precautions. For external cleaning with high-pressure jet, use a flat-mouth nozzle only. Carry out external cleaning as follows: a) Remove coarse dirt. b) Spray on cleaner sparingly and leave it for 1 to 5 minutes. c) Use the high-pressure jet to remove the loosened dirt. d) During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must be observed. The temperature of the cleaning medium must not exceed 80 C.
TIM-ID: 0000010171 - 018
M015241/03E 2011-12 | Operation | 39
5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule. Task W0500 W0501 W0504 W0505 W0506 W0507 W0508 W0525 W1001 W1002 W1003 W1006 W1008 W1009 Maintenance tasks Check engine oil level Visually inspect engine for leaks and general condition Check HP fuel pump weep holes Check relief bores of coolant pump(s) Check engine for abnormal running noises, exhaust color and vibrations Drain water and dirt from fuel prefilter (if fitted) ( Page 96) ( Page 36) ( Page 36) ( Page 108) ( Page 116) ( Page 36) ( Page 36)
Check reading on differential pressure gage of fuel prefilter (if ( Page 36) fitted) Check battery-charging generator for contamination, clean if necessary Replace fuel filter or fuel filter element Check valve clearance Check drive belt condition and tension, replace if necessary Replace fuel injectors Replace engine oil filter at each oil change or when the time limit (years) is reached, at the latest Check layer thickness of oil residue, clean and replace filter sleeve of centrifugal oil filter (if fitted) at every oil change, at the latest Perform endoscopic inspection of combustion chambers Check engine wiring system externally for damage Crankcase breather: Clean filter Remove battery-charging generator and clean thoroughly with compressed air ( Page 119) ( Page 89) ( Page 76) ( Page 117) ( Page 82) ( Page 100) ( Page 101)
W1011 W1022 W1044 W1209 W1697 W1698
( Page 67) ( Page 127) ( Page 74) ( Page 120)

TIM-ID: 0000034281 - 001
Check carbon brushes at flywheel (if fitted), replace if neces sary Replace carbon brushes at flywheel (if fitted) -
Table 1: Maintenance task reference table [QL1]
40 | Maintenance | M015241/03E 2011-12
6 Troubleshooting
6.1 Troubleshooting
Engine does not turn when starter is actuated
Component Battery Cause Low or faulty Cable connections faulty Starter Engine cabling Engine/generator control system DDEC Engine Engine cabling or starter faulty Faulty Assemblies or connectors possibly loose Plug-in connections possibly loose Running gear blocked (engine cannot be barred manually) Action Charge or replace (see manufacturer's documentation). Check if cable connections are proper ly secured (see manufacturer's docu mentation). Check if cable connections are proper ly secured, contact Service. Check ( Page 127). Perform visual inspection (see manu facturer's documentation). Check plug-in connections ( Page 130). Contact Service.
Engine turns but does not fire

Component Starter Engine cabling Fuel system DDEC Cause Poor rotation by starter: Battery low or faulty Faulty Air in fuel system Faulty Action Charge or replace battery (see manu facturer's documentation). Check ( Page 127). Vent fuel system ( Page 88). Contact Service.
Engine fires unevenly

Component Fuel injection equip ment Engine cabling Fuel system
TIM-ID: 0000002542 - 002
Cause Injector faulty Faulty Air in fuel system Faulty
Action Replace ( Page 82). Check ( Page 127). Vent fuel system ( Page 88). Contact Service.
DDEC
Engine does not reach rated speed

Component Fuel supply Air supply Cause Fuel prefilter clogged Easy-change fuel filter clogged Air filter clogged Action Clean or replace filter element. Replace ( Page 89). Check signal ring position of service in dicator ( Page 93).
M015241/03E 2011-12 | Troubleshooting | 41
Component Fuel injection equip ment Engine cabling Engine
Cause Injector faulty Faulty Overloaded
Action Replace ( Page 82). Check ( Page 127). Contact Service.
Engine speed not steady

Component Fuel injection equip ment Speed sensor Fuel system DDEC Cause Injector faulty Faulty Air in fuel system Faulty Action Replace ( Page 82). Contact Service. Vent fuel system ( Page 88). Contact Service.
Charge air temperature too high

Component Engine coolant Intercooler Engine room Cause Engine coolant treatment incorrect Contaminated Air-intake temperature too high Action Check (MTU test kit). Contact Service. Check fans and intake/exhaust lines.
Charge-air pressure too low

Component Air supply Intercooler Cause Air filter clogged Contaminated Action Check signal ring position of service in dicator ( Page 93). Contact Service. Contact Service.
Exhaust turbocharger Faulty
Coolant leaks at intercooler

Component Intercooler Cause Leaking, major coolant discharge Action Contact Service.
Black exhaust gas

Component Air supply Fuel injection equip ment Engine Cause Air filter clogged Injector faulty Overloaded Action Check signal ring position of service in dicator ( Page 93). Replace ( Page 82). Contact Service.
TIM-ID: 0000002542 - 002
42 | Troubleshooting | M015241/03E 2011-12
Blue exhaust gas

Component Engine oil Cause Too much oil in engine Filter element in oil separator is clog ged Exhaust turbocharg Faulty er, cylinder head, pis ton rings, cylinder lin er Action Drain engine oil ( Page 97). Replace ( Page 72). Contact Service.
White exhaust gas

Component Engine Fuel system Cause Not at operating temperature Water in fuel Action Run engine to reach operating temper ature. Drain fuel prefilter ( Page 90) ( Page 91). Check fuel system. Intercooler Leaking Contact Service.
TIM-ID: 0000002542 - 002
6.2 DDEC alarms

The DDEC generates alarms which are indicated in different ways depending on the equipment configu ration: Two-digit flash code Fault code and text on a display or PC screen To facilitate troubleshooting without additional auxiliary equipment, the two-digit flash codes can be read out from the DDEC by means of the vehicle-side alarm lamps CHECK ENGINE LIGHT (yellow) and STOP ENGINE LIGHT (red). For this purpose, two DIAGNOSTIC REQUEST switches must be provided in the vehicle). The first switch is used for reading out the flash codes of the master DDEC unit, the second one to read out the receiver DDEC unit. The flash-code signals from master and receiver are transmitted to the same alarm lamps. Active codes: indicated by STOP ENGINE LIGHT (red) Activation of flash codes: 1. Operate IGNITION switch to position ON. 2. Operate DIAGNOSTIC REQUEST switch of master or receiver unit. 3. Read off codes. 4. Identify the fault according to the DDC fault code list. Example: Active code 23: STOP ENGINE LIGHT lamp is flashing: Flashing phase 1 two times flashing Flashing phase 2 three times flashing Inactive code 34: CHECK ENGINE LIGHT lamp is flashing: Flashing phase 1 three times flashing Flashing phase 2 four times flashing Inactive codes: indicated by CHECK ENGINE LIGHT (yellow)
There is a pause of 0.5 seconds between the flashing phases 1 and 2. When a fault code changes from active to inactive, the pause is 3 seconds. To terminate flash code indication, switch DIAGNOSTIC REQUEST and IGNITION switches off. IGNITION is allowed to be switched on again only after 30 seconds. This method does not allow exact fault diagnostics, since a flash code may indicate faults with several causes. The Diagnostic Data Reader (DDR) facilitates more detailed troubleshooting. The Diagnostic Data Reader (DDR) is intended to: Read out alarms from the DDEC electronic system Change parameters (limited extent) The DDR provides the possibility to read out active and inactive fault codes via separate menus. Addi tionally, the inactive fault codes stored in the DDEC can be deleted. For detailed functional description, refer to the description of the DDR. The DDR (Part No. 5355383601/77) consists of: the Pro Link 9000 basic unit the MPC Cartridge to integrate a PCMCIA card a PCMCIA card a connection cable an additional adapter cable is required (Part No. J 38500 60A) 44 | Troubleshooting | M015241/03E 2011-12
TIM-ID: 0000003162 - 001
Accessory equipment: Printer (Part No. J-38699) for direct connection to the DDR Spare paper (Part No. J-38480-5) for printer (5 rolls) The following information will be available by reading out fault codes with the DDR. Example: 33 TURBO INPUT A1 MID:128 BOOST VOLTAGE PID: 102 Engine SENSOR HIGH FMI:3
Explanation: 33 Flash code MID: 128 Indicates origin of alarm TURBO-BOOST-SENSOR-INPUT-VOLTAGE-HIGH Fault text further faults are present A= active, I= inactive MID (Message Identification Character) Indicates origin of alarm MID 128 Master MID 175 Receiver 1 MID 183 Receiver 2 PID (Parameter Identification Character) To identify transmitted data: (e. g. engine speed, coolant temperature etc.) PID 0-127 1 data byte PID 128-191 2 data bytes PID 192-253 variable SID (Subsystem Identification Character) Identifies the origin of alarms from subsystems, which can be replaced as a complete unit (e.g. injec tors). FMI (Failure Mode Identifier) Identifies the type of fault. FMI 0 Measured value exceeds the limit value (monitoring for TOO HIGH), example: Coolant tem perature FMI 1 Measured value does not reach the limit value (monitoring for TOO LOW), example: Lube oil pressure FMI 3 Signal path interrupted or signal is exceeds the permissible measuring range (sensor defect) FMI 4 Signal path short circuit against (-) supply of sensor or signal does not reach permissible measuring range (sensor defect) Flash PID code 11
TIM-ID: 0000003162 - 001
SID
FMI 4
Description Position sensor of variable speed governor voltage too low. Control system / variable speed governor voltage too high. Position sensor of variable speed governor voltage too high.
Tasks Contact Service.
187
11
187
Contact Service.
12
187
Contact Service.
Flash PID code 13 111
SID
FMI 4
Description Coolant level sensor, input voltage too low.
Tasks 1. Check coolant condition ( Page 109). 2. Check coolant level, top up if required ( Page 103). 3. Check wiring. 4. Contact Service.
13
111
Sensor "Top up coolant", in 1. Check coolant condition put voltage too low. ( Page 109). 2. Check coolant level, top up if required ( Page 103). 3. Check wiring. 4. Contact Service.
14
52
Temperature sensor/inter cooler, input voltage too high. Coolant temperature sen sor, input voltage too high. Oil temperature sensor, in put voltage too high. Temperature sensor/inter cooler, input voltage too low. Coolant temperature sen sor, input voltage too low. Oil temperature sensor, in put voltage too low. Coolant level sensor, input voltage too high.
1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. Contact Service. 1. Check coolant condition ( Page 109). 2. Check coolant level, top up if required ( Page 103). 3. Check cooler for contamina tion. 4. Check wiring. 5. Contact Service.
14 14 15
110 175 52
3 3 4
15 15 16
110 175 111
4 4 3
16 17 17 17
111 51 72 354
5 3 3 3
Throttle sensor, input volt age too high. Blower bypass position, in put voltage too high. Humidity sensor, electric circuit defective / high (ver sion 33.0 or later).
1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service.
TIM-ID: 0000003162 - 001
Sensor "Top up coolant", in 1. Check wiring. put voltage too high. 2. Contact Service.
Flash PID code 18 18 18 51 72 354
SID
FMI 4 4 4
Description Throttle sensor, input volt age too low. Blower bypass position, in put voltage too low. Humidity sensor, electric circuit defective / low (ver sion 33.0 or later). Throttle sensor, input volt age too high. Throttle sensor, input volt age too low. Fuel temperature sensor, input voltage too high. Oxygen concentration cir cuit, input voltage too high.
Tasks 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. No search for faults.
21 22 23 23 24 24 25 26 26 27
91 91 174 65 174 65
3 4 3
4 4
Fuel temperature sensor, input voltage too high. Oxygen concentration cir cuit, input voltage too low. Reserved for "No Codes".
25 61 105
11 11 3
Auxiliary shutdown 1 active. Contact Service. Auxiliary shutdown 2 active. Contact Service. Inlet elbow temperature sensor, input voltage too high. Outside temperature sen sor, input voltage too high. Air temperature sensor, in put voltage too high. Inlet elbow temperature sensor, input voltage too low. Outside temperature sen sor, input voltage too low. Air temperature sensor, in put voltage too low. Circuit exhaust turbocharg er inlet temperature defec tive / low (version 33.0 or later). 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service. 1. Check wiring. 2. Contact Service.
27 27 28
171 172 105
3 3 4
28
TIM-ID: 0000003162 - 001
171 172 351
4 4 4
28 29
SID
FMI 4
Description Temperature sensor / ex haust turbocharger outlet, input voltage too low (ver sion 32.0 or later).
Tasks 1. Check wiring. 2. Contact Service.
31 31
51 51
3 4
Auxiliary output 3, open cir Contact Service. cuit (side "high") S3. Auxiliary output 3, ground short circuit (side "high") S3. Auxiliary output 3, fault in mechanical system S3. Contact Service.
31 31 31
51 52 52
7 3 4
Contact Service.
Auxiliary output 4, open cir Contact Service. cuit (side "high") S3. Auxiliary output 4, ground short circuit (side "high") T3. Auxiliary output 4, fault in mechanical system T3. Contact Service.
31 32 32 32 32 33 34 35 35 36 36 37 37 102 102 19 100 19 100 18 94
52 238 238 239 239
7 3 4 3 4 3 4 3 3 4 4 3 3
Contact Service.
SEL, short circuit on battery 1. Check wiring. circuit (plus). 2. Contact Service. SEL, open circuit . 1. Check wiring. 2. Contact Service. CEL, short circuit on battery 1. Check wiring. circuit (plus). 2. Contact Service. CEL, open circuit . 1. Check wiring. 2. Contact Service. Charge-air pressure sensor, 1. Check wiring. input voltage too high. 2. Contact Service. Charge-air pressure sensor, 1. Check wiring. input voltage too low. 2. Contact Service. Oil pressure sensor upper 1. Check wiring. level, input voltage too high. 2. Contact Service. Oil pressure sensor, input voltage too low. 1. Check wiring. 2. Contact Service.
TIM-ID: 0000003162 - 001
Oil pressure sensor upper 1. Check wiring. level, input voltage too high. 2. Contact Service. Oil pressure sensor, input voltage too low. 1. Check wiring. 2. Contact Service.
Fuel pressure sensor upper 1. Check wiring. level, input voltage too high. 2. Contact Service. Fuel pressure sensor, input 1. Check wiring. voltage too high. 2. Contact Service.
SID
FMI 3
Description Fuel- differential pressure sensor, input voltage too high.
Tasks 1. Check wiring. 2. Contact Service.
38 38 38
18 94 95
4 4 4
Fuel pressure sensor upper 1. Check wiring. level, input voltage too low. 2. Contact Service. Fuel pressure sensor, input 1. Check wiring. voltage too low. 2. Contact Service. Fuel differential pressure sensor, input voltage too low. EGR system leaking, charge-air pressure (ver sion 33.0 or later). EGR system leaking, ex haust brake operation (ver sion 33.0 or later). EGR valve does not re spond (version 33.0 or lat er). VNT nozzles do not re spond, charge-air pressure (version 33.0 or later). VNT nozzles at maximum, exhaust brake operation (version 33.0 or later). 1. Check wiring. 2. Contact Service. Contact Service.
39
146
39
146
12
Contact Service.
39
146
Contact Service.
39
147
Contact Service.
39
147
11
Contact Service.
39
147
12
VNT nozzles do not re Contact Service. spond, brake pressure (ver sion 33.0 or later). Exhaust gas recirculation flow too low, VNT nozzles do not respond, charge-air pressure (version 33.0 or later). Contact Service.
39
147
14
39 39
147 152
7 7
VNT vanes do not respond, Contact Service. EGR (version 33.0 or later). No signal from EGR valve (version 29.0 or later). 1. Check signal ring position of service indicator ( Page 93). 2. Contact Service.
TIM-ID: 0000003162 - 001
39
153
VNT vanes do not respond, 1. Check signal ring position of (version 29.0 or later). service indicator ( Page 93). 2. Contact Service. Too many SRS (TRS miss Contact Service. ing). Not enough SRS (SRS missing). Contact Service.
41 42
21 21
0 1
SID
FMI 1
Description Coolant level too low.
Tasks 1. Check coolant level, top up if required ( Page 103). 2. Contact Service. 1. Check coolant condition ( Page 109). 2. Check coolant level, top up if required ( Page 110). 3. Check intercooler for contam ination. 4. Contact Service.
44
52
Intercooler coolant temper ature too high.
44
105
Inlet elbow temperature too 1. Check signal ring position of high. service indicator ( Page 93). 2. Contact Service. Coolant temperature too high. 1. Check coolant condition ( Page 109). 2. Check coolant level, top up if required ( Page 103). 3. Check cooler for contamina tion. 4. Contact Service.
44
110
44
172
Intake air temperature too high. Oil temperature too high.
1. Check signal ring position of service indicator ( Page 93). 2. Contact Service. 1. Check engine oil level ( Page 96). 2. Contact Service. 1. Check signal ring position of service indicator ( Page 93). 2. Contact Service.
44
175
105
14
Inlet elbow temperature: power reduction.
110
14
Coolant temperature: power 1. Check coolant condition reduction. ( Page 109). 2. Check coolant level, top up if required ( Page 103). 3. Check cooler for contamina tion.
45
19
High range: Oil pressure too low. Oil pressure too low.
1. Check engine oil level ( Page 96). 2. Contact Service. 1. Check engine oil level ( Page 96). 2. Contact Service. Contact Service.
45
100
46
168
ECM battery voltage too low.
TIM-ID: 0000003162 - 001
4. Contact Service.
Flash PID code 46
SID 214
FMI 1
Description Real-time clock auxiliary battery, voltage too low (version 29.0 or later). Sensor supply voltage too low. High range: Fuel pressure too high. Fuel pressure too high. Charge-air pressure too high. Injection control pressure too high. High range: Fuel pressure too low.
46 47 47 47 47 47 48 18 94 102 106 164 18
232
1 0 0 0 0 0 1
Contact Service. Contact Service. Contact Service. Contact Service.
Air intake pressure too high. Contact Service. Contact Service. 1. Check fuel prefilter ( Page 90) and ( Page 91). 2. Check fuel filter ( Page 89). 3. Top up tank if required. 4. Contact Service.
48
94
Fuel pressure too low.
1. Check fuel prefilter ( Page 90) and ( Page 91). 2. Check fuel filter ( Page 89). 3. Top up tank if required. 4. Contact Service.
48 48 48
106 164 351
1 1 1
Air intake pressure too low. Contact Service. Injection control pressure too low. Exhaust turbocharger inlet temperature below range (version 33.0 or later). Contact Service. Contact Service.
48
404
Exhaust turbocharger outlet Contact Service. temperature too low (ver sion 33.0 or later). EGR OPD low (version 33.0 Contact Service. or later). EGR temperature too low (version 33.0 or later). EGR temperature too low. EGR differential pressure too low. Contact Service. Contact Service. Contact Service.
48 48
TIM-ID: 0000003162 - 001
411 412 154 155 351
1 1 1 1 0
48 48 49
Temperature at exhaust tur 1. Check signal ring position of bocharger inlet above range service indicator ( Page 93). (version 33.0 or later). 2. Check exhaust system. 3. Contact Service.
SID
FMI 0
Description
Tasks
Temperature at exhaust tur 1. Check signal ring position of bocharger outlet too high service indicator ( Page 93). (version 32.0 or later). 2. Check exhaust system. 3. Contact Service. TCO temperature: power reduction. Contact Service.
404 51 351
14 3
Temperature sensor on ex 1. Check wiring. haust turbocharger inlet, cir 2. Contact Service. cuit defective / high. Temperature sensor on ex 1. Check wiring. haust turbocharger outlet, 2. Contact Service. input voltage too high (ver sion 32.0 or later). A/D conversion faulty. Nonvolatile check sum er ror. Write error EEPROM. Out of calibration. Vehicle's speed sensor de fect. Contact Service. Contact Service. Contact Service. Contact Service. 1. Check wiring. 2. Contact Service.
51
404
52 53 53 53 54 55 84
254 253 253 253
12 2 12 13 12
216
14
Fault of other control unit Contact Service. (version 27.0 or later). This fault is stored in connection with another fault to refer to missing information of an other control unit. Data connection J1939 faul Contact Service. ty. System-related data con nection faulty (master). System-related data con nection (repeater). Contact Service. Contact Service.
55 55 55 56 57 58 61 62 92
231 248 248 250 249
12 8 9 12 12 0
Data connection J1587 faul Contact Service. ty. Data connection J1922 faul Contact Service. ty. Torque too high. Contact Service.
TIM-ID: 0000003162 - 001
xxx 26
0 3
Reaction time injection noz Contact Service. zle xxx too long. Auxiliary output 1, short cir Contact Service. cuit on battery circuit (plus) F3. Auxiliary output 1, open cir Contact Service. cuit F3.
62
26
Flash PID code 62
SID 26
FMI 7
Description
Tasks
Auxiliary output 1, mechani Contact Service. cal system does not re spond correctly F3. Auxiliary output 2, short cir Contact Service. cuit on battery circuit (plus) A2. Auxiliary output 2, open cir Contact Service. cuit A2. Auxiliary output 2, mechani Contact Service. cal system does not re spond correctly A2. Auxiliary output 5, short cir Contact Service. cuit on battery circuit (plus) W3. Auxiliary output 5, open cir Contact Service. cuit W3. Auxiliary output 5, mechani Contact Service. cal system does not re spond correctly W3. Auxiliary output 6, short cir Contact Service. cuit on battery circuit (plus) X3. Auxiliary output 6, open cir Contact Service. cuit X3. Auxiliary output 6, mechani Contact Service. cal system does not re spond correctly X3. Auxiliary output 7, short cir Contact Service. cuit on battery circuit (plus) Y3. Auxiliary output 7, open cir Contact Service. cuit Y3. Auxiliary output 7, mechani Contact Service. cal system does not re spond correctly Y3. Auxiliary output 8, short cir Contact Service. cuit on battery circuit (plus) A1. Auxiliary output 8, open cir Contact Service. cuit A1. Auxiliary output 8, mechani Contact Service. cal system does not re spond correctly A1. PWM 1 above normal range. PWM 1 below normal range. Contact Service. Contact Service.
62
40
62 62
40 40
4 7
62
53
62 62
53 53
4 7
62
54
62 62
54 54
4 7
62
55
62 62
55 55
4 7
62
56
TIM-ID: 0000003162 - 001
62 62
56 56
4 7
63 63
57 57
0 1
Flash PID code 63 63 63 63 63 63 63 63 63 63 63 63 63 63 64 64 103 103
SID 57 57 58 58 58 58 59 59 59 59 60 60 60 60
FMI 3 4 0 1 3 4 0 1 3 4 0 1 3 4 0 8
Description
Tasks
PWM 1 short circuit on bat Contact Service. tery circuit (plus). PWM 1 open circuit. PWM 2 above normal range. PWM 2 below normal range. Contact Service. Contact Service. Contact Service.
PWM 4 short circuit on bat Contact Service. tery circuit (plus). PWM 4 open circuit. Exhaust turbocharger speed too high. Exhaust turbocharger speed sensor, input signal faulty (irregular period). Contact Service. Contact Service. Contact Service.
65 65 65 65 65 65 66 66
51 51 51 51 107 107 99 99
0 1 2 7 3 4 3 4
Throttle position above nor Contact Service. mal range. Throttle position below nor Contact Service. mal range. Throttle position not regular. Contact Service. Throttle does not respond. Contact Service.
TIM-ID: 0000003162 - 001
Air filter differential pressure 1. Check wiring. sensor, voltage too high. 2. Contact Service. Air filter differential pressure 1. Check wiring. sensor, voltage too low. 2. Contact Service. Oil filter differential pressure 1. Check wiring. sensor, voltage too high. 2. Contact Service. Oil filter differential pressure 1. Check wiring. sensor, voltage too low. 2. Contact Service.
Flash PID code 66 66 66 66 67 20
SID 76 76 76 76
FMI 0 3 4 7 3
Description Engine knock level above normal range.
Knock sensor, input voltage Contact Service. too high. Knock sensor, input voltage Contact Service. too low. Knock sensor does not re spond. Coolant pressure sensor, high range (input voltage too high). Coolant pressure sensor, high range (input voltage too low). Air intake pressure sensor, input voltage too high. Air intake pressure sensor, input voltage too low. Coolant pressure sensor, input voltage too high. Coolant pressure sensor, input voltage too low. Contact Service. Contact Service.
67
20
Contact Service.
67 67 67 67 68
106 106 109 109 230
3 4 3 4 5
Contact Service. Contact Service. Contact Service. Contact Service.
Idling recognition pedal Contact Service. travel sensor (TPS), fault in circuit (circuit open). Idling recognition pedal Contact Service. travel sensor (TPS), fault in circuit (ground short circuit). Reaction time injection noz Contact Service. zle xxx too short. Vehicle's speed too high. Vehicle's speed too high (absolute). Oxygen concentration too high. Oxygen concentration too low. Contact Service. Contact Service. Contact Service. Contact Service.
68
230
71 72 72 72 72
TIM-ID: 0000003162 - 001
xxx 84 84 65 65 107
1 0 11 0 1 0
73
Air filter differential pressure 1. Check signal ring position of too high. service indicator ( Page 93). 2. Contact Service. Gas valve position above normal range. Gas valve position below normal range. Gas valve position input voltage too high. Contact Service. Contact Service. Contact Service.
73 73 73
77 77 77
0 1 3
Flash PID code 73 73 73 73
SID 77 77 151 226
FMI 4 7 14 11
Description Gas valve position input voltage too low. Gas dosing valve does not respond.
Tasks Contact Service. Contact Service.
ESS transmission, engaged Contact Service. gear step jamming. Transmission idling switch defective, (ESS transmis sion). Analog auxiliary input: data failing irregularly or defec tive (ESS transmission). Analog auxiliary input 1, voltage too high (ESS transmission). Contact Service.
73
227
Contact Service.
73
227
Contact Service.
73
227
Analog auxiliary input 1, Contact Service. voltage too low (ESS trans mission). Optimized idle security loop) ground short circuit. Oil filter plugged. Contact Service. 1. Replace oil filter ( Page 100) 2. Contact Service. Contact Service. Contact Service.
74 74
70 99
4 0
75 75
168 214
0 0
ECM battery voltage too high. Real time clock backup, battery voltage too high (version 29.0 or later). Sensor supply voltage too high. Engine overspeed with ex haust brake. Cylinder head temperature too high.
75 76 77 77 77 77 77 77 77 77 121 3 19 20 72 72 73 81 81
232
0 0 0 0 0 0 1 1 0 1
Contact Service. Contact Service. Contact Service.
High range: oil pressure too Contact Service. high. High range: coolant pres sure too high. Blower bypass position too high. Blower bypass position too low. Exhaust back pressure too high. Exhaust back pressure too low. Contact Service. Contact Service. Contact Service.
TIM-ID: 0000003162 - 001
Fire pump pressure too low. Contact Service. Contact Service. Contact Service.
Flash PID code 77 77 77 77 77 77 77 77 77 77 77 77 77 77 81 81 81 95 99 100 102 105 107 108 108 109 110 111
SID
FMI 3 4 12 1 1 0 1 1 1 0 1 0 1 0
Description
Tasks
Exhaust back pressure sen Contact Service. sor voltage too high. Exhaust back pressure sen Contact Service. sor voltage too low. Exhaust back pressure near Contact Service. limit for power reduction. Fuel filter differential pres sure too low. Contact Service.
Oil filter differential pressure Contact Service. too low. Engine oil pressure too high. Charge-air pressure too low. Contact Service. Contact Service.
Inlet elbow temperature too Contact Service. low. Air filter differential pressure Contact Service. too low. Atmospheric pressure too high. Atmospheric pressure too low. Coolant pressure too high. Coolant temperature too low. Coolant level too high. Contact Service. Contact Service. Contact Service. Contact Service. 1. Check coolant level ( Page 103). 2. Contact Service. Contact Service. Contact Service. Contact Service. Contact Service. Contact Service. Contact Service. Contact Service.
77 77 77 77 77
TIM-ID: 0000003162 - 001
171 171 172 174 174 175 222 251 251 252 252
0 1 1 0 1 1 14 10 13 10 13
Outside temperature too high. Outside temperature too low. Intake air temperature too low. Fuel temperature too high. Fuel temperature too low. Engine oil temperature too low. Theft protection faulty.
77 77 77 77 77 77
Clock module with irregular Contact Service. alteration speed. Clock module faulty. Contact Service. Clock module with irregular Contact Service. alteration speed. Clock module faulty. Contact Service.
SID
FMI 0
Description Relative air humidity above range (version 33.0 or lat er). Relative air humidity under range (version 33.0 or lat er). Cylinder head temperature above range (version 33.0 or later).
77
354
Contact Service.
77
446
Contact Service.
77
151
11
Maintenance display lamp, Contact Service. faulty / service interval ex ceeded (version 32.0 or lat er). Self-adaptive speed control Contact Service. faulty (version 27.0 or later). Oil level sensor, input volt age too high. Crankcase pressure sen sor, input voltage too high. Crankcase pressure, input voltage too high (version 27.0 or later). Injection control pressure sensor, input voltage too high. Exhaust gas temperature sensor, input voltage too high. EGR OPD, circuit defec tive / high (version 33.0 or later). EGR temperature too high (version 33.0 or later). Exhaust duct temperature 1, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 2, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 3, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 4, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 5, sensor voltage too high (version 32.0 or later). Contact Service. Contact Service. Contact Service.
78 81 81 81
86 98 101 153
14 3 3 3
81
164
Contact Service.
81
173
Contact Service.
81
411
Contact Service.
81 81
412 129
3 3
Contact Service. Contact Service.
81
130
Contact Service.
81
132
Contact Service.
81
133
Contact Service.
TIM-ID: 0000003162 - 001
81
131
Contact Service.
Flash PID code 81
SID 134
FMI 3
Description Exhaust duct temperature 6, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 7, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 8, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 9, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 10, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 11, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 12, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 13, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 14, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 15, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 16, sensor voltage too high (version 32.0 or later). EGR temperature, input voltage too high. EGR differential pressure, input voltage too high. EGR mass flow, intelligent sensor does not respond (version 33.0 or later).
81
135
Contact Service.
81
136
Contact Service.
81
137
Contact Service.
81
138
Contact Service.
81
139
Contact Service.
81
140
Contact Service.
81
141
Contact Service.
81
142
Contact Service.
81
143
Contact Service.
81
144
Contact Service.
81 81 81
TIM-ID: 0000003162 - 001
154 155 277
3 3 9
81
277
12
EGR mass flow, intelligent Contact Service. sensor failure (version 33.0 or later). Oil level sensor, input volt age too low. Crankcase pressure sen sor, input voltage too low. Contact Service. Contact Service.
82 82
98 101
4 4
SID
FMI 4
Description Crankcase pressure sen sor, input voltage (version 27.0 or later). Injection control pressure sensor, input voltage too low. Exhaust gas temperature sensor, input voltage too low.
82
164
Contact Service.
82
173
Contact Service.
82
411
EGR OPD, sensor circuit Contact Service. defective / low (version 33.0 or later). EGR temperature too low (version 33.0 or later). Exhaust duct temperature 1, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 2, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 3, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 4, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 5, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 6, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 7, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 8, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 9, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 10, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 11, sensor voltage too low (version 32.0 or later). Contact Service. Contact Service.
82 82
412 129
4 4
82
130
Contact Service.
82
131
Contact Service.
82
132
Contact Service.
82
133
Contact Service.
82
134
Contact Service.
82
135
Contact Service.
82
136
Contact Service.
82
137
Contact Service.
TIM-ID: 0000003162 - 001
82
138
Contact Service.
82
139
Contact Service.
Flash PID code 82
SID 140
FMI 4
Description Exhaust duct temperature 12, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 13, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 14, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 15, sensor voltage too low (version 32.0 or later). Exhaust duct temperature 16, sensor voltage too low (version 32.0 or later). EGR- temperature, input voltage too high. EGR differential pressure input voltage too low. EGR temperature, intelli gent sensor does not re spond (version 33.0 or lat er).
82
141
Contact Service.
82
142
Contact Service.
82
143
Contact Service.
82
144
Contact Service.
82 82 82
154 155 412
4 4 9
82
412
12
EGR temperature, intelli Contact Service. gent sensor failure (version 33.0 or later). Pump pressure too high. Oil level too high. Contact Service. 1. Check engine oil level ( Page 96). 2. Contact Service. Contact Service. Contact Service. Contact Service. Contact Service. Contact Service. Contact Service.
83 83
73 98
0 0
83 83 83 83
TIM-ID: 0000003162 - 001
101 153 173 411 412 129
0 0 0 0 0 0
Crankcase pressure too high. Crankcase pressure too high (version 27.0 or later). Exhaust gas temperature too high. EGR OPD, high (version 33.0 or later). EGR temperature too high (version 33.0 or later). Exhaust duct temperature 1, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 2, sensor voltage too high (version 32.0 or later).
83 83
83
130
Contact Service.
Flash PID code 83
SID 131
FMI 0
Description Exhaust duct temperature 3, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 4, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 5, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 6, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 7, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 8, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 9, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 10, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 11, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 12, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 13, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 14, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 15, sensor voltage too high (version 32.0 or later). Exhaust duct temperature 16, sensor voltage too high (version 32.0 or later). Oil level low.
83
132
Contact Service.
83
133
Contact Service.
83
134
Contact Service.
83
135
Contact Service.
83
136
Contact Service.
83
137
Contact Service.
83
138
Contact Service.
83
139
Contact Service.
83
140
Contact Service.
83
141
Contact Service.
83
142
Contact Service.
83
143
Contact Service.
84
98
1. Check engine oil level ( Page 96). 2. Contact Service. Contact Service.
84 84
101 153
1 1
Crankcase pressure too low.
Crankcase pressure too low Contact Service. (version 27.0 or later).
TIM-ID: 0000003162 - 001
83
144
Contact Service.
Flash PID code 85 85 86 86 87 87 88 88 89 89 190 190 73 108 73 108 20 109 95 111
SID
FMI 0 14 3 3 4 4 1 1 0 12
Description
Tasks
Engine idle speed too high. Contact Service. Engine overspeed signal (version 28.0 or later). Pump pressure sensor, in put voltage too high. Atmospheric pressure sen sor, input voltage too high. Pump pressure sensor, in put voltage too low. Atmospheric pressure sen sor, input voltage too low. High range: coolant pres sure too low. Coolant pressure too low. Fuel differential pressure too high. Contact Service. Contact Service. Contact Service. Contact Service. Contact Service. Contact Service. Contact Service. Contact Service.
Coolant level, maintenance 1. Check coolant level note, fault. ( Page 103). 2. Contact Service.
TIM-ID: 0000003162 - 001
7 Task Description
7.1 Engine
7.1.1 Engine Barring manually
Preconditions

Designation / Use Barring device Barring device Adapter Ratchet
DANGER
Part No. F6555766 F6783293 F6558528 F30006212
Qty. 1 1 1 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.
Barring engine manually (lateral installation)

1. 2. 3. 4. 5. Remove guard plate. Engage barring device (2) in ring gear (3) and install on flywheel housing. Use barring device F6555766. Set ratchet (1) onto barring device (2). Rotate crankshaft in engine direction of ro tation. Apart from the normal compression resistance, there should be no resistance. For barring device removal follow reverse sequence of working steps.
64 | Task Description | M015241/03E 2011-12
TIM-ID: 0000002521 - 004
Barring engine manually (installation on lower side)

1. 2. Remove grounding device or guard plate. Engage barring device (2) with ring gear (1) and mount on flywheel housing. For 12/16V engines, use barring device F6555766 with adapter F6558528. For 20V engines, use barring de vice F6783293. Set ratchet (3) onto barring device (2). Rotate crankshaft in engine direction of ro tation. Apart from the normal compression resistance, there should be no resistance. For barring device removal follow reverse sequence of working steps.
3. 4. 5.
TIM-ID: 0000002521 - 004
M015241/03E 2011-12 | Task Description | 65
7.1.2
DANGER

Unguarded rotating and moving engine components. Risk of serious injury Danger to life! Before barring the engine, ensure that nobody is in the danger zone.

1. Remove screws (1, 3) and take off perforat ed plate (2).
2.
3. Note: 4. Note: 5. 6.
Withdraw plug (5) from crankshaft angle sensor for injection timing of any cylinder ( Page 26). For this purpose, unlock latch (4). Bar engine in unloaded condition: Press START button. Interrupt engine start after maximum ten seconds for thirty seconds to prevent starter from overheating. Let the crankshaft rotate until oil pressure is indicated. If no oil pressure is indicated after three start cycles, contact Service. Slide on connector (5) until lock (4) latches into position. Fit perforated plate (2) and secure with two screws (1, 3).
TIM-ID: 0000002786 - 001
7.2 Cylinder Liner

7.2.1 Cylinder liner Endoscopic examination
Preconditions
Engine is stopped and starting disabled

Designation / Use Endoscope Part No. Y20097353 Qty.
Preparatory steps
1. 2. Remove cylinder head cover ( Page 80). Remove injector ( Page 83).
Positioning crankshaft at BDC

1. 2. Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached BDC. Insert endoscope into cylinder liner through injector seat.
Cylinder liner endoscopic examination

Findings Thin carbon coating on carbon scraper ring Slight localized additive deposits at top edge Localized smooth areas at bottom edge Carbon deposits on entire circumference between top piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless, even honing pattern First signs of marks left by lower cooling bores Running pattern seems darker Measure No action required
Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined and do not cover the entire stroke area Dark areas in the upper section of the cooling bore, remaining cir cumference cannot be faulted Piston rings cannot be faulted
TIM-ID: 0000003304 - 003
Further endoscopic examina tion required as part of main tenance work
On the entire circumference, apart from light areas of discoloration Cylinder liner must be re (do not impair operation) clearly darker stripes that start at the top placed; Service must be con piston ring tacted Heat discoloration in the direction of stroke and honing pattern dam age Heat discoloration of piston rings 1. 2. 3. Compile endoscopy report using the table. Use technical terms for description of the liner surface ( Page 69). Depending on findings: Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service; cylinder liner must be replaced. M015241/03E 2011-12 | Task Description | 67
Final steps
1. 2. Install injector ( Page 83). Install cylinder head cover ( Page 80).
TIM-ID: 0000003304 - 003
7.2.2
Instructions and comments on endoscopic and visual examination of cylinder liners

Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami nation report. Findings Light scoring Measure Minor dirt scores can occur during the assembly of a new engine (honing prod ucts, particles, broken-off burrs). Removed cylinders clearly exhibit such scor ing on the running surface under endoscope magnification. Cannot be felt with the fingernail. Findings not critical. Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area and cross through the honing pattern in the direction of stroke. Findings not critical. Scored area These areas consist of scores of different lengths and depths next to one an other. In most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/exhaust) along the transverse engine axis. Findings not critical. Smoothened area Smoothened areas are changes to the running surface but almost the whole honing pattern is still visible. Smoothened areas appear brighter and more bril liant than the surrounding running surface. Findings not critical. Polished area Polished areas are on the running surface and show local removal of the hon ing pattern. Grooves from the honing process are not visible any more. New cylinder liners must be fitted in the following cases Polished area: covers more than 20% of the entire piston running surface, covers more than 30 of the circumference and extends over more than 50% of piston stroke, is wider than 15 mm over the entire piston stroke. Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem perature differences around the liner. It appears rather darker within the honed structure in contrast to the bright metallic running surface. The honing pattern is undisturbed. Discolorations extend in stroke direction and may be interrupt ed. Findings not critical.
TIM-ID: 0000003285 - 003
Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves in the overlap (open) position. They are clearly visible due to the dark color of the honing groove bottom. This corrosion is not critical unless there is corrosion pitting. Black lines Black lines are a step towards heat discoloration. They are visible as a clear discoloration from TDC to BDC in the running surface and the start of localized damage to the honing pattern. Cylinders with a number of black lines around the running surface have limited service life and should be replaced. M015241/03E 2011-12 | Task Description | 69
Findings Discolorations (Heat)
Measure These are caused by a disturbance 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 onwards and less pro nounced from TDC-ring 1. The honing pattern is usually no longer visible and displays a clearly defined (straight) edge to the undisturbed surface. The dam aged surface is usually discolored. The circumferential length varies. Liners with heat discoloration starting in the TDC-ring 1 have to be replaced. Seizure marks are of irregular circumferential length and depth. Can be caused by either the piston skirt or the piston crown. Material deposits on the liner (smears) show heavy discoloration and scoring. Replace liner.
Seizures, Seizure marks
Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough in vestigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid un necessary disassembly work, it is recommended that another inspection be carried out after further oper ation of the engine.
TIM-ID: 0000003285 - 003
7.3 Crankcase Breather

7.3.1 Crankcase breather Oil separator check
Preconditions
Engine is running.
Checking oil separator

Note: 1. 2. A thin oil film is admissible. Check oil separator for damage and exces sive oil discharge (arrow). Replace oil separator if it is defective ( Page 72).
TIM-ID: 0000003511 - 005
7.3.2
Crankcase breather Filter element replacement

Preconditions

Designation / Use Torque wrench 10-60 Nm Filter element
WARNING
Part No. F30510423 ( Spare Parts Catalog)
Qty. 1
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.
Crankcase breather (closed-circuit crankcase ventilation) Filter element replacement

1. 2. 3. 4. 5. 6. 7. 8. Loosen clamps (1), push rubber sleeves (2) over tubes (3). Operate lever (6) to relieve clamping band (4). Remove cover (7). Replace filter element (5). Fit cover (7). Operate lever (6) to tension clamping band (4). Push back rubber sleeve (2) and tighten clamp (1). Replace further filter elements in the same way.
TIM-ID: 0000003532 - 001
Crankcase breather (open-circuit crankcase ventilation) Filter element cleaning or replacement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Clean filter (6) outside. Undo clamp (2) and screw (7). Pull hose (1) off cover (3). Loosen clamp (5). Remove cover (3). Clean filter element (4) ( Page 74) or re place. Fit cover (3). Use torque wrench to tighten clamp (5) to specified torque 12 Nm to 14 Nm. Push hose (1) onto cover (3). Tighten clamp (2) and screw (7). Replace further filter elements (2) in the same way.
TIM-ID: 0000003532 - 001
7.3.3
Crankcase breather (open-circuit crankcase ventilation) Filter element cleaning

Preconditions
WARNING
Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors. Excessive reaction time of cleaning agents on components. Damage to component! Observe manufacturer's instructions. Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Filter element Removal / installation .

u ( Page 72)
Crankcase breather (open-circuit crankcase ventilation) Filter element cleaning

1. 2. 3. Clean filter element with cleaning agent. Remove cleaning agent. Blow out filter element thoroughly with compressed air.
TIM-ID: 0000003508 - 002
7.4 Valve Drive

7.4.1 Valve gear Lubrication
Preconditions

Designation / Use Engine oil Part No. Qty.
Valve gear Lubrication

1. 2. 3. Remove cylinder head covers ( Page 80). Fill oil chambers of rocker arms and adjust ing screws with oil. Install cylinder head covers ( Page 80).
TIM-ID: 0000004337 - 004
7.4.2
Valve clearance Check and adjustment

Preconditions
Engine is stopped and starting disabled. Engine coolant temperature is max. 40 C. Valves are closed.

Designation / Use Feeler gage Torque wrench 60-320 Nm Socket box wrench Engine oil Part No. Y20010128 F30047446 F30039526 Qty. 1 1 1
Preparatory steps
1. 2. 3. Remove cylinder head cover ( Page 80). Install barring gear ( Page 64). Turn crankshaft in direction of engine rota tion with barring gear until OT-A1 mark and pointer are aligned.
TIM-ID: 0000004357 - 005
Diagram for 8V Two crankshaft positions

1. 2. 3. 4. Crank drive position 1: cylinder A1 in firing TDC Crank drive position 2: cylinder A1 in over lap TDC Inlet valve (I) Exhaust valve (X)


1. 2.
TIM-ID: 0000004357 - 005
3. 4.
Crank drive position 1: cylinder A1 in firing TDC Crank drive position 2: cylinder A1 in over lap TDC Inlet valve (I) Exhaust valve (X)

Checking valve clearance in two crankshaft positions

1. 2. 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. If the rocker arms are under load on cylinder A1, the piston is in overlap TDC. Check valve clearance with cold engine: Inlet valves (long rocker arm) = 0.2 mm Exhaust valves (short rocker arm) = 0.5 mm Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per diagram. Use feeler gage to determine the distance between valve bridge and rocker arm. If the deviation from the specified value exceeds 0.1 mm, adjust valve clearance.
Adjusting valve clearance

1. 2. 3. 4. Release locknut (1). Insert feeler gage between valve bridge and rocker arm. Turn adjusting screw (2) with Allen key until appropriate valve clearance is set. Feeler gage must just pass through the gap.
5.
Tighten locknut (1) to specified torque using a torque wrench holding adjusting screw (2) firmly in so do ing. Name Nut Size Type Lubricant (Engine oil) Value/Standard 90 Nm +9 Nm M16 x 1.5 Tightening torque
6. 7.
Replace or rectify adjusting screws and/or locknuts which do not move freely. Check valve clearance.
TIM-ID: 0000004357 - 005
Final steps
1. 2. Remove barring gear ( Page 64). Install cylinder head cover ( Page 80).
TIM-ID: 0000004357 - 005
7.4.3
Cylinder head cover Removal and installation

Preconditions
Engine shut down and starting disabled.

Designation / Use Gasket Part No. ( Spare Parts Catalog) Qty.
Removing cylinder head cover

1. 2. 3. Clean cylinder head covers prior to removal if they are heavily soiled. Remove screws. Remove cylinder head cover with gasket from cylinder head.
Installing cylinder head cover

1. 2. 3. 4. Clean mating face. Check condition of gasket, replace if necessary. Place gasket and cylinder head cover on cylinder head. Install cylinder head cover.
TIM-ID: 0000000923 - 005
7.5 Injection Pump / HP Pump

7.5.1
DANGER
HP pump Relief bore check

WARNING
Checking HP pump relief bore

1. 2. 3. Check relief bore for oil and fuel discharge by visual inspection. If relief bore is contaminated, stop the en gine, disable engine start, and clean relief bore. Note the following in case of fluid dis charge: Heavy discharge means continuous dis charge of fluids (leakage). Contact Serv ice. Minor discharge of fluids up to 10 drops per day is normal (moistening) and not considered a leakage.
TIM-ID: 0000000924 - 004
7.6 Injection Valve / Injector

7.6.1 Injector Replacement
Designation / Use Injector Part No. ( Spare Parts Catalog) Qty.
Replacing injector
u Remove injector and install new injector ( Page 83).
TIM-ID: 0000000022 - 011
7.6.2
Injector Removal and installation

Preconditions

Designation / Use Installation and removal tool for injector Milling cutter Slotted nut screwdriver Torque wrench, 0.5-5 Nm Torque wrench, 10-60 Nm Torque wrench, 60-320 Nm Assembly paste (Optimoly Paste White T) Grease (Kluthe Hakuform 30-10/emulsifier) Engine oil
WARNING
Part No. F6790161 F30452739 F30452578 0015384230 F30510423 F30047446 40477 X00058060
Qty. 1 1 1 1 1 1 1 1
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Removal of all injectors. Damage to component! Ensure that the high-pressure fuel accumulator is secured on the engine through two HP lines.
CAUTION
CAUTION
Cable damage during operation. Fire hazard! Twist cables when installing. Ensure that cables do not touch components.
Preparatory steps
1. 2. Shut off fuel inlet to engine. Remove cylinder head cover ( Page 80).
TIM-ID: 0000000952 - 004
Removing injector
Note: Always replace the first and last injectors of one engine side first. Replace the inner in jectors only after the installation of the outer injectors on this engine side is completed. Undo cable terminal screws (arrow) on in jector and remove cable terminals.
1.
2. 3.
Remove screw (2) and take off hold-down clamp (1). Remove high-pressure fuel line (5).
4. 5. 6.
Install installation/removal device on cylin der head. Remove injector with installation/removal device. Remove installation/removal device.
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7. 8. 9.
Remove sealing ring (1) from injector or use a self-made wire hook to extract it from the cylinder head. Remove O-rings (2) from injector. Cover all connections and bores, or seal with suitable plugs.
Installing injector
1. 2. 3. 4. Remove all plugs before installing. Coat nozzle retaining nut area of injector with assembly paste. Fit new O-rings on injector and coat with grease. Fit new sealing ring on injector with grease ensuring correct installation position of seal ing ring.
5. 6. 7. 8.
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Clean sealing surface on cylinder head and protective sleeve with milling cutter. Insert injector into cylinder head ensuring that the HP line connection is aligned cor rectly. Press in injector with installation/removal device. Remove installation/removal device.
9.
Use slotted screwdriver to check thrust ring at both line ends for secure seating.
10.
Tighten loose thrust ring to the specified tightening torque. Name Thrust ring Size Type Tightening torque Lubricant Value/Standard 5 Nm to 10 Nm
11.
Coat screw head mating face (2) and thread with engine oil.
12.
Place hold-down clamp (1) in correct installation position. Tighten screw (2) with torque wrench to the specified initial tightening torque. Name Screw Size M12 Type Preload torque Lubricant (Engine oil) Value/Standard
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5 Nm to 10 Nm
13. 14.
Fit O-rings (4) and (6) on high-pressure fuel line (5) and coat with grease. Tighten high-pressure fuel line (5) to the specified initial tightening torque. Name HP line Size Type Preload torque Lubricant (Engine oil) Value/Standard 5 Nm to 10 Nm
15.
Tighten screw (2) to specified torque using a torque wrench. Name Screw Size M12 Type Tightening torque Lubricant Value/Standard 100 Nm + 10 Nm
16.
Tighten union nut of connecting piece (limiting valve) to specified torque using a torque wrench. Name Union nut Size Type Tightening torque Lubricant Value/Standard 140 Nm + 10 Nm
17.
Tighten union nut of connecting piece (injector) to specified torque using a torque wrench. Name Union nut Size Type Tightening torque Lubricant Value/Standard 120 Nm +10 Nm
18.
Twist cable several times.
19.
Insert cable terminals (arrows) underneath screws on injector and tighten screws to specified torque us ing a torque wrench. Name Screw Size Type Tightening torque Lubricant Value/Standard 1.5 Nm
Final steps
1. 2. Install cylinder head cover ( Page 80). Open up fuel inlet to engine.
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7.7 Fuel System

7.7.1 Fuel system Venting
Preconditions

Designation / Use Filling device Diesel fuel
WARNING
Part No. B80144852
Qty. 1
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. Connect filling device to connection (3). Disconnect return line at connection (4). Use hand pump to fill fuel system, providing pressure of min. 0.5 bar / max. 2.0 bar, until fuel emerges without bubbles at connection (4). Connect return line to connection (4). Open vent plug (1) on filter housing (2). Use hand pump to fill fuel system, providing pressure of min. 0.5 bar / max. 2.0 bar, until fuel emerges without bubbles at connection (1). Close vent plug (1). Remove filling device and seal connection (3).
4. 5. 6.
7. 8.
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7.8 Fuel Filter

7.8.1 Fuel filter Replacement
Preconditions

Designation / Use Filter wrench Engine oil Easy-change filter
WARNING
Qty. 1
Replacing fuel filter

1. 2. 3. 4. 5. 6. Remove easy-change filter using filter wrench. Clean sealing surface on filter head. Slightly lubricate seal on the easy-change filter. Screw on easy-change filter by hand until the seal connects and tighten manually. Vent fuel system ( Page 88). Replace other easy-change filters in the same way.
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7.8.2
Fuel prefilter Draining

Preconditions

Designation / Use Diesel fuel
WARNING
Part No.
Qty.
Draining fuel prefilter

1. 2. 3. 4. 5. 6. 7. 8. Shut down the filter unit (5/8) to be changed at valves (3) and (4) or (9) and (10). Open threaded vent plug (1) or (2) on filter to be drained. Open drain valve (6) or (7). Drain water and contaminants from the filter until pure fuel emerges. Close drain valve (6) or (7). Open fuel return line (3) or (10). Open fuel inlet (4) or (9). Close threaded vent plug (1) or (2) on filter to be drained when clean fuel emerges.
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7.8.3
Edge-type fuel filter Draining

Preconditions

Designation / Use Diesel fuel Sealing ring
WARNING
Part No. ( Spare Parts Catalog)
Qty.
Edge-type fuel filter Draining

1. 2. 3. 4. 5. 6. 7. Rotate edge-type filter (2) with handle (1) clockwise several times. Do not apply force when rotating handle. Close fuel supply. Remove drain plug (3) from edge-type filter (2). Drain water and contaminants through drain plug opening (3) until pure fuel emerges from filter. Fit drain plug (3) with new sealing ring and screw in. Open fuel supply.
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7.9 Charge-Air Cooling

7.9.1
DANGER
Intercooler Check drain for coolant leakage and obstruction

WARNING
WARNING
Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors.
Intercooler Check drain for coolant leakage and obstruction

1. Verify that air emerges from condensate drain bore(s) on left and right engine sides at driving end when engine is running. If no air emerges: Clean drain bore(s) Blow out with compressed air If a large amount of coolant is continuously discharged, the intercooler is leaking. Con tact Service.
2.
Emergency measures prior to engine start with a leaking intercooler

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1. 2. 3. 4.
Remove injectors ( Page 83). Bar engine manually ( Page 64). Crank engine on starting system to blow out combustion chambers ( Page 66). Install injectors ( Page 83).
7.10 Air Intake

7.10.1 Service indicator Check
See manufacturer's documentation.
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7.11 Starting Equipment

7.11.1 Starter Condition check
Preconditions
Checking starter condition

1. 2. Check securing screws of starter for secure seating and tighten if required. Check wiring ( Page 127).
TIM-ID: 0000000905 - 011
7.11.2
Cold start system with ether injection Check

Preconditions

Designation / Use Ether cartridge
DANGER
Qty.
Cleaner is an explosive and poisonous substance. Danger to life, major material damage! Avoid open flames, electrical sparks and ignition sources. Wear goggles/facial protection. Only work in a well-ventilated room. Do not smoke.
Checking filling level and condition of system

Note: After two successive starting trials with cold start system, make next starting trial after 10 minutes only. If the next two staring trials fail, contact Service. If the indicator lamp on the relay module (5) lights up, fit a new ether cartridge (1). Check the condition of lines (2) and con nections. If damage is found, contact Serv ice. Check the condition of electric lines (4) and connections. If damage is found, contact Service. In case of system failure, check the fuses in the fuse holder (3). If fuses are broken, con tact Service.
1. 2. 3. 4.
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7.12 Lube Oil System, Lube Oil Circuit

7.12.1 Engine oil level Check
Preconditions
Checking oil level prior to engine start

1. 2. 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. The oil level must reach mark (1) or exceed mark (1) by up to 2 cm. Top up with oil to mark (1) as necessary ( Page 97). Insert oil dipstick into guide tube up to the stop.
Note:
3. 4. 5.
Checking oil level after the engine is stopped

1. 2. 3. 4. 5. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it. Insert oil dipstick into guide tube up to stop, withdraw after approx. 10 seconds and check oil level. Oil level must be between marks (1) and (2). Top up with oil to mark (1) as necessary ( Page 97). Insert oil dipstick into guide tube up to the stop.
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7.12.2
Engine oil Change

Preconditions
Engine is stopped and starting disabled. Engine is at operating temperature. MTU Fluids and Lubricants Specifications (A001061/..) are available.

Designation / Use Torque wrench, 40-200 Nm Ratchet adapter Engine oil Sealing ring
WARNING
Part No. F30027337 F30027341 ( Spare Parts Catalog)
Qty. 1 1
Procedure without pump: Draining oil via drain plug(s) on oil pan
1. 2. 3. Provide a suitable container to collect the oil. Remove drain plug(s) and drain oil. Install drain plug(s) with new sealing ring.
Procedure with pump: Oil extraction

1. 2. Provide a suitable container to collect the oil. Extract all oil from oil pan using the pump.
Draining residual oil at equipment carrier

1. 2. 3. Provide a suitable container to collect the oil. Remove drain plug (1) and drain oil (ap prox. 7 liters) from oil heat exchanger and oil filter. Remove drain plugs (2) and (3) and drain oil: at drain plug (2) approx. 12 liters at drain plug (3) approx. 5 liters Install drain plug(s) with new sealing ring.
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4.
5.
Tighten drain plugs (2) and (3) with torque wrench to the specified torque. Name Screw Size Type Lubricant (Engine oil) Value/Standard 100 Nm +10 Nm M26 x 1.5 Tightening torque
Filling with new oil

1. 2. 3. 4. 5. Open cover on filler neck. Fill oil through filler neck up to "max." mark at oil dipstick. Close cover on filler neck. Check engine oil level ( Page 96). After oil change, bar engine with starting system ( Page 66).
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7.12.3
Engine oil Sample extraction and analysis

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

Designation / Use MTU test kit
DANGER
Part No. 5605892099/00
Qty. 1
WARNING
Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! Wear protective clothing, gloves, and goggles / safety mask. Avoid contact with skin. Do not inhale oil vapor. Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
WARNING
Engine oil sample extraction and analysis

1. 2. 3. 4. 5. With the engine running at operating tem perature, open screw on flange of centrifu gal oil filter by 1 to 2 rotations. Drain approx. 2 liters engine oil to flush out the oil sludge. Drain approx. 1 liter engine oil into a clean container. Close screw. Using the equipment and chemicals of the MTU test kit, examine oil for: Dispersing capacity (spot test); Water content; Fuel dilution.
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7.13 Oil Filtration / Cooling

7.13.1 Engine oil filter Replacement
Preconditions

Designation / Use Filter wrench Engine oil Oil filter
WARNING
Qty. 1
Engine oil filter Replacement

1. 2. Note: 3. 4. 5. 6. 7. Remove oil filter using the filter wrench. Clean the sealing surface of the filter head. Use only oil filters with integrated safety valve. Check condition of the new sealing ring and coat it with oil. Screw on and tighten new oil filter by hand. Replace further oil filters in the same way. After each oil change and filter replace ment, bar engine with starting system ( Page 66). Check oil level ( Page 96).
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7.13.2
Centrifugal oil filter Cleaning and filter sleeve replacement

Preconditions

Designation / Use Filter wrench Torque wrench, 6-50 Nm Ratchet adapter Cold cleaner (Hakutex 60) Grease (Kluthe Hakuform 30-10/emulsifier) Filter sleeve Sealing ring Sealing ring
WARNING
Part No. F30379104 F30027336 F30027339 50602 X00029933 ( Spare Parts Catalog) ( Spare Parts Catalog) ( Spare Parts Catalog)
Qty. 1 1 1 1 1
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. Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors.
WARNING
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Cleaning centrifugal oil filter and replacing filter sleeve

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Undo screw (1) and remove. Remove clamp (3) and take off hood (2). Carefully remove rotor (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7). Take off rotor cap (8). Remove filter sleeve (9), stiffener plate (10) and sealing ring (11). Measure thickness of oil residues on filter sleeve. If maximum layer thickness of oil residues exceeds 30 mm, shorten maintenance in terval. Remove standpipe (12) from lower rotor section (13). Wash hood (2), rotor cap (8), stiffener plate, (10) standpipe (12), rotor lower sec tion (13) and nozzles (14) with cold cleaner and blow out with compressed air. Do not use sharp objects for cleaning. Check nozzles (14) for obstructions. Press standpipe (12) onto rotor lower sec tion (13). Insert new filter sleeve (9) with stiffener plate (10) into rotor cap (8), ensuring that smooth surface of filter sleeve (9) faces ro tor cap (8). Check sealing ring (11), replace if necessa ry. Coat sealing ring with grease and insert in groove of rotor cap (8). Place rotor cap (8) onto standpipe (12). Hold rotor assembly (5) firmly in position with filter wrench and tighten knurled nut (7). Lubricate bearings of rotor (5) with oil, in sert into housing (6) and check for ease of movement. Check sealing ring (4), replace if necessary. Fit sealing ring on housing (6). Fit hood (2). Tighten screw (1) by hand. Install clamp (3) and tighten to specified torque using a torque wrench. Clamp 22. Tightening torque 6 Nm + 1 Nm
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11. 12. 13.
14. 15. 16. 17. 18. 19. 20. 21.
Name
Size
Type
Lubricant
Value/Standard
Tighten screw (1) to specified torque using a torque wrench. Name Screw Size Type Tightening torque Lubricant Value/Standard 6 Nm + 1 Nm
7.14 Coolant Circuit, General, High-Temperature Circuit

7.14.1 Coolant level - Check
Preconditions
Engine shut down and starting disabled. MTU Fluids and Lubricants Specifications (A001061/..) are available.
WARNING
Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask.
Checking coolant level at filler neck:

1. 2. 3. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counterclockwise and remove. Check coolant level (coolant must be visible at the lower edge of the cast-in eye).
Checking coolant level at remote cooler:

1. 2. 3. 4. Check coolant level (coolant must be visible at marking plate). Top up coolant if necessary ( Page 106). Check and clean breather valve. Place breather valve on filler neck and close.
Coolant level check by means of level sensor:

TIM-ID: 0000000937 - 010
1. 2.
Switch on engine control system and check readings on the display. Top up coolant if necessary ( Page 106).
7.14.2
Engine coolant Change

Designation / Use Engine coolant Part No. Qty.
Changing engine coolant

1. 2. Drain engine coolant ( Page 105). Fill with engine coolant ( Page 106).
TIM-ID: 0000000036 - 024
7.14.3
Engine coolant Draining

Preconditions
WARNING
Preparatory steps
1. 2. Provide an appropriate container to drain the coolant into. Switch off preheating unit.
Engine coolant Draining

1. 2. 3. 4. Turn breather valve on coolant expansion tank counterclockwise up to the first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove. Draw off separated corrosion inhibitor oil in expansion tank through the filler neck. Open drain valves and/or drain plugs and drain coolant at the following points: At the preheating unit; At the HT coolant pump elbow; At the crankcase, left and right side.
5.
6. 7.
Additional drain points on 12/16V 4000 M engines: T-piece (3) on engine driving end; Intercooler (2), left and right side; Carrier-housing cover (1), left and right side. Close all open drain points. Place breather valve on filler neck and close.
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7.14.4
Engine coolant Filling

Preconditions

Designation / Use Engine coolant
WARNING
Part No.
Qty.
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. Formation of cracks in components! Fill / top up coolant only into cold engine.
CAUTION
Preparatory steps
1. 2. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove.
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Filling coolant with pump

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Connect appropriate pump with hose to drain valve. Open drain valve and pump coolant into en gine at 0.5 bar minimum. Fill expansion tank until overflow edge is reached. Close drain valve. Check proper condition of breather valve, clean sealing faces if required. Set breather valve onto filler neck and close it. Start engine ( Page 35). After the engine has run at unloaded condi tion for 10 seconds, stop engine ( Page 37). Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove. Check coolant level ( Page 103) and top up if required: a) Fill in coolant in expansion tank until the coolant level at top edge of filler neck remains constant. b) Set breather valve onto filler neck and close it. c) Repeat the steps from "Start engine" ( Step 7) until coolant is no longer needed to be topped up. d) Disconnect pump and hose.
Filling coolant through filler neck

1. 2. 3. 4. 5. 6. 7. Alternatively: Fill in coolant in expansion tank until the coolant level at top edge of filler neck remains constant. Check proper condition of breather valve, clean sealing faces if required. Set breather valve onto filler neck and close until first stop is reached. Start engine ( Page 35). After the engine has run at unloaded condition for 10 seconds, stop engine ( Page 37). Turn breather valve counterclockwise and remove. Check coolant level ( Page 103) and top up if required: a) Repeat the steps from "Start engine" ( Step 4) until coolant is no longer needed to be topped up. b) Check proper condition of breather valve, clean sealing faces if required. c) Set breather valve onto filler neck and close it.
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Final steps
1. 2. Start the engine and operate it at unloaded condition for some minutes. Check coolant level ( Page 103) and top up if required.
7.14.5
DANGER
Engine coolant pump Relief bore check

WARNING
Checking relief bore on engine coolant pump

1. 2. 3. Checking relief bore for oil and coolant dis charge. Stop engine ( Page 37) and disable en gine start, observe general safety instruc tions for maintenance and repair. Clean the relief bore with a wire if it is dirty. Permissible coolant discharge: up to 10 drops per hour. Permissible oil discharge: up to 5 drops per hour. If discharge exceeds the specified limits: Contact Service.
4.
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7.14.6
Coolant Sample extraction and analysis

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

Designation / Use MTU test kit
DANGER
Part No. 5605892099/00
Qty. 1
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. Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
WARNING
Coolant sample extraction and analysis

1. 2. 3. 4. 5. With the engine running, open drain valve (1). Flush sample-extraction point by draining approx. 1 liter coolant. Drain approx. 1 liter coolant into a clean container. Close drain valve (1). Using the equipment and chemicals of the MTU test kit, check the coolant for: Antifreeze concentration Corrosion inhibitor concentration pH value. For coolant change intervals, see ( MTU Fluids and Lubricants Specifications.)
6.
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7.15 Low-Temperature Circuit

7.15.1 Charge-air coolant Level check
Preconditions
WARNING
Checking charge-air coolant level at filler neck:

1. 2. 3. 4. 5. 6. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove. Check coolant level (coolant must be visible at marking plate). Top up coolant if necessary ( Page 113). Check proper condition of breather valve, clean sealing faces if required. Fit breather valve and close it.
Checking charge-air coolant level by means of level sensor:

1. 2. Switch on engine control system and check display (coolant level is automatically monitored by engine control system). Top up coolant if necessary ( Page 113).
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7.15.2
Charge-air coolant Change

Designation / Use Charge-air coolant Part No. Qty.
Charge-air coolant Change

1. 2. Drain charge-air coolant ( Page 112). Fill with charge-air coolant ( Page 113).
TIM-ID: 0000000041 - 009
7.15.3
Charge-air coolant Draining

Preconditions

Designation / Use Sealing ring
WARNING
Qty.
Charge-air coolant Draining

1. 2. 3. 4. 5. Provide an appropriate container to drain the coolant into. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove. Draw off separated corrosion inhibitor oil in expansion tank through the filler neck. Open drain valves and/or drain plugs and drain coolant at the following points: At the LT coolant pump; At the coolant lines to and from the inter cooler.
6. 7. 8.
Draining of residual coolant: At the intercooler Close all drain valves and screw in drain plugs with new sealing rings. Set breather valve onto filler neck and close it.
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7.15.4
Charge-air coolant Filling

Preconditions

Designation / Use Coolant Sealing ring
WARNING
Qty.
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. Formation of cracks in components! Fill / top up coolant only into cold engine.
CAUTION
Preparatory steps
1. 2. Turn breather valve of coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Turn breather valve counterclockwise and remove.
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Filling with coolant using a pump

1. Connect a suitable pump with a hose to the drain valve (arrowed).
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
14. 15.
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Open vent on intercooler (arrow). Open drain valve and pump coolant into en gine at 0.5 bar minimum. Close venting point when coolant emerges. Fill expansion tank up to overflow. Close drain valve. Check proper condition of breather valve and clean sealing faces if required. Place breather valve on filler neck and close. Start engine ( Page 35). After 10 seconds of running the engine without load, shut down the engine ( Page 37). Turn breather valve of coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Turn breather valve counterclockwise and remove. Check coolant level ( Page 110) and top up coolant as required: a) Top up with coolant via expansion tank until the coolant level is constant at the overflow. b) Place breather valve on filler neck and close. Repeat the steps from "Start engine" ( Step 8) until coolant is no longer needed to be topped up. Disconnect pump and hose.
Alternatively: Filling coolant through filler neck

1. Remove plug screws from filling points (ar rows) on coolant lines from and to the inter cooler.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
12.
Open air bleed on the intercooler (arrow). Fill coolant via the filling points on the cool ant lines to and from the intercooler and via the expansion tank up to the overflow. Close venting point when coolant emerges. Install plug screws of filling points with new sealing rings. Check proper condition of breather valve and clean sealing faces if required. Set breather valve onto filler neck and turn to the first stop. Start engine ( Page 35). After 10 seconds of running the engine without load, shut down the engine ( Page 37). Turn breather valve counterclockwise and remove. Check coolant level ( Page 110) and top up coolant as required: a) Top up with coolant via expansion tank until the coolant level is constant at the overflow. b) Place breather valve on filler neck and close. Repeat the steps from "Start engine" ( Step 7) until coolant is no longer needed to be topped up.
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Final steps
1. 2. Start the engine and run it without load for some minutes. Check coolant level ( Page 110) and top up coolant as required.
7.15.5
DANGER
Charge-air coolant pump Relief bore check

WARNING
Charge-air coolant pump Relief bore check

1. 2. 3. Check relief bore for oil and coolant dis charge. Stop engine ( Page 37) and disable en gine start, observe general safety instruc tions for maintenance and repair. Clean the relief bore with a wire if it is dirty. Permissible coolant discharge: up to 10 drops per hour. Permissible oil discharge: up to 5 drops per hour. If discharge exceeds the specified limits: Contact Service.
4.
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7.16 Belt Drive

7.16.1 Drive belt Condition check
Preconditions
Engine is stopped and starting disabled. Guard is removed.
Drive belt Condition check
Item Drive belt A Drive belt Drive belt B Drive belt C
Findings Singular cracks Belt is oily, shows signs of over heating Cracks on entire circumference Chunking
Action None Replace( Page 122)
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7.17 Battery-Charging Generator

7.17.1 Battery-charging generator Condition check
Preconditions
Battery-charging generator Condition check

1. 2. 3. Check if securing screws of battery-charging generator fit firmly. Tighten any loose threaded connections. Check wiring ( Page 127).
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7.17.2
Battery-charging generator Check

Preconditions
WARNING
Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors.
Checking battery-charging generator

Item Ventilation area (arrow) Ventilation area (arrow) Findings Clean Contaminated Measure None Clean
Cleaning battery-charging generator

Note: 1. 2. Dry-clean battery-charging generator only. Remove coarse dirt from battery-charging generator. Blow out ventilation area (arrow) with compressed air until all dust is cleared.
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7.17.3
Battery-charging generator Removal and installation

Preconditions

Designation / Use Torque wrench, 20-100 Nm Ratchet adapter
WARNING
Part No. F30026582 F30027340
Qty. 1 1
Heavy object. Risk of crushing! Use appropriate lifting devices and appliances.
Removing battery-charging generator

1. 2. 3. 4. 5. 6. Undo screws (1), (2) and (3). Remove protective cover (8). Mark electric cables on battery-charging generator and remove. Protect all cables from damage. Slacken screws (4) and (5) by half a turn. Place socket adapter or box wrench on screw (6) and press belt tensioner in the di rection indicated by the arrow as far as it will go. Tighten screw (4). Remove drive belt (7).
7. 8.
9. 10. 11. 12.
Release screws (arrow). Remove battery-charging generator (1). Clean battery-charging generator (1) thor oughly ( Page 119). Install battery-charging generator (1) follow ing reverse sequence of working steps.
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Tensioning drive belt

1. 2. Result: 3. Fit drive belt (7). Slacken screw (4) by half a turn. Belt tensioner moves against the drive belt and tensions it. Use torque wrench to tighten screw (4) to specified tightening torque. Name Screw 4. Size M10x1.5 Type Tightening torque Lubricant Value/Standard 60 Nm +5 Nm
Use torque wrench to tighten screw (5) to specified tightening torque. Name Screw Size M10x1.5 Type Tightening torque Lubricant Value/Standard 42 Nm
5. 6.
Install protective cover (8). Readjust belt tension after 30 minutes and again after 8 hours engine runtime ( Page 123).
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7.17.4
Battery-charging generator drive Drive belt and belt tensioner replacement

Preconditions

WARNING
Part No. F30026582 F30027340
Qty. 1 1
Heavy object. Risk of crushing! Use appropriate lifting devices and appliances.
Replacing drive belt and belt tensioner

1. 2. 3. 4. Undo screws (1), (2) and (3). Remove protective cover (8). Slacken screws (4) and (5) by half a turn. Place socket adapter or box wrench on screw (6) and press belt tensioner in the di rection indicated by the arrow as far as it will go. Tighten screw (4). Remove drive belt (7). Screw on screw (5) and replace belt ten sioner. Fit new drive belt (7).
5. 6. 7. 8.
Tensioning drive belt

1. Result: 2. Slacken screw (4) by half a turn. Belt tensioner moves against the drive belt and tensions it. Use torque wrench to tighten screw (4) to specified tightening torque. Name Screw 3. Size M10x1.5 Type Tightening torque Lubricant Value/Standard
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60 Nm +5 Nm
Use torque wrench to tighten screw (5) to specified tightening torque. Name Screw Size M10x1.5 Type Tightening torque Lubricant Value/Standard 42 Nm
4. 5.
Install protective cover (8). Readjust belt tension after 30 minutes and again after 8 hours engine runtime ( Page 123).
7.17.5
Battery-charging generator drive Drive belt tension adjustment

Preconditions

WARNING
Part No. F30026582 F30027340
Qty. 1 1
Spring/circlip/tensioning roller preload. Risk of injury! Only use specified tool and equipment.
Adjusting belt tension

1. 2. Result: Undo screw (arrow) and remove protective cover (3). Slacken screws (1) and (2) by half a turn. Belt tensioner moves against the drive belt and tensions it.
3.
Tighten screw (2) to specified torque using a torque wrench. Name Screw Size M10x1.5 Type Tightening torque Lubricant Value/Standard 60 Nm +5 Nm
4.
Tighten screw (1) to specified torque using a torque wrench. Name Size M10x1.5 Type Tightening torque Lubricant Value/Standard 42 Nm Screw
TIM-ID: 0000007386 - 002
5.
Install protective cover (3).
7.18 Fan Drive

7.18.1 Fan drive belt Tension check / adjustment
Preconditions

Designation / Use Optibell 2 belt tension tester Part No. Y4345711 Qty. 1
Preparatory steps
1. 2. Result: Remove guard cover. Check belt condition visually ( Page 117). If required, replace drive belt ( Page 126).
Checking Vee belt tension

1. 2. 3. Switch on belt tension tester. Hold measuring tip of belt tension tester over belt drive. Tap drive belt (arrowed) with a suitable tool. Hold belt tension tester over belt drive until the measured value is indicated. Initial assembly at MTU 36 Hz 5 Hz Initial operation with fan 49 Hz 5 Hz Belt tension adjustment 44 Hz 5 Hz
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Adjusting drive belt tension

1. 2. 3. Release screws (2) until fan coupling can be moved. Tighten stud (1) until the required frequency is achieved. Tighten screws (2) to 250 Nm 25 Nm.
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7.18.2
Fan drive Drive belt replacement

Preconditions

Designation / Use Drive belt Part No. ( Spare Parts Catalog) Qty.
Preparatory steps
1. 2. Remove protective cover. Remove fan.
Replacing drive belt

1. 2. 3. 4. 5. Release screws (2). Slacken off stud (1) until drive belt can be removed. Clean belt pulleys. Fit new drive belt on belt pulleys, ensuring that it is not under tension. Adjust belt tension ( Page 124).
TIM-ID: 0000007457 - 003
7.19 Wiring (General) for Engine/Gearbox/Unit

7.19.1 Engine wiring Check
Preconditions

Designation / Use Isopropyl alcohol Part No. X00058037 Qty. 1
Engine wiring Check

1. 2. 3. 4. 5. Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely. Check that cable ties are firm, tighten loose cable ties. Replace faulty cable ties. Visually inspect the following electrical line components for damage: connector housings; contacts; sockets; cables and terminals; plug-in contacts. ( Contact Service) if cable conductors are damaged. 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. Note: 7. 8.
TIM-ID: 0000000029 - 016
7.20 Accessories for (Electronic) Engine Governor / Control System

7.20.1 DDEC and connectors Cleaning
Preconditions

Designation / Use Isopropyl alcohol
DANGER
Part No.
Qty.
Cleaner is an explosive and poisonous substance. Danger to life, major material damage! Avoid open flames, electrical sparks and ignition sources. Wear goggles/facial protection. Only work in a well-ventilated room. Do not smoke.
DDEC and connectors Cleaning

1. 2. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alco hol. Remove dirt from surface of connectors (1), connector sockets and shrink sleeves (2) using a cloth moistened with isopropyl alco hol. Check legibility of cable labels. Clean or replace illegible labels.
3.
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Cleaning severely contaminated connectors on DDEC

1. 2. 3. 4. 5. Disconnect connectors on both sides of DDEC. For this purpose, withdraw connec tors (1). Unscrew connectors (3). Remove covers (2). Clean connector housings, connector sock et housings and all contacts with isopropyl alcohol. When connectors, sockets and all contacts are dry: Install connectors and check plugin connection on DDEC ( Page 130).
TIM-ID: 0000008476 - 001
7.20.2
DDEC Checking plug-in connections

Preconditions
Checking plug-in connections on DDEC

1. 2. 3. 4. 5. Check all plug-in connections on both sides of DDEC for secure seating. Slide connectors (1) on until they latch into position. Screw in connectors (3) securely. Seal non-assigned connector bases with covering caps (2). If plug-in connection is defective, contact Service.
TIM-ID: 0000008478 - 001
8 Appendix A
8.1 Abbreviations
Abbreviation A/D ADEC AFRS ANSI ATL ATS BR BV CAN CDC CEL Meaning Analog/Digital Advanced Diesel Engine Controller Air Filter Restriction Sensor American National Standards Institute Abgasturbolader Air Temperature Sensor Baureihe Betriebsstoffvorschrift Controller Area Network Calibration Drift Compensation Stop Engine Light Series MTU Fluids and Lubricants Specifications, Publication No. A01061/.. Data bus system, bus standard Setting of drift compensation in engine gov ernor with DiaSys 1st function: Warning lamp (rectify fault as soon as possible) 2nd function: Read out fault codes CKT CLS CPS CTS DDEC DDL DDR DIN DL DOC
TIM-ID: 0000000858 - 008
Explanation Transformer: transforms sensor voltages into numeric values Engine management system Association of American standardization or ganizations Exhaust turbocharger (ETC)
Circuit Coolant Level Sensor Coolant Pressure Sensor Coolant Temperature Sensor Detroit Diesel Electronic Controls Diagnostic Data Link Diagnostic Data Reader Deutsches Institut fr Normung e. V. Default Lost Diesel Oxidation Catalyst Diesel Particulate Filter Diagnostic Tool Electronic Control Module Engine Control Unit Engine Data Module Electrically Erasable Programmable Read Only Memory Electronic Foot Pedal Assembly M015241/03E 2011-12 | Appendix A | 131 Diagnostic unit Electronic control unit of the DDEC system Engine governor Memory module for engine data Monitors coolant level Monitors coolant pressure Monitors coolant temperature Engine control system made by Detroit Die sel Diagnostic lines Diagnostic unit At the same time identifier of German stand ards (DIN = Deutsche Industrie-Norm) Alarm: Default CAN bus failure Oxidation catalyst upstream of the diesel particulate filter
DPF DT ECM ECU EDM EEPROM EFPA
Abbreviation EGR EMU ETK EUI FPS FRS FTS FWCP GND HD HI HIHI HT IDM INJ ISO KGS KS LED LO LOLO LSG N/A LP OEM OI OLS OPS OTS OT PAN PIM PWM P-xyz RL
Meaning Exhaust Gas Recirculation Engine Monitoring Unit Ersatzteilkatalog Electronic Unit Injector Fuel Pressure Sensor Fuel - Differential Pressure Sensor Fuel Temperature Sensor Fire Water Control Panel Ground Hochdruck High High High High Temperature Interface Data Module Injector International Organization for Stand ardization Kraftgegenseite Kraftseite Light Emitting Diode Low Low Low Limiting Speed Governor Not Applicable Low Pressure Original Equipment Manufacturer Optimized Idle Oil Level Sensor Oil Pressure Sensor Oil Temperature Sensor Oberer Totpunkt Panel Peripheral Interface Module Modulated signal Pressure-xyz Redundancy Lost
Explanation
Spare Parts Catalog (SPC) Monitors fuel pressure Monitors fuel temperature Control cabinet High Pressure (HP) Alarm: Measured value exceeds 1st maxi mum limit Alarm: Measured value exceeds 2nd maxi mum limit value Memory module for interface data International umbrella organization for all na tional standardization institutes Engine free end in accordance with DIN ISO 1204 Engine driving end in accordance with DIN ISO 1204 Alarm: Measured value lower than 1st mini mum limit value Alarm: Measured value lower than 2nd mini mum limit value
Monitors oil level Monitors oil temperature Top Dead Center (TDC) Control panel
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Monitors oil pressure
Pressure measuring point, xyz specifies the measuring point designation Alarm: Redundant CAN bus failure
132 | Appendix A | M015241/03E 2011-12
Abbreviation SAE SD SEL
Meaning Society of Automotive Engineers Sensor Defect Stop Engine Light
Explanation U.S. standardization organization Alarm: Sensor failure 1st function: Warning lamp (stop engine and rectify fault) 2nd function: Read out fault codes
SID SRS SS TBS TCI TCO TD TPS TRS T-xyz UT VNT VSG VSS WZK
System Identifier Synchronous Reference Sensor Safety System Turbocharger Boost Sensor Turbo Compressor Inlet Turbo Compressor Outlet Transmitter Deviation Throttle Position Sensor Timing Reference Sensor Temperature-xyz Unterer Totpunkt Variable Nozzle Turbine Variable-Speed Governor Vehicle Speed Sensor Werkzeugkatalog Tool Catalog (TC) Temperature measuring point, xyz specifies the measuring point designation Bottom Dead Center (BDC) Alarm: Deviation in transmitter values TDC cylinder 1 Safety system alarm Monitors charge-air pressure
TIM-ID: 0000000858 - 008
M015241/03E 2011-12 | Appendix A | 133
8.2 MTU contacts/service partners

Service
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you - either during operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply. Your contact at Headquarters:Service-support@mtu-online.com
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare part at the right time at the right place. With this aim in mind, we can call on a globally networked spares logistics system - a central depot at Headquarters, as well as decentralized depots among our subsidiaries, representa tives and contractual workshops. Your contact at Headquarters: E-mail: spare.parts@mtu-online.com Phone: +49 7541 908555 Fax: +49 7541 908121
134 | Appendix A | M015241/03E 2011-12
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9 Appendix B
9.1 Special Tools
Adapter Part No.: Qty.: Used in: Barring device Part No.: Qty.: Used in: Barring device Part No.: Qty.: Used in: Endoscope Part No.: Qty.: Used in: Feeler gage Part No.: Qty.: Used in: Filling device Part No.: Qty.: Used in: Filter wrench Part No.:
DCL-ID: 0000015148 - 001
F6558528 1 7.1.1 Engine Barring manually ( Page 64)
Y20097353 7.2.1 Cylinder liner Endoscopic examination ( Page 67)
Y20010128 1 7.4.2 Valve clearance Check and adjustment ( Page 76)
B80144852 1 7.7.1 Fuel system Venting ( Page 88)
F30379104 1 7.8.1 Fuel filter Replacement ( Page 89) 1 7.13.1 Engine oil filter Replacement ( Page 100) 1 7.13.2 Centrifugal oil filter Cleaning and filter sleeve replacement ( Page 101)
Qty.: Used in: Qty.: Used in: Qty.: Used in:
M015241/03E 2011-12 | Appendix B | 135
Installation and removal tool for injector Part No.: Qty.: Used in: Milling cutter Part No.: Qty.: Used in: MTU test kit Part No.: Qty.: Used in: Qty.: Used in: 5605892099/00 1 7.12.3 Engine oil Sample extraction and analysis ( Page 99) 1 7.14.6 Coolant Sample extraction and analysis ( Page 109) F30452739 1 7.6.2 Injector Removal and installation ( Page 83) F6790161 1 7.6.2 Injector Removal and installation ( Page 83)
Optibell 2 belt tension tester Part No.: Qty.: Used in: Ratchet Part No.: Qty.: Used in: Ratchet adapter Part No.: Qty.: Used in: Ratchet adapter Part No.: Qty.: Used in: Ratchet adapter Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: F30027340 1 7.17.3 Battery-charging generator Removal and installation ( Page 120) 1 7.17.4 Battery-charging generator drive Drive belt and belt tensioner replacement ( Page 122) 1 7.17.5 Battery-charging generator drive Drive belt tension adjustment ( Page 123) F30027339 1 7.13.2 Centrifugal oil filter Cleaning and filter sleeve replacement ( Page 101)
DCL-ID: 0000015148 - 001
Y4345711 1 7.18.1 Fan drive belt Tension check / adjustment ( Page 124)
F30027341 1 7.12.2 Engine oil Change ( Page 97)
136 | Appendix B | M015241/03E 2011-12
Slotted nut screwdriver Part No.: Qty.: Used in: F30452578 1 7.6.2 Injector Removal and installation ( Page 83)
Socket box wrench Part No.: Qty.: Used in: F30039526 1 7.4.2 Valve clearance Check and adjustment ( Page 76)
Steam jet cleaner Part No.: Qty.: Used in: 1 4.7 Plant Cleaning ( Page 39)
Torque wrench 10-60 Nm Part No.: Qty.: Used in: F30510423 1 7.3.2 Crankcase breather Filter element replacement ( Page 72)
Torque wrench 60-320 Nm Part No.: Qty.: Used in: F30047446 1 7.4.2 Valve clearance Check and adjustment ( Page 76)
Torque wrench, 0.5-5 Nm Part No.: Qty.: Used in: 0015384230 1 7.6.2 Injector Removal and installation ( Page 83)
Torque wrench, 10-60 Nm Part No.: Qty.: Used in: F30510423 1 7.6.2 Injector Removal and installation ( Page 83)
Torque wrench, 20-100 Nm Part No.:

DCL-ID: 0000015148 - 001
F30026582 1 7.17.3 Battery-charging generator Removal and installation ( Page 120) 1 7.17.4 Battery-charging generator drive Drive belt and belt tensioner replacement ( Page 122) 1 7.17.5 Battery-charging generator drive Drive belt tension adjustment ( Page 123)
Qty.: Used in: Qty.: Used in: Qty.: Used in:
M015241/03E 2011-12 | Appendix B | 137
Torque wrench, 40-200 Nm Part No.: Qty.: Used in: F30027337 1 7.12.2 Engine oil Change ( Page 97)
Torque wrench, 6-50 Nm Part No.: Qty.: Used in: F30027336 1 7.13.2 Centrifugal oil filter Cleaning and filter sleeve replacement ( Page 101)
Torque wrench, 60-320 Nm Part No.: Qty.: Used in: F30047446 1 7.6.2 Injector Removal and installation ( Page 83)
138 | Appendix B | M015241/03E 2011-12
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9.2 Index
16V 4000 E20 engine data28 A Abbreviations131 After stopping the engine38 B Battery-charging generator Check 119 Battery-charging generator drive Drive belt and belt tensioner replacement122 Battery-charging generator drive Drive belt tension ad justment123 Battery-charging generator Condition check 118 Battery-charging generator Removal and installation 120 C Centrifugal oil filter Cleaning and filter sleeve replacement 101 Charge-air coolant Change 111 Draining 112 Filling 113 Level check 110 Charge-air coolant level Check 110 Charge-air coolant pump Relief bore check 116 Cold start system with ether injection Check95 Contact persons134 Coolant Sample extraction and analysis 109 Coolant - charge air Level check 110 Coolant - charge-air Change 111 Coolant level Check 103 Crankcase breather Oil separator check 71 Crankcase breather (open-circuit crankcase ventilation) Filter element cleaning 74 Crankcase breather Filter element replacement72 Crankshaft transport locking device10 Cylinder head cover Removal and installation 80 Cylinder liner Endoscopic examination 67 D DDEC alarms44 DDEC and connectors Cleaning128 DDEC Checking plug-in connections130 Drive belt Condition check 117 E Edge-type fuel filter Draining91 Engine Barring manually 64 Shutdown in manual mode 37 Start in manual mode 35 Wiring check 127 Engine coolant Change 104 Engine coolant pump Relief bore check 108 Engine coolant Draining105 Engine coolant Filling 106 Engine layout21 Engine oil Change 97 Sample extraction and analysis 99 Engine oil filter Replacement100 Engine oil level Check 96 Engine side and cylinder Designations 25 Engine wiring Check 127 Engine Barring with starting system66 F Fan drive Drive belt replacement 126 Fan drive belt Tension check / adjustment 124 Fire prevention and environmental protection17 Firing order32 Fluids and lubricants17 Fuel filter Replacement 89 Fuel prefilter - Draining90 Fuel system Venting88 G General conditions7 H HP pump Relief bore check 81 I Injector Removal and installation 83 Replacement 82 Inspection port cover Explosion hazard 13 Instructions and comments on endoscopic and visual ex amination of cylinder liners69 Intercooler Drain, coolant leakage 92
DCL-ID: 0000015148 - 001
M015241/03E 2011-12 | Appendix B | 139
M Maintenance and repair work Safety regulations 14 MTU contact persons134 O Operational checks 36 P Personnel and organizational requirements8 Plant Cleaning 39 Putting the engine into operation Preparation after scheduled out-of-service-period 34 Putting the engine into operation after extended out-ofservice periods (>3 months)33 S Safety instructions20 Sensors and actuators Overview26 Service indicator Check 93 Service partners134 Starter Condition check 94 Startup and operation Safety regulations 12 T Transport9 Troubleshooting41 V Valve clearance Adjustment 76 Check and adjustment 76 Valve gear Lubrication 75 W Wiring - engine Check 127
140 | Appendix B | M015241/03E 2011-12
DCL-ID: 0000015148 - 001

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Operating Instructions

Diesel engine 16 V 4000 E20

7 Task Description 7.1 Engine

7.2 Cylinder Liner

7.3 Crankcase Breather

7.4 Valve Drive

7.5 Injection Pump / HP Pump 7.6 Injection Valve / Injector

7.7 Fuel System 33 34 35 36 37 38 39 7.8 Fuel Filter

DCL-ID: 0000015148 - 001

7.9 Charge-Air Cooling

7.11 Starting Equipment

7.12 Lube Oil System, Lube Oil Circuit

M015241/03E 2011-12 | Table of Contents | 5

7.13 Oil Filtration / Cooling

7.18 Fan Drive

124 126 127

7.14 Coolant Circuit, General, HighTemperature Circuit

7.15 Low-Temperature Circuit

8 Appendix A 8.1 Abbreviations 8.2 MTU contacts/service partners 131 134

7.16 Belt Drive

7.17 Battery-Charging Generator

9 Appendix B 9.1 Special Tools 9.2 Index 135 139

6 | Table of Contents | M015241/03E 2011-12

DCL-ID: 0000015148 - 001

TIM-ID: 0000000860 - 016

M015241/03E 2011-12 | Safety | 7

1.2 Personnel and organizational requirements

Working clothes and protective equipment

8 | Safety | M015241/03E 2011-12

TIM-ID: 0000000874 - 016

Placement after transport

M015241/03E 2011-12 | Safety | 9

1.4 Crankshaft transport locking device

Transport locking device

Removing the transport locking device from driving end (KS)

10 | Safety | M015241/03E 2011-12

Fitting the transport locking device on driving end (KS)

TIM-ID: 0000033943 - 001

M015241/03E 2011-12 | Safety | 11

1.5 Safety regulations for startup and operation

Safety requirements for operators

Operation of electrical equipment

12 | Safety | M015241/03E 2011-12

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1.6 Explosion hazard when removing inspection port cover on engine

TIM-ID: 0000022931 - 006

M015241/03E 2011-12 | Safety | 13

1.7 Safety regulations for maintenance and repair work

TIM-ID: 0000000879 - 022

Hydraulic installation and removal

Working on electrical/electronic assemblies

Working with laser equipment

M015241/03E 2011-12 | Safety | 15

16 | Safety | M015241/03E 2011-12

TIM-ID: 0000000879 - 022

1.8 Fluids and lubricants, fire prevention and environmental protection

Environmental protection and disposal

Fluids and lubricants

TIM-ID: 0000000880 - 014

M015241/03E 2011-12 | Safety | 17

Acids and alkaline solutions

18 | Safety | M015241/03E 2011-12