OPERATING INSTRUCTION MTU 16V 4000

Service Publication

Diesel Engine 16V4000G20 16V4000G40 16V4000G60 16V4000G80

Operating Instructions M015345/20E

DaimlerChrysler Powersystems Off-Highway

Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Außerhalb dieses Verwendungszwecks darf das Handbuch ohne unsere vorherige Zustimmung nicht benutzt, vervielfältigt oder Dritten sonstwie zugänglich gemacht werden. Änderungen bleiben vorbehalten. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Other than for this purpose, the handbook shall not be reproduced, used or disclosed to others without our prior consent. Subject to alterations and amendments.

Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite. En dehors de cet usage, le manuel ne pourra être utilisé ni reproduit ou rendu accessible de quelque autre manière à des tiers, sans notre consentement préalable. Nous nous réservons le droit d’entreprendre toute modification. El Manual debe tenerse presente para evitar anomalias o daños durante el servicio, y, por dicho motivo, el usuario debe ponerlo a disposición del personal de mantenimiento y de servicio. Fuera de este fin de aplicación, el Manual no se debe utilizar, copiar ni poner en manos de terceros, sin nuestro consentimiento previo. Nos reservamos el derecho de introducir modificaciones. Il manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’ utente al personale addetto alla manutenzione e alla condotta. Senza nostra approvazione preventiva non è ammesso impiegare il manuale per scopi diversi, riprodurlo o metterlo a disposizione di terzi. Con riserva di modifiche.

Wichtig – Important – Importante Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen GmbH zurücksenden. Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten LogistikSupport (Gewährleistung, Ersatzteile etc.). 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 (warranty, spare parts, etc.). Veuillez séparer la carte “Signalisation de mise en service“ et la renvoyer à la MTU Friedrichshafen GmbH. Les informations concernant la signalisation de mise en service constituent la base pour l’assistance en exploitation contractuelle (garantie, rechanges, etc.). Rogamos separen la tarjeta “Aviso de puesta en servicio“ y la devuelvan rellenada a MTU Friedrichshafen GmbH. Las informaciones respecto al aviso de puesta en servicio constituyen la base para H el soporte logistíco contractual (garantía, piezas de repuesto, etc.). Staccare “Avviso di messa in servizio” e rispedirlo debitamente compilato alla MTU Friedrichshafen GmbH. Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.).

Postcard

MTU Friedrichshafen GmbH Abteilung SCSD 88040 Friedrichshafen GERMANY

Bitte in Blockschrift ausfüllen! Please use block capitals! Prière de remplir en lettres capitales! ¡A rellenar en letras de imprenta! Scrivere in stampatello!

Motornr.: Engine No.: No du moteur: No de motor: Motore N.:

Auftragsnr.: MTU works order No.: No de commande: No de pedido: N. commessa:

Motortyp: Engine model: Type du moteur: Tipo de motor: Motore tipo:

Inbetriebnahmedatum: Date put into operation: Mise en service le: Fecha de puesta en servicio: Messa in servizio il:

Eingebaut in: Installation site: Lieu de montage: Lugar de montaje: Installato:

Schiffstyp / Schiffshersteller: Vessel/type/class / Shipyard: Type du bateau / Constructeur: Tipo de bugue / Constructor: Tipo di Barca / Costruttore:

Endabnehmer/Anschrift: End user‘s address: Adresse du client final: Dirección del cliente final: Indirizzo del cliente finale: Bemerkung: Remarks: Remarques: Observaciones: Commento:

Inbetriebnahmemeldung

Commissioning Note

Notice de mise en service

Aviso de puesta en servicio

Avviso di messa in servizio

Amendment Service! Any changes in contents will be sent to you in the form of an amendment, provided you complete the reverse of this receipt card and return it to us.

Postcard

MTU Friedrichshafen GmbH Department SCT 88040 Friedrichshafen GERMANY

No. Please mark all filed amendments here.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Please use block capitals!

Receipt

Amendment No.

1. 2. 3.

Publication number:

4.

M015345/20E

5. 6.

Name Manufacturer

7. 8. 9.

Department Fax Street Postal box number

10. Telephone

11. 12. 13. 14.

(Postal code) City

15.

Country

16.

Date

Name

!

Safety Instructions Summary

A

Product Summary Engine layout, technical data

C

Operating Instructions Task descriptions

D

Operating Instructions Time schedule and maintenance task chart

E

Troubleshooting Causes, remedies

G

Task Description Inspection and maintenance tasks

K

Preservation Engine preservation

T

Transportation Locking Device Drawing, instructions

?

Keyword Index Alphabetical index of key terms

Safety Instructions

Section Page

! 1

Safety, Accident Prevention and Environmental Protection Instructions These instructions must be read and followed by every person involved in operation, maintenance or transportation of the machinery plant. General In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory regulations regarding accident prevention must be observed. This engine is a state-of-the-art product and conforms with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of • Incorrect use • Operation, maintenance and repair by unqualified personnel • Modifications or conversions • Non-compliance with the Safety Instructions

Correct Use The engine is intended exclusively for the application specified in the contract or upon delivery. Any other use is considered improper use. The manufacturer will accept no liability for any resultant damage. The responsibility is borne by the user alone. Correct use also includes observation of and compliance with the maintenance specifications.

Personnel Requirements Work on the engine must only be carried out by properly qualified personnel. The specified legal minimum age must be respected. Responsibilities of the operating, maintenance and repair personnel must be specified.

Modifications or Conversions Modifications made by the customer to the engine may affect safety. MTU will accept no liability or warranty claims for any damage caused by unauthorised modifications or conversions.

Organisational Measures This publication must be issued to all personnel involved in operation, maintenance, repair or transportation. It must be kept at hand near the engine and accessible to all personnel involved in operation, maintenance, repair or transportation. The personnel must be instructed on engine operation and repair by means of this publication, and in particular the safety instructions must be explained. This is especially important for personnel who work on the engine only on an occasional basis. Such personnel must be given instructions repeatedly.

Spare Parts Only genuine MTU spare parts must be used to replace components or assemblies. In event of any damage caused by the use of other spare parts, no liability or warranty claims vis-à-vis the engine manufacturer will be accepted.

Working Clothes and Protective Equipment Wear proper work clothing for all work. Depending on the kind of work, use additional protective equipment, e.g. protective goggles, protective gloves, protective helmet, apron. Work clothing must be tight-fitting so that it does not catch on rotating or projecting components. Do not wear jewellery (e.g. rings, chains, etc.).

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Safety Instructions

Transportation Lift the engine only with the lifting eyes provided. Use only the transport and lifting equipment approved by MTU. Take note of the engine centre of gravity. The engine must only be transported in installation position. In the case of special packaging with aluminium foil, suspend the engine on the lifting eyes of the bearing pedestal or transport with equipment suitable for heavy loads (forklift truck). Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and engine mounts. Secure the engine against tilting during transportation. The engine must be especially secured against slipping or tilting when going up inclines and ramps.

Setting the Engine down after Transportation Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan unless expressly authorised by MTU on a case-by-case basis to do so.

Working with Laser Equipment When working with laser equipment, always wear special laser-protection goggles. Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes. Laser equipment must be fitted with the protective devices necessary for safe operation according to type and application. 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 only 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.

Engine Operation When the engine is running, always wear ear protectors. Ensure that the engine room is well ventilated. Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent. Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health hazard. The exhaust pipework must be leak-free and must discharge the gases to atmosphere. During engine operation, do not touch battery terminals, generator terminals or cables. Inadequate protection of electrical components can lead to electric shocks and serious injuries. When the engine is running, never release coolant, oil, fuel, compressed air or hydraulic lines.

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Section Page

Safety Instructions

! 3

Maintenance and Repair Compliance with maintenance and repair specifications is an important safety factor. Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. The engine must be secured against inadvertent starting and the battery disconnected. Attach sign “Do not operate” in operating area or to control equipment. Persons not involved must keep clear. Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools required. Maintenance and repair work must only be carried out by authorised, qualified personnel. Use only the proper, calibrated tools. Do not work on engines or components which are only held by lifting equipment or crane. Always support these components in accordance with regulations on suitable frames or stands before beginning any maintenance or repair work. Before barring the engine, make sure that nobody is standing in the danger zone. After working on the engine, check that all guards have been reinstalled and that all tools and loose components have been removed from the engine. Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before starting work, relieve pressure in systems and H.P. lines which are to be opened. Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean. Always seal connections with caps or covers if a line is removed or opened. During maintenance and repair work, take care not to damage the fuel lines. To tighten connections when installing lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly. Ensure that all fuel injection lines and compressed oil lines have sufficient play to avoid contact with other components. Do not place fuel or oil lines near hot components, except when necessary for design reasons during installation. Take care with hot fluids in lines, pipes and chambers. ⇒ Risk of injury! Note cooling period for components which are heated for installation or removal.

⇒

Risk of injury!

Take special care when removing ventilation or plugs from engine. In order to avoid the discharge of highly pressurised liquids, hold a cloth over the screw or plug. It is even more dangerous if the engine has recently been shut down, as the liquids can still be hot. Take special care when draining hot fluids ⇒ Risk of injury! When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or soak them up with a suitable bonding agent. When changing engine oil or working on the fuel system, ensure that the engine room is adequately ventilated. When working high on the engine, always use suitable ladders and work platforms. Make sure components are placed on stable surfaces. In order to prevent back injuries when lifting heavy components, adults should only lift weights between max. 10 kg and 30 kg, depending on age and sex. •

Use lifting gear or seek assistance.

•

Ensure that all chains, hooks, slings, etc. are tested and authorised, are sufficiently strong and that hooks are correctly positioned. Lifting eyes must not be unevenly loaded.

Welding Operations Never carry out welding work on the engine or engine-mounted units. Never use the engine as an earth connection. – (This prevents the welding current passing through the engine and causing scorching or burning at bearings, sliding surfaces and tooth flanks, which can lead to pitting or other material damage). Never position the welding power supply cable adjacent to, or crossing MTU plant wiring harnesses. (The welding current can be induced in the wiring harnesses, which could damage the electrical unit.)

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! 4

Safety Instructions

The welding unit earth connection must not be more than 60 cm from the weld point. If components (e.g. exhaust manifold) are to be welded, they must first be removed from the engine. When carrying out work on MTU electronics components, it is not necessary to remove connectors provided that the master switch for power supply has been moved from “ON” to “OFF” and the cable is disconnected from the battery negative and positive terminals.

Hydraulic Installation and Removal Only the hydraulic installation and removal equipment specified in the work schedule and in the assembly instructions must be used. The max. permissible push-on pressure specified for the equipment must not be exceeded. The H.P. lines for hydraulic installation and removal are tested with 3800 bar. 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 system 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 piston retracted.

•

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

For a hydraulic installation / removal tool with central expansion pressure supply, screw spindle into shaft end until correct sealing is achieved. During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the component to be installed / removed. As long as the system is under pressure, there is the risk that the component to be installed / removed may be suddenly released from the pressure connection. Before use, the tools must be checked at regular intervals (crack test).

Working on Electrical Assemblies Switch off all live appliances before carrying out any work on electrical assemblies. Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to come into contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery body. Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is not damaged by contact with sharp objects, by rubbing against another component or by a hot surface. Do not secure wiring to fluid-carrying lines. On completion of the maintenance and repair work, any cables which have become loose must be correctly connected and secured. Always tighten connectors with connector pliers. If wires are installed beside mechanical components and there is a risk of chafing, use cable clamps to properly support the wires. For this purpose, no cable straps must be used as, during maintenance and / or repair work, the straps can be removed but not installed a second time.

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Safety Instructions

Section Page

! 5

Operation of Electrical Equipment When operating electrical equipment, certain components of this equipment are live. Noncompliance with the warning instructions given for this equipment may result in serious injury or damage to property.

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 lubricants lying around on the engine. Do not store combustible fluids near the engine. Do not weld pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid. When starting the engine with a foreign 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 foreign power source to the ground lead of the engine or to the ground terminal of the starter. Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarise 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. At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors (protective wadding, plugs or capsules).

Environmental Protection Dispose of used fluids and lubricants and filter in accordance with local regulations. Manipulation of the injection or control system can influence the engine performance and exhaust emissions. As a result, compliance with environmental regulations may no longer be guaranteed. Only fuels of the specified quality required to achieve emission limits must be used. In Germany, the VAwS (= regulations governing the use of materials that may affect water quality) is applicable, which means work must only be carried out by authorised specialist companies. (MTU is such a company.)

Auxiliary Materials Use only fluids and lubricants that have been tested and approved by MTU. Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions applicable to the product. Take care when handling hot, chilled or caustic materials. When using inflammable materials, avoid all sparks and do not smoke. ⇒ Lead

When working with lead or lead-containing pastes, avoid direct contact to the skin and do not inhale lead vapours. Adopt suitable measures to avoid the formation of lead dust! Switch on fume extraction system! After coming into contact with lead or lead-containing materials, wash hands! ⇒ Acids

and Alkaline Solutions

When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing. Immediately remove clothing wetted by acids and alkalis! Rinse injuries with plenty of clean water! Rinse eyes immediately with eyedrops or clean tap water!

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Safety Instructions

⇒ Painting

When painting in other than spray booths equipped with extractors, ensure good ventilation. Make sure that adjacent work areas are not affected. It is absolutely essential to wear masks providing protection against paint and solvent fumes. Observe fire prevention regulations! No smoking! No naked flame! ⇒ Liquid

Oxygen

Liquid oxygen is highly inflammable! Liquid oxygen should only be stored in small quantities and in regulation containers (without fixed seals)! Do not bring liquid oxygen into contact with the body (hands) as this causes frostbite and possibly the loss of tissue. No smoking, no naked flame (risk of explosion)! Excessive oxygen in the air leads to explosive combustion. Do not store combustible substances (e.g. oils and greases) within 5 m of the working area! Under no circumstances should clothing be oily or greasy! Do not allow vapours to penetrate clothing! Oxygen enrichment in fabric can cause working clothes to ignite suddenly! After working with liquid oxygen, do not smoke until clothing is free of vapours! Take great care to avoid impact and shock when working with liquid oxygen! ⇒ Liquid

Nitrogen

Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. Do not bring liquid nitrogen into contact with the body (eyes, hands), as this causes frostbite and numbing. Wear protective clothing (including gloves and closed shoes) and protective goggles! Ensure the room is well ventilated (88% contamination of breathing air with nitrogen will result in suffocation). Avoid all knocks and jars to the containers, fixtures or workpieces! ⇒ Compressed

Air

Compressed air is air which has been compressed at excess pressure and is stored in tanks from which it can then be extracted. The pressure at which the air is kept can be read off at pressure gauges which must be connected to the compressed air tanks and the compressed air lines. When working with compressed air, safety precautions must be constantly observed: • Pay special attention to the pressure level in the compressed air network and pressure vessel! • Connecting devices and equipment must either be designed for this pressure or, if the permitted 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 coupling and connections must be securely attached! • Always wear protective goggles when blowing off tools or extracting chips! • The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents air-borne particles being reflected and thereby prevents injury to eyes. • 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! • Unauthorised 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 explosion”!

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Section Page

Safety Instructions

•

! 7

Do not blow dirty clothing with compressed air when being worn on the body! Even compressed air at low pressure penetrates clothing and, if the jet is directed at the back, the air can enter the anal cavity and fatally rupture the intestines!

⇒ Used

Oil

Used oil may contain health-threatening combustion residues. Rub barrier cream into hands! Wash hands after contact with used oil!

Warning Signs

Before putting the engine into service and before working on the engine, read and follow all warning signs. Do not paint over warning signs. Replace illegible signs.

Warning Notices Publication contains especially emphasised safety instructions in accordance with the American standard ANSI Z535, which begin with one of the following signal words according to the degree of danger:

DANGER In event of immediate danger. Consequences: Death or serious injury

WARNING In event of dangerous situations. Consequences: Serious injury

CAUTION In event of dangerous situations. Consequences: Slight injury or material damage Take extreme care in these situations! Read and become acquainted with all warning notices and symbols before operating or repairing this product! Pass on all safety instructions to your operating, maintenance, repair and transport personnel!

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Safety Instructions

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Section

Product Summary

A

Contents

A000.000.01

Engine layout

A000.000.03

Engine model designation

A000.000.05

Enginesideandcylinderdesignations

A000.000.09

Main engine dimensions

A000.000.13

Engine weight

A000.000.17

Main engine specifications

A000.000.19

Engine power

A000.000.21O

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . .

perational data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . .

A000.000.25

Engine and exhaust noise

A050.000.01

Timingdata(valveclearanceadjusted)

A055.050.01V A180.000.01 A202.000.01C

alve clearances capacity Oil

...................................................5 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . .

oolant capacity

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...........................................3 ....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . .

Section

A

Product Summary

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Product Summary

Section Page

A000.000.01 Engine Layout Illustrations may show additional equipment

1 2 3 4 5 6 7 8 9 10

Coolant system vent connection Engine oil heat exchanger Centrifugal oil filter Exhaust turbocharger Exhaust outlet Air filter Governor / engine control system Charge air line Starter Engine mount

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11 Engine oil filter (easy-change filter) 12 Fuel duplex filter (easy-change filter) 13 H.P. fuel pump 14 Vibration damper 15 Charge air coolant pump 16 Charge air coolant thermostat 17 Charge air coolant inlet 18 Engine coolant outlet 19 Charge air coolant outlet 20 Crankcase ventilation

A 1

Section

A

Page

2

1 2 3 4 5 6 7 8 9 10

Air filter Crankcase ventilation Charge air line Exhaust turbocharger Charge air coolant outlet Cylinder head cover / cylinder head Engine lifting eyes Engine coolant pump Oil filler neck Oil pan

Product Summary

11 Oil dipstick 12 Oil drain plug 13 Starter 14Flywheel 15 Flywheel housing 16 Charge air line 17 Governor / engine control system 8 1 Intercooler

A000.000.03 Engine Mod el Desi gnation Explanation of engine type designation 16V4000G20, 16V4000G40, 16V4000G60, 16V4000G80 16 V 4000 G 2, 4, 6, 8

= = = = =

number of cylinders Veeconfiguration displacement per cylinder in cm 3 application for stationary power generation external charge air cooling

0

= designindex

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Product Summary

Section Page

A 3

A000.000.05 Engine Side and Cylinder Designations Engine sides are always designated as viewed from the driving end. The cylinders on the left engine side are designated “A” and those of the right engine side “B” (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. The numbering of other engine components is also from the driving end, starting with No. 1.

Applicable designations and abbreviations Driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . .KS ..... Free end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .KGS ..

A000.000.09 Main Engi ne Dim ensions A B C D

= = = =

Overalllength . . . . . . . . . . . .approx. . 2880mm Overallwidth . . . . . . . . . . . . .approx. . 1665mm Overallheight . . . . . . . . . . . .approx. . 2400mm Engine length to flange surface . . . . . . . . . . . . . . . . . .approx. . 2610mm E = Crankshaft centreline to oil pan . . . . . 635 . mm F = Crankshaft centreline to engine mount 340 mm

A000.000.13 Engine Weight Enginedry weight (with standard accessories withoutcoupling)

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. . . . . . . . . . . . . . . . . . . . . . . . . .approx. . . . . . 6950 kg

Section

A

Page

4

Product Summary

A000.000.17 Main Engine Spe cifications Operatingmethod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .four-stroke . . . . . cycle,single-acting Combustion method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .direct . . injection ..... Injectionmethod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .common . . . . . rail(accumulatorinjection) Mode of supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .exhaust . . . . .turbocharging .. Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .liquid-cooling ...... Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 . . °. .Vee ... Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .mm . . . . . . .165 ....... Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . . . .190 ....... Displacement, cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.06 . . litres ...... Number cylinders of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ............... Displacement, total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64.96 . . .litres ..... Compressionratiowith16V4000G20;G60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.6 . .1:. . . . . . . Compression ratio with 16V4000G40; G80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 1.: . . . . . . . . . Directionofrotation(viewedondrivingend) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c.c.w. . . . .(non-reversible) .. Firingorder . . . . . . . . . . . . . . . . . . .A1 . –A 7 –B 4 – B6 –A 4 –B 8 – A2 – A8 – B3 –B 5 –A 3 –A 5–B 2 –A 6 – B1 – B7 Finalcompressionpressureat120rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 .to .24 .bar .......

A000.000.19 Engine Pow er Continuouspowerwith16V4000G20 Continuouspowerwith16V4000G40 Continuouspowerwith16V4000G60

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1760 . . . .kW . .at.1500rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990 . . . .kW . .at.1800rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1940 . . . .kW . .at.1500rpm

Continuouspowerwith16V4000G80

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2190 . . . .kW . .at.1800rpm

Reference conditions – Intake air temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . .°C ... – Charge air coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 . . °. C. . – Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 . . .m ... – Exhaust backpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 . . .mbar .. – Intake air pressure loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . .mbar ..

15345/20 E 00–05

Product Summary

Section Page

A 5

A000.000.21 Operational Data The Engine Acceptance Test Records operational data are binding. All figures relate to the engine at operating temperature. The engine may be operated at full power up to the specified limit values. The normal values may approach the limit values as a result of different reference conditions or faults when the prescribed service life is reached. If the limit values are exceeded, determine and rectify the cause.

Coolas ny t stem

Unit

Normal

Limit

Coolant temperature at engine outlet

°C

93

Coolant temperature after engine – warning

°C

95

– –

Coolant temperature after engine – shutdown

°C

–

97

Engine coolant preheat temperature, measured after engine

°C

40

–

Engine oil system Engine oil operating temperature before engine

°C

Engine oil operating temperature before engine – warning

°C

Engineoiloperatingpressurebeforeengine Engineoilpressurebeforeengine–warning

bar bar

85 95 – 95

–

5.0–6.0 4.5

–

Fuel system Primingpressurebeforeenginedeliverypump“min”

bar

–

0.0

Primingpressurebeforeenginedeliverypump“max”

bar

–

1.5

Peripheral conditions for max. power Intake depression Exhaust backpressure

mbar mbar

25 30

35 50

A000.000.25 Engine an d Exh aust Nois e Sound power level as per ISO 8528–10 Applicable to engine model 16V4000G20 – Engine surface noise (free-field level) at distance of 1 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. .. 107 dB (A) – Undamped exhaust noise (free-field level) at distance of 1 m . . . . . . . . . . . . . . . . . . . . . . . . . . .approx. . 116 dB (A) Applicable to engine model 16V4000G40 – Engine surface noise (free-field level) at distance of 1 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. .. 106 dB (A) – Undamped exhaust noise (free-field level) at distance of 1 m . . . . . . . . . . . . . . . . . . . . . . . . . . .approx. . 115 dB (A) Applicable to engine model 16V4000G60 – Engine surface noise (free-field level) at distance of 1 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. .. 108 dB (A) – Undamped exhaust noise (free-field level) at distance of 1 m . . . . . . . . . . . . . . . . . . . . . . . . . . .approx. . 118 dB (A) Applicable to engine model 16V4000G80 – Engine surface noise (free-field level) at distance of 1 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. .. 108 dB (A) – Undamped exhaust noise (free-field level) at distance of 1 m . . . . . . . . . . . . . . . . . . . . . . . . . . .approx. . 118 dB (A)

15345/20 E 00–05

Section

A

Page

6

Product Summary

A050.000.01 Timing Data (Valve Clearance Adjusted) Valve clearance adjusted

°Crank

1Inletvalveopens . . . . . . . . . . . 42.6 ... 2Inletvalvecloses . . . . . . . . . . . .66.6 .. 3Exhaustvalveopens . . . . . . . . 57.6 ..

before TDC ° after BDC ° before BDC

angle

°

4 Exhaust valve closes . . . . . . . . . . . .°

 

Overlap 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 . . . . . . 6 Start of delivery . . . . . Performance-map controlled I . . . . . . . . . . . . . . . . . . . . . . .Top . dead center (TDC) II . . . . . . . . . . . . . . . . . . . Bottom . dead center (BDC)

A055.050.01 Valve Clearances With engine cold – Inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.20 . . . .mm .. – Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.50 . . . .mm ..

A180.000.01 Oil Cap acity

Oil capacity, oil pan – to lower mark on oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. . . . . . 190 litres – to upper mark on dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. . . . . . 230 litres Total capacity – for initial filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. . . . . . . 290 litres – for oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. . . . . . . 250 litres

A202.000.01 Coolant Capacity – Engine circuit (without cooler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. . . . . . 175 litres – Charge air circuit (without cooler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .approx. . . . . 40 litres

15345/20 E 00–05

Section

Operating Instructions

C

Contents

C000.000.01

Operating instructions – Preface

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 ....

C000.000.03

Preparationsforinitialoperation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . .

C000.000.05I

nitial operation

C000.000.07

Operationalchecks–MaintenanceEchelonW1–

C000.000.09

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.

C000.000.11

After shutdown

C000.000.13

Out-of-service period

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. .

C000.000.17

Engine transportation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. .

15345/20 E 00–05

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . .

Section

C


15345/20 E 00–05


Section

C

Page

1

C000.000.01 Operating Instructions – Preface Low operating and maintenance costs as well as operational reliability and availability depend on maintenance and servicing being carried out in compliance with our specifications and instructions. Our Product Support service is available at all times should assistance be needed. Prior to engine start-up it must be determined whether start-up is: – After a short, scheduled operational shutdown, – After an extended out-of-service period, – Initial startup of a new engine. Accordingly the Before-Operation Services are sub-divided into: – B1- Before-Operation Services after a short, scheduled operational shutdown (B1) – B2- Before-Operation Services after an extended operational shutdown (exceeding 1 week) (B2) – B3- Before-Operation Services before initial startup of a new or preserved engine (B3). Correct engine installation and alignment according to our regulations are basic requirements for initial engine startup. In the event of an engine malfunction a decision must be made as to whether – The engine is to be shut down – operation may be continued, for a short period, using emergency measures, until rectification can be effected. Prior to engine shutdown it must be determined whether: – a short, scheduled operational shutdown, or – an extended out-of-service period is involved. NOTE: The code numbers on the following pages refer to the group numbers in Section G. This Maintenance Schedule may include components which are not installed on your engine; these may be disregarded.

15345/20 E 00–05

Section

C

Page

2


C000.000.03 Preparations for Initial Operation Code

Task Description

G080.000.03 Fuelsystem G124.051.01 Charge air manifold G180.000.01 Engineoil

Check drain line for water discharge and obstruction Checklevel

G202.000.03 Engine coolant

Check level

G202.400.01 Enginecoolant

Preheat

G203.000.03 Charge air coolant

Check level

G307.001.01 Guards

Check

G364.050.01 Fuel G364.200.03 Fuel supply system

Checksupply Open shut-off valve(s)

G500.000.01 Engine control system

Switch on

G500.000.09 Enginewiring

Check

G000.000.05 Running gear

Bar engine manually

G202.651.01 Engine coolant system

Check vent line for obstructions

G203.551.01 Charge air coolant system

Check vent line for obstructions

K000

Depreservation

Carry out before-operation services

G055.000.03 Valvegear

Lubricate

G120.000.07 Air system

Ensure cover plates are removed

G140.000.03 Exhaust s ystem

Check tightness of securing screws

G140.000.07 Exhaust system

Ensure cover plates are removed

G180.000.03 Engineoil

Fillsystem


Fill system

G202.401.01 Preheater G203.000.01 Charge air coolant G309.001.03 Battery G364.200.05 Fuel supply system G500.000.07 Engine control system

B 1 2 3

Fillsystem

Switchon Fill system Fillwith acid / alkaline solution Fill fuel suction line to engine Switch on

T036.051.01

Crankshaft

Ensure transportation locking device is removed

T231.001.01

Engine mounting

Ensure locking device is removed

15345/20 E 00–05


C000.000.05 Initial Operation Code

Task Description

G000.000.07 Engine

Turnengineonstarter: – only on initial operation after engine oil change after engine oil filter change after extended out-of-service period (exceeding 1 month) Startengine

Carry out before-operation services

G000.000.09 Engine G000.000.11

Engine operation

G000.000.13 Engine operation G000.000.15 Engine operation

Carry out warm-up procedure Check speed Check pressures (where gauges are installed)

G000.000.17 Engine operation

Check t emperatures (where gauges a re installed)


Check running noises


Check engine and external pipework for leaks

For B2 or B3 and after W6, in addition: G055.000.01 Valvegear

Checkoilsupply

G080.000.05 Engine test run

Check fuel delivery pump supply pressure


Check intake depression


Check exhaust backpressure

C000.000.07 Operational Checks – Maintenance Echelon W1– Carry out tasks in accordance with Maintenance Schedule Section D.

15345/20 E 00–05

Section

C

Page

3

Section

C

Page

4


C000.000.09 Shutdown Code

Task Description

G000.000.23 Engine

Shutdownengine

G000.000.35 Engine

Disengageload

C000.000.11 After Shutdown Code

Task Description


Checklevel

C000.000.13 Out-of-Service Perio d If the engine is to remain out of service for more than 1 week, seal the engine air and exhaust sides. If the engine is to remain out of service for more than 1 month, carry out preservation in accordance with Section K. Code

Task Description

G202.000.07 Enginecoolant

Drain (1)

G202.401.05 Engine coolant G203.000.05 Charge air coolant

Switch off preheating unit Drain (1)

G500.000.03 Engine control system

Switch off

(1) only

– – – –

when freezing temperatures are expected and the engine is to remain out of service for an extended period and

the engine coolant has no antifreeze additive the engine room cannot be heated the coolant cannot be maintained at a suitable temperature the antifreeze concentration is insufficient for the engine room temperature

– or with an antifreeze concentration of 50% and at an engine room temperature below –40 °C, if the antifreeze additive conforms to the current MTU/DDC Fluid and Lubricants Specification.

C000.000.17 Engine Tra nsportation Before transporting the engine, the transportation locking devices for the crankshaft (Section T) must be installed. The engine must only be lifted using the lifting eyes provided.

15345/20 E 00–05

Maintenance Schedule

Section

D

Contents

D000.000.01

Maintenance schedule – Preface

D000.000.03

Maintenance system

D000.000.05

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.

D000.000.07

Maintenance frequency chart

D000.000.11

Maintenance schedule

D000.000.15

Maintenance echelon W6

D000.000.17

Out-of-service periods

15345/20 E 00–05

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. .

Section

D


15345/20 E 00–05


Section Page

D 1

D000.000.01 Maintenance Schedule – Preface Low operating and maintenance costs as well as operational reliability and availability depend on maintenance and servicing being carried out in compliance with our specifications and instructions. The overall system, of which the engine is an integral part, must be maintained in such a way as to ensure troublefree engine operation at all times. For this purpose, always: – Ensure that sufficient fuel is available – Ensure that the combustion air is dry and clean – Use only clean, filtered raw water Preventive maintenance instructions – Special care should be taken to keep the machinery plant in a clean and serviceable condition at all times to facilitate detection of possible leaks and prevent subsequent damage. – Protect rubber and synthetic parts from oil and fuel, never treat with organic detergents. Wipe with a dry cloth only. – Always replace all seals and gaskets.

D000.000.03 Maintenance System The MTU maintenance concept is a preventive maintenance concept and features the W1 to W6 Maintenance Echelons as outlined below. Preventive maintenance permits advance operational planning and increases availability. Main features of maintenance echelon W1:

Operationalchecks.

W2, W3 and W4:

Periodic maintenance services to be carried out during out-of-service periods without the need for engine disassembly.

W5

–

W6:

Major overhaul. This echelon requires complete engine disassembly.

The time intervals according to which W2 to W6 maintenance operations are to be performed and the relevant inspection and maintenance tasks are based on operational experience. They have been determined so as to ensure correct engine operation until the next scheduled maintenance echelon. Particular operating conditions may require the Maintenance Schedule to be altered to compensate. NOTE: The code numbers on the following pages refer to the group numbers in Section G. This Maintenance Schedule may include components which are not installed on your engine; these may be disregarded.

D000.000.05 Application 3D:

Emergency power operation

4C: 4C:

Short-term operation: Drive for industrial machinery (e.g. fire-fighting pumps, emergency water supply) Continuous operation, restricted (emergency power operation) Continuous operation, restricted (peak-load operation) – see maintenance schedule MO 50 479

15345/20 E 00–05

Section Page

D 2


D000.000.07 Maintenance Frequency Chart Maintenanceechelon

W1:

every month in extended operation daily

1

W2:

every months operating hours limit

6 250

W3:

every year operating hours limit

1 500

W4:


4 1 500

W5:


8 3 000

W6:


16 6 000

D000.000.11 Maintenance Sch edule Code

One-time services after the first 50 operating hours on a new engine, or after W5 or W6 maintenance

G055.050.01 Valvegear

Check valve clearances

G073.051.07 H.P. fuel pump

Check relief bore for obstructions

G083.051.03 Fuel duplex filter

Replace filter element

G083.101.03 Fuel prefilter

Drain water and contaminants



G083.101.15 Fuelprefilter

Clean


Check tightness of securing screws

G180.000.04 Engine oil G202.051.01 Engine coolant pump

Used oil – take sample and analyse Check relief bore for obstructions

G203.051.01 Charge air coolant pump


Code

Maintenance echelon W1 – Monthly test run / operational checks


Check speed


Check pressures (where gauges are installed)


Check t emperatures (where gauges a re installed)


Check running noises


Check engine and external pipework for leaks


Drain water and contaminants

G121.052.01 Air filter

Check contamination indicator

G124.051.01 Air supply pipework

Check drain bore for water discharge and obstruction


Check exhaust gas colour

G140.000.11

Exhaust system


Drain (if drain provided) Checklevel


Check level

G203.000.03 Charge air coolant

Check level

G303.000.03 Compressed air system

Drain condensate

G303.000.03 Compressed air system

Check operating pressure

G510.070.01 Monitoring s ystem

Carry out lamp test

15345/20 E 00–05


Code

Section Page

Task Description

W 2 3 4 5

G120.000.03

Air supply pipework

Check intake side for leaks or damage

G180.000.04

Engine oil

Used oil – take sample and analyse

G180.000.05

Engineoil

Change – after every 2 years – at the latest with oil category 1 after every 250 operating hours oil category 2 after every 500 operating hours

G183.052.03

Engineoilfilter

Replace – when changing oil

G055.050.01 G083.051.03

Valve gear Fuel duplex filter

G083.101.09

Fuel prefilter


G083.101.15

Fuelprefilter

Clean

G140.000.11

Exhaust s ystem

Check, check drain bore for obstruction

G202.000.05

Engine coolant

Take sample and analyse (engine coolant change – see MTU Fluids and Lubricants Specification)

G202.051.01

Engine coolant pump


G203.000.07

Charge air coolant

Take sample and analyse, change if necessary (see MTU Fluids and Lubricants Specification)

G203.051.01

Charge air coolant pump


G205.051.01

Engine coolant cooler

Check cooler elements for external contamination

G205.051.03

Charge air coolant cooler

Check cooler elements for external contamination

G073.051.07

H.P. fuel pump


G121.051.01

Airfilter

Replacefilterelements

G172.051.09

Starter

Check condition (visual inspection)

G213.051.01

Generator drive

Check drive belt condition and tension

G213.051.08 G231.051.01

Generator Engine mounting

Check condition (visual inspection) Check tightness of securing screws

G231.051.03

Engine mounting

Check condition of resilient mounts

G231.051.11

Enginemounting

Check bufferc learance

G252.051.01

Coupling ( flywheel e nd)

Check c ondition ( visual i nspection)

G500.000.09

Enginewiring

Check

G510.000.01

Monitoring s ystem

Check valve clearances Replace filter element

Check function of monitoring units

At < 2000 operating hours, the * tasks may be omitted: Before starting W5 maintenance services, drain coolant and flush coolant systems. * Valve gear

Remove and check rocker arms and valve bridges Check rocker arms, rollers, pushrod seats and rocker arm bearings for wear

* Cylinder heads

Remove, check valve guides, recondition valves and valve seats Replace O-rings on protective sleeves Replace gaskets

* Fuelinjectors

Replace

* Crankcase

Check wear pattern of cylinder liners

* Vibration damper

Examine, repair if necessary

Exhaust turbocharger

Visual inspection, check bearing clearance, replace if necessary

Air supply pipework

Remove, clean, and replace gaskets

Intercooler

Remove, clean, check for leaks, replace gaskets

Generator H.P.fuelsensor Engine coolant pump

Checkcarbonbrushes Replace Check for leaks, disassemble if necessary, replace gaskets

Charge air coolant pump

Check for leaks, disassemble if necessary, replace gaskets

Engine coolant cooler

Clean, check for leaks

Charge air coolant cooler

Clean, check for leaks

Engine coolant thermostat

Check, replace thermal element

Charge air coolant thermostat

Check, replace thermal element

15345/20 E 00–05

D 3

Section Page

D 4


Engine coolant preheating

Overhaul

Engine oil heat exchanger

Remove, clean and check for leaks, replace sealing rings

Crankcase breather

Check oil separator, replace if necessary

D000.000.15 Maintenance Ech elon W6 The W6 echelon requires complete disassembly of the engine. Repair / overhaul of the relevant components is determined by the actual condition of the components and their dimensions, which are referenced to the Tolerances and Wear Limits List.

D000.000.17 Out-of-Service Perio ds If the engine is to remain out of service for several weeks, spray engine oil into the engine air intake. Operate the engine shutdown device and use the starting equipment to turn the engine over while performing this procedure. The maintenance schedule will then be governed by the time limits specified. In addition, the engine must be turned over by hand once a month. If the engine is to remain out of service for more than 1 month, carry out engine preservation in accordance with Section K.

15345/20 E 00–05

Section

Troubleshooting

E

Contents

E000.000.01

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.

E000.000.02

Enginedoesnotturnwhenstarterisactuated

E000.000.03

Engine turns but does not fire

E000.000.05

Engine fires unevenly

E000.000.07

Enginedoesnotreachfull-loadspeed

E000.000.09

Engine speed not steady

E000.000.11

Compression pressure too low

E070.000.01

Fuel pressure too low

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . .

E070.000.03

Fuel pressure too high

.....................................................4 .......

E073.051.01

H.P. pump leaking at relief bore

E080.000.01

Fuel pressure too low

E101.011.01

Abnormalturbochargerrunningnoises

E110.000.01

Charge air temperature too high

E110.000.03

Charge air pressure too low

E114.051.01

Coolantdischargeatintercoolerreliefbore

E140.000.01

Exhaust gases black

E140.000.02

Exhaust gases blue

E140.000.03

Exhaust gases white

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . .

E172.000.01

Power supply faulty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . .

E180.000.01

Engineoilconsumptionabnormallyhigh

E180.000.03

Engine oil level abnormally high

E180.000.05

Engine oil temperature too high

E180.000.07

Engine oil pressure too high

.................................................8 .......

E180.000.09

Engine oil pressure too low

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. . . . . . .

E202.000.01

Enginecoolanttemperaturetoohigh

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. . . .

E202.000.02

Enginecoolanttemperaturetoolow

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. . . .

E202.000.05

Engine coolant pressure too low

E202.000.07

Coolant loss

E202.000.09

Engine coolant level rising

E202.051.01

Enginecoolantpumpleakingatreliefbore

E202.400.01

Preheat temperature too low

15345/20 E 00–05

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . ........................................................2 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . ...............................................7 ......

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ......

Section

E

Troubleshooting

15345/20 E 00–05

Troubleshooting

Section Page

E 1

E000.000.01 General In Event of Internal Coolant Leakage Subsequent damage caused by corrosion must be avoided. If the engine cannot be repaired immediately, carry out the following operations: – Drain coolant and engine oil – Introduce corrosion-inhibitor oil, kerosene or diesel fuel into the crankcase via the oil filler neck until the max. level is reached – Remove the charge air/coolant manifolds – Remove the fuel injectors – Bar the engine manually and spray corrosion-inhibitor oil, kerosene or diesel fuel into the combustion chambers via the opening inlet valves It is essential to change the engine oil after 50 operating hours as the new oil may be contaminated by coolant residues left in the crankcase. NOTE: The anti-corrosive protection is restricted to a few days. Repair the engine as soon as possible and thoroughly clean the components.

Before restarting the repaired engine, fill with new oil and coolant in compliance with the MTU Fluids and Lubricants Specification.

Engine Oil Diluted by Fuel It is essential to change the engine oil before restarting the engine after rectifying the fault. Remove the old oil from the crankcase with particular care. Replace the engine oil filter.

After Work on Engine If running gear components, e.g. pistons, piston rings, cylinder liners, etc. have been replaced, carry out the engine running-in procedure.

E000.000.02 Engine does not turn when starter is actuated Probable Causes

Check

Remedial Action

Battery

Battery charge state Cable connections

Charge battery, replace if necessary Connect, replace if necessary

Starter

Starter/engine wiring Start repeat relay Starter Ring gear

Connect, replace if necessary Replace Replace Replace

Running gear blocked

Whether engine can be turned by hand

Repair running gear

Engine wiring

Engine wiring

Check – see G500.000.09

ECU

Check security of connectors and cables

Check – see G508.000.01

E000.000.03 Engine turns but d oes not fir e Probable Causes

Check

Remedial Action

Engine coolant preheat temperature too low

See E202.400.01

–

Fuel pressure too low, no start release

See E070.000.01

–

15345/20 E 00–05

SectionE Page 2

Troubleshooting

Probable Causes

Check

Remedial Action

Engine receiving insufficient combustion air

Air filter contamination indicator (G121.051.01) Air filter Intercooler

– – Replace (G121.051.01) Clean, replace if necessary

Engine does not reach firing speed

Battery Starter

Charge, replace if necessary Replace

Engine wiring

Engine wiring

Check – see G500.000.09

E000.000.05 Engine fires unevenly Probable Causes

Check

Remedial Action


See E202.400.01

–

Fuel system is not yet vented

Whether engine fires steadily after short period

–

Fuel injection equipment faulty

Injectors Pressure maintaining valves Injection pump solenoid valve

Replace (G075.051.05) Replace

Engine wiring

Engine wiring

Check – see G500.000.09

E000.000.07 Engine does not reach full-load speed Probable Causes

Check

Remedial Action


See E110.000.03

–

Engine receiving insufficient fuel

See E080.000.01

–


Injectors Pressure maintaining valves


H.P. pump generating insufficient pressure

See E070.000.01

–

Charge air temperature too high

See E110.000.01

–

Power take-off too high

Auxiliary PTO (power consumption too high) Dialogue unit/data recorder (speedsensitive fuel limiter actual/specified injection)

Contact MTU Service

15345/20 E 00–05

Troubleshooting

Section Page

E000.000.09 Engine speed not steady Probable Causes

Check

Remedial Action


Injectors Pressure maintaining valves


H.P. pump

Fuel pressure with dialogue unit/ data recorder

Contact MTU Service

Suction valve sluggish

Check suction valve for ease of movement

Repair, replace if necessary

Speed sensor faulty

Crankshaft speed sensor (G510.000.01) Camshaft speed sensor – see Repair Manual

– –

E000.000.11 Compression pre ssure too low Probable Causes

Check

Remedial Action

Cylinder head gasket leaking

Cylinder head gasket

Replace

Valve seats in cylinder head worn

Cylinder head (G000.000.33)

Repair if necessary

Valves do not close

Valve clearances (G055.050.01) Valves

Adjust (G055.050.03) Recondition, replace if necessary

Piston rings worn

Piston rings

Replace

Combustion chamber

Cylinder liner (G000.000.33) Piston (G000.000.33)

Replace if necessary Replace if necessary

E070.000.01 Fuel pressure too low Probable Causes

Check

Remedial Action

Pressure sensor faulty

Pressure sensor (G510.000.01)

–

H.P. pump of fuel quantity regula- Suction valve tor / pressure regulator (actuating solenoid)


Pressure relief valve leaking

Fuel return from pressure relief valve

Replace pressure relief valve

Fuel pressure less than 4 bar

See E080.000.01

–

H.P. pump generating insufficient pressure


Replace H. P. fuel pump

Fuel injector faulty


Replace injector (G075.051.05)

15345/20 E 00–05

E 3

SectionE Page 4

Troubleshooting

E070.000.03 Fuel pressure too high Probable Causes

Check

Remedial Action

H.P. pump of fuel quantity regula- Harsh engine running noise at idling, Repair, replace if necessary tor / pressure regulator (actuating connector and wiring solenoid) Suction valve Pressure sensor faulty


–

E073.051.01 H.P. pump leaking at relief bore Probable Causes

Check

Remedial Action

H.P. pump seals leaking

For engine oil or fuel discharge

Replace H. P. fuel pump

E080.000.01 Fuel pressure too low Probable Causes

Check

Remedial Action

Fuel supply blocked

Shut-off valve in fuel system

Open (G364.000.03)

Fuel level too low

Fuel supply

Top up fuel

Fuel line

Seals

Renew seals, replace if necessary

Fuel filter contaminated

Fuel prefilter

Clean filter (G083.101.15), replace if necessary (G083.101.09) Replace filter (G083.051.03)

Fuel duplex filter Fuel delivery pump faulty

Fuel delivery pump, fuel delivery pump drive


E101.011.01 Abnormal turbocharger running noises Probable Causes

Check

Remedial Action

Exhaust turbocharger dirty


Clean

Exhaust turbocharger faulty

Turbocharger bearing Rotor assembly

Replace Replace

E110.000.01 Charge ai r temp erature too hig h Probable Causes

Check

Remedial Action

Intercooler dirty

Intercooler

Clean

Charge air coolant temperature too high

See E203.000.01

–

Antifreeze concentration too high

Charge air coolant

Rectify concentration as per specifications

Incorrect corrosion inhibitor (deposits in intercooler)

Charge air coolant Corrosion inhibitor

Clean coolant system. Treat engine coolant in accordance with the current MTU Fluids and Lubricants Specification, replace intercooler if necessary

15345/20 E 00–05

Troubleshooting

Section Page

E110.000.03 Charge air pr essure too low Probable Causes

Check

Remedial Action


Air filter-contamination indicator (G121.052.01) Charge air pressure (A000.000.21) Air filter Intercooler Air supply pipework

–



–

Exhaust turbocharger faulty


Repair

– Replace (G121.051.01) Clean, replace if necessary Seal pipework

E114.051.01 Coolant discharge at intercooler relief bore Probable Causes

Check

Remedial Action

Intercooler leaking

Whether coolant discharges from condensate drain line (not condensate)

Replace intercooler

E140.000.01 Exhaust gases black Probable Causes

Check

Remedial Action


See E110.000.03

–


See E000.000.07

Resistance in exhaust system

Exhaust backpressure

Clean exhaust silencer

Power take-off too high, engine overload

Auxiliary PTO (power consumption too high) Dialogue unit/data recorder (speedsensitive fuel limiter actual/specified injection)

Contact MTU Service

E140.000.02 Exhaust gases blue Probable Causes

Check

Remedial Action

Too much oil in combustion chambers

Engine oil level (G180.000.01) Exhaust turbocharger Crankcase breather Valve stem seals

Correct oil level (G180.000.01) Repair Replace (G018.101.03) Replace

Piston rings Valve guides Cylinder liners

Replace Replace Replace

15345/20 E 00–05

E 5

SectionE Page 6

Troubleshooting

E140.000.03 Exhaust gases white Probable Causes

Check

Remedial Action


See E202.400.01

–

Engine cold

Engine coolant temperature

See E202.000.02

Coolant in combustion chambers

Exhaust turbocharger Intercooler

Repair Replace

Cylinder head gaskets Cylinder heads (G000.000.33) Cylinder liners (G000.000.33)

Replace Replace if necessary Replace if necessary

E172.000.01 Power supply faulty Probable Causes

Check

Remedial Action

Battery not or insufficiently charged

Generator drive belt Generator Battery

Adjust tension (G213.051.01), replace drive belt if necessary (G213.051.05) Repair Replace

Charge indicator lamp does not light up when engine is inoperative and propulsion control lever is switched on

Connection cable Charge indicator lamp Battery Generator voltage regulator Generator

Secure Replace Replace Replace Repair

With engine inoperative, charge indicator lamp burns brightly but becomes dark when engine running

Connection Generator cable

Secure Repair

Charge indicator lamp still lights up brightly at higher speed

Connection cable from generator to starter/battery Generator drive Generator

Secure

Charge indicator lamp flickers

Generator Generator drive belt

Tighten cable fixtures Adjust tension (G213.051.01) Replace drive belt if necessary (G213.051.05)

Wiring faulty

Wiring

Check G500.000.09

Replace Repair

15345/20 E 00–05

Troubleshooting

Section Page

E 7

E180.000.01 Engine oil consumption abnormally high Probable Causes

Check

Remedial Action

Crankcase ventilation faulty

Crankcase breather

Replace

Engine oil system leaking externally

External subassemblies External pipework Engine oil drains Shaft seals Oil pan Crankcase

Seal pipework Check connections, tighten if necessary Seal (G180.000.05) Replace Seal pipework Repair

Intake air depression too high

Air filter contamination indicator (G121.052.01)

Replace air filter (G121.051.01)

Oil pipes to engine oil heat exchanger leaking

Oil in coolant system

Replace sealing rings

Exhaust turbocharger leaking


Replace bearings

Engine wear

Valve stem seal Piston rings Valve guides Cylinder liners

Replace Replace Replace Replace

Combustion chamber

Combustion chamber (G000.000.33) –

E180.000.03 Engine oil le vel ab normally high Probable Causes

Check

Remedial Action

Fuel or engine coolant in engine oil

Engine oil quality

see

Fuel in engine oil

Injectors H.P. pump Relief bore

Replace seal to cylinder head In event of fluid discharge, replace H.P. pump

Engine coolant in engine oil

Cylinder heads Cylinder liner seals Cylinder liners Crankcase Coolant distribution housing

Replace if necessary Replace Replace Repair Replace

– “Fuel in engine oil” – “Coolant in engine oil”

E180.000.05 Engine oi l temp erature too hig h Probable Causes

Check

Remedial Action

Engine oil heat exchanger dirty

Engine oil heat exchanger

Clean, replace if necessary

Engine coolant temperature too high

See E202.000.01

See E202.000.01

Temperature sensor faulty

Temperature sensor (G510.000.01)

–

Combustion chamber

Combustion chamber (G000.000.33) –

15345/20 E 00–05

SectionE Page 8

Troubleshooting

E180.000.07 Engine o il pre ssure too h igh Probable Causes

Check

Remedial Action

Oil viscosity too high

Engine oil viscosity

Change engine oil

Engine oil system

Engine oil pressure relief valve

Replace

Engine coolant in engine oil

Engine oil quality

See E180.000.03



–

E180.000.09 Engine oil pr essure too low Probable Causes

Check

Remedial Action

After oil filter change, the pure oil Drain plugs on equipment carrier or contaminated oil drain plugs on equipment carrier are still open

Close drain plugs

Oil level too low

Engine oil level

Top up engine oil

Engine oil system leaking externally

See E180.000.01

See E180.000.01

Fuel in engine oil

Engine oil quality

See E180.000.03

Engine oil filter dirty

–

Replace filter (G183.052.03)

Engine oil pressure relief valve

Opening pressure

Adjust or replace

Engine oil pump

Engine oil pump


Pressure loss in running gear

Running gear lubrication points

Replace bearings



–

E202.000.01 Engine coolant temperature too high Probable Causes

Check

Remedial Action

Engine coolant level too low

Engine coolant level

Top up engine coolant

Engine coolant system contaminated

Engine coolant system Vent lines Engine coolant heat exchanger

Clean Clean Clean, replace if necessary

Engine coolant pressure too low

See E202.000.05

See E202.000.05



Replace


Temperature sensor (G510.000.01)

–

E202.000.02 Engine coolant temperature too low Probable Causes

Check

Remedial Action



Replace


Temperature sensor (G510.000.01).

–

15345/20 E 00–05

Troubleshooting

Section Page

E 9

E202.000.05 Engine co olant pre ssure too low Probable Causes

Check

Remedial Action

Coolant system not sealed

Cover closed Breather valve

Close cover Replace cover

Engine coolant system leaking externally

External pipework External subassemblies Coolant drain points Engine coolant heat exchanger Crankcase

Check connections, tighten if necessary Check connections, tighten if necessary Seal Repair Check for leaks, replace if necessary

Engine coolant level too low

Engine coolant level

Top up engine coolant

Engine coolant pump faulty

Engine coolant pump

Replace

Engine coolant system leaking internally

Engine oil quality Cylinder heads Injector protective sleeve gasket Cylinder liner gaskets

Change engine oil (G180.000.05) Replace Replace Replace



–

Check

Remedial Action

E202.000.07 Coolant lo ss Probable Causes

Engine coolant system leaking ex- See E202.000.05 ternally

–

Engine coolant system leaking internally

See E202.000.05

–

Engine coolant pump leaking

Engine coolant pump

Repair

Level monitor display error

Level monitor, wiring


E202.000.09 Engine c oolant le vel ri sing Probable Causes

Check

Remedial Action

Engine oil in engine coolant

Engine coolant quality Engine oil heat exchanger

(G202.000.05) Repair, replace if necessary

Air in engine coolant

Vent lines

Clean

E202.051.01 Engine coolant pump leaking at relief bore Probable Causes

Check

Remedial Action

Engine coolant pump leaking

For oil discharge

Replace sealing ring Replace engine coolant pump if necessary Replace rotary seal Replace engine coolant pump if necessary

For water discharge

15345/20 E 00–05

SectionE Page 10

Troubleshooting

E202.400.01 Preheat temp erature too lo w Probable Causes

Check

Remedial Action

Power supply for preheater

Power supply available

Provide power supply

Preheater not working

Preheater switched on

See Operating Instructions of Manufacturer

15345/20 E 00–05

Section

Task Description

G

Contents

G000.000.01 G000.000.03E

Engine start disabling

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .

ngine start release

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . .

G000.000.05

Barring engine manually

G000.000.07

Barringenginewithstartingsystem

G000.000.09

Engine starting

G000.000.11

Engine warm-up procedure

G000.000.13E

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 ....

ngine speed check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . .

G000.000.15

Engine pressure checks

G000.000.17

Engine temperature checks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . .

G000.000.19

Engine running noise check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . .

G000.000.21

Engineandexternallinesleakcheck

G000.000.23

Engine shutdown

G000.000.25E

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . .

mergency shutdown

..........................................................4 ...

G000.000.27

Attachments security check

G000.000.29

Attachments,hosesandhoseconnectionscheck

G000.000.33

Cylinderchamberendoscopicexamination

G000.000.39

Cleaning engine externally

G018.101.03

Crankcaseventilation,oilseparatorcheck

G030.001.01

Engine barringtool installation

G030.001.03

Engine barring tool removal

G055.000.01

Valve gear oil supply check

G055.000.03

Valve gear lubrication

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 .....

G055.050.01

Valve clearance check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 .....

G055.050.03

Valve clearance adjustment (Valve bridge with adjusting screw M16 (Locknut 24 AF))

......

15

G055.050.03

Valve clearance adjustment (Valve bridge with adjusting screw M12 (Locknut 19 AF))

......

20

G055.101.01

Cylinder head cover removal

G055.101.03

Cylinderheadcoverinstallation

G073.051.07

High-pressurepump,reliefboreobstructioncheck

G075.051.01I

njector removal

G075.051.05

Injector replacement

G075.051.09

Injector installation

G080.000.03F

uel system filling

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . ........................................8 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 .......

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 ......

G080.000.05 G083.051.03

Fuelsystem,fueldeliverypumpsupplycheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ..... Fuel duplex filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 .....

G083.101.01

Fuel prefilter priming

G083.101.03

Fuelprefilter,waterandcontaminantsdraining

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 ...

G083.101.09

Fuelprefilter,elementandgasketreplacement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 ...

G083.101.15

Fuel prefilter cleaning

G101.011.01

Exhaust turbocharger, engine operation in event of turbocharger failure

G101.011.05

Exhaustturbochargerconnectionscheck

G120.000.03

Intakeairsystem,intakesideleakanddamagecheck

15345/20 E 00–05

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 .....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 ..... . . . . . . . . . . . . . . . . . . 39

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 ....

Section

G

Task Description

G120.000.05

Intakeairsystem,intakedepressioncheck

G120.000.07

Intake air system check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 ....

G121.051.01

Air filter replacement

G121.052.01

Airfilter,contaminationindicatorpositioncheck

G124.051.01

Charge air manifold, drain water discharge and obstruction check

G124.051.03

Chargeairmanifolddraincleaning

G140.000.01

Exhaust system check

G140.000.03

Exhaust system security check

G140.000.05

Exhaustsystem,exhaustgascolourcheck

G140.000.07

Exhaust system check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 .....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 .....

G140.000.09

Exhaustsystem,exhaustbackpressurecheck

G140.000.11

Exhaustsystemdrainobstructioncheck

G146.000.01

Exhaust system, security and exhaust manifold insulation checks

G172.051.09

Starter condition check

G180.000.01

Engine oil level check

G180.000.03

Engine oil system filling

G180.000.04

Engineoilsampleextractionandanalysis

G180.000.05E

. . . . . . . . . . . . . . . . . . . . . .42 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 .....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 .... . . . . . . . . . . . . . . . . . . . . . . 44 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 .....

ngine change oil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 ......

G180.000.07

Engine oil draining

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 ......

G180.000.09

Corrosion inhibitor oil Filling

G180.000.11

Corrosion inhibitor oildraining

G183.052.03

Engine oil filter replacement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 .....

G183.101.01

Centrifugal oil filter cleaning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 .....

G202.000.01

Engine coolant system filling

G202.000.03

Engine coolant level check

G202.000.05

Enginecoolantsampleextractionandanalysis

G202.000.07

Drain engine coolant

G202.000.09

Engine coolant change

G202.051.01

Enginecoolantpumpreliefborecheck

G202.400.01

Engine coolant preheating

G202.401.01

Enginecoolantpreheatingunitinitialoperation

G202.401.03

Enginecoolantpreheatingunit,switchingon

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ....

G202.401.05

Enginecoolantpreheatingunit,switchingoff

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ....

G202.651.01

Enginecoolantsystem,ventlineobstructioncheck

G203.000.01

Chargeaircoolantsystemfilling

G203.000.03 G203.000.05

Charge air coolant level check Charge air coolant draining

G203.000.07

Chargeaircoolantsampleextractionandanalysis

G203.051.01

Chargeaircoolantpumpreliefborecheck

G203.551.01

Chargeaircoolantsystem,ventlineobstructioncheck

G205.051.01

Enginecoolantcooler,externalelementcontaminationcheck

G205.051.03

Chargeair coolant cooler, external element contamination check

G208.101.01

Breather valve opening

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 .....

G208.101.03

Breather valve closing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 .....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 .....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 ......

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 ... . . . . . . . . . . . . . . . . . . . . . . . . . .62 . . . . . . . . . . . . . . . . . . . . . . . .62 .

15345/20 E 00–05

Section

Task Description

G213.051.01

Generatordrive,drivebeltconditionandtensioncheck

G213.051.05

Generatordrivebeltinstallation/replacement

G213.051.08

Generator condition check

G231.051.01

Engine mount security check

G231.051.03

Enginemountresilientelementcheck

G250.000.01

Drivesystem(drivingend)securitycheck

G252.051.01

Coupling condition check

G303.000.01

Compressedairsystemcondensatedraining

G303.000.03

Compressedairsystem,operatingpressurecheck

G307.001.01

Protective device check

G

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 .....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 .....

G309.001.01

Battery check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 .....

G309.001.03

Battery filling

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 .....

G309.001.05

Battery charge state check

G364.050.01F

uel supply check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 ......

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 ......

G364.200.01

Fuelsupplysystem,shut-offvalveclosing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 ....

G364.200.03

Fuelsupplysystem,shut-offvalveopening

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 ....

G364.200.05

Fuelsupplysystem–fillingintakelinetoengine

G365.000.01

Exhaustsystemcondensatedraining

G365.000.03

Exhaustsystemdrainobstructioncheck

G500.000.01

Enginecontrolsystemswitchingon

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 .....

G500.000.03

Enginecontrolsystemswitchingoff

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 .....

G500.000.07

Enginecontrolsysteminitialoperation

G500.000.09

Engine wiring check

G510.000.01

Monitoringsystem,equipmentfunctioncheck

G510.070.01

Monitoring equipment lamp test

15345/20 E 00–05

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 .....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 ....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 ....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 .....

Section

G

Task Description

15345/20 E 00–05

Task Description

Section

G

Page

1

G000.000.01 Engine Sta rt Disa bling Switch off power supply for Engine Control System at control panel / master switch. Disconnect battery. Shut off fuel supply to engine (G364.000.01). Attach “Danger” sign to control panel / master switch.

G000.000.03 Engine St art Re lease Remove “Danger” sign from control panel / master switch. Connect battery. Open fuel supply to engine (G364.000.03). Switch on power supply for Engine Control System at control panel / master switch.

G000.000.05 Barring Eng ine Man ually Special tools: Engine barring tool No. F6 555 766 Disable engine start (G000.000.01). Install engine barring tool (G030.001.001). Attach ratchet to engine barring tool. Bar engine manually. Note: Apart from the normal compression resistance, there should be no abnormal resistance.

Remove ratchet. Remove engine barring tool (G030.001.03). Release engine start (G000.000.03).

15345/20 E 00–05

Section Page

Task Description

G 2

G000.000.07 Barring Engine with Starting System DANGER Unguarded rotating and moving engine components can cause injury. Risk of fatal injury! After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine. Before barring or starting the engine, ensure that nobody is in the danger zone.

Disconnect plug-in connection (X4) from ECU. Engine start (engine barring) by pressing start button – see G000.000.09. Note: Engine start is automatically interrupted after approx. 5 seconds. If necessary, repeat engine start after approx. 10 seconds.

Screw plug-in connection (X4) to ECU – see G508.000.01.

G000.000.09 Engine Starting DANGER Unguarded rotating and moving engine components can cause injury. Risk of fatal injury! After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine. Before barring or starting the engine, ensure that nobody is in the danger zone.

When the preparatory work has been carried out in accordance with the Operating Instructions (Section C), the engine can be restarted. Note: Always start the engine under no-load conditions.

Carry out engine start procedure. Do not actuate starter for longer than max. 10 seconds. Before repeating a start attempt, wait at least 20 seconds so that the starter cools down. Do not increase engine speed until oil pressure is displayed. Note: If the engine oil pressure is not built up within the time specified in Engine Monitoring, the engine is shut down by the Engine Control System.

Determine cause and rectify.

15345/20 E 00–05

Task Description

Section

G

Page

3

G000.000.11 Engine Warm-up Procedure Operate the engine with load increasing as slowly as possible until an engine coolant temperature of 40 °C has been reached. Note: Operate the engine at full load only after coolant has reached a temperature of 40 C. 

G000.000.13 Engine Speed Check Check idle and full-load speeds.

G000.000.15 Engine Pre ssure Chec ks Check engine oil pressure. Specified values (A000.000.21)

G000.000.17 Engine Temperature Checks Check engine coolant temperature. Specified values (A000.000.21)

G000.000.19 Engine Running Noise Check Run engine at idling speed. Apart from the usual running noises, no abnormal sounds must be heard.

G000.000.21 Engine and External Lines Leak Check DANGER Exhaust gases in closed areas are harmful to health. Risk of poisoning! Ensure that engine room is well ventilated. Repair leaking exhaust pipework immediately.

Run engine under load. Check engine and all pipework for leaks. If leaks are found, shut down engine. When the engine has cooled, rectify the cause. Note: Never tighten lines when under pressure.

15345/20 E 00–05

Section Page

Task Description

G 4

G000.000.23 Engine Shutdown Note: Never shut down engine directly from full-load operation, as this may result in overheating and wear of the engine components.

Before shutting down the engine, run the engine at idling speed until falling and then constant temperatures are indicated. Press engine Shutdown button on driver’s console.

G000.000.25 Emergency Shu tdown Press Emergency Shutdown button on driver’s console.

G000.000.27 Attachments Security Check Exhaust system (G146.000.01) PTO system, driving end (G250.000.01) Engine (G231.051.01)

G000.000.29 Attachments, Hoses a nd Hose Connections Check Check all hoses and hose connections on the engine for condition and leaks. Immediately replace hoses showing signs of scuffing, aging or cracking.

15345/20 E 00–05

Task Description

Section

G

Page

5

G000.000.33 Cylinder Chamber Endoscopic Examination Note: For engines in service, if possible carry out a combustion chamber endoscopic examination after operation under load. Use an endoscope with an adequate light rating and a prism which pivots 95 (5) (total viewing angle 140 ), see –No. 1–. 



If an endoscope with pivoting prism is not available, individual endoscopes with prism settings of, 045 and 90 are required, see –No.II–. 





Max. possible diameter (a): 16 mm.

Before the endoscopic examination: Remove injector (G075.051.01). Bar engine with starting system (G000.000.07). Disable engine start (G000.000.01). Use engine barring tool to turn engine until, for the respective cylinder, – the piston is at BDC for cylinder liner inspection. – the piston is at a position which permits unobstructed and exact inspection of components for inspecting piston crown and cylinder head lower side and valves. – all valves are open or closed for inspection of valves and valve seats.

Endoscopic examination: Connect endoscope to light source (4) and insert it through the cylinder head (fuel injector bore) to the combustion chamber. Use the focussing device (2) to focus the eyepiece (1) and adjuster ring (3) to align the prism (5) with the area under inspection. Visually assess the cylinder liners, piston crowns, underside of the cylinder heads and valves. To do this, rotate the endoscope through 360 ° in each case and set the prism accordingly.

15345/20 E 00–05

Section Page

Task Description

G 6

Assessment Cylinder liners are OK when: – the honing pattern is clearly visible. – no or only locally limited polished areas are evident in the honing structure. – no or only minor scoring is evident (minor scoring can be caused during piston installation). – no or only minor corrosion is evident (film rust after extended out-of-service periods is possible). Piston crowns are OK when: – injector spray pattern is clearly visible. – only minor carbon or oil deposits are evident. – no or only minor corrosion is evident. Cylinder heads and valves are OK when: – only minor carbon or oil deposits are evident. – no or only minor corrosion is evident. – only minor pitting is evident on valves and valve seats. – the valves close fully. Note: If extensive wear or damage due to mechanical, chemical or thermal action is found, or the inspection results are otherwise suspect: remove the affected cylinder heads and recheck, repair or replace the individual components as necessary.

After the endoscopic examination Remove engine barring tool (G030.001.03). Install injector (G075.051.09). Release engine start (G000.000.03).

15345/20 E 00–05

Task Description

Section

G

Page

7

G000.000.39 Cleaning Engine Externally WARNING When working with high-pressure and steam jets, never aim at persons, animals, electrical or electronic equipment. Risk of injury and scalding! Wear protective clothing,protective gloves and protective goggles / safety mask.

When removing deposits and / or cleaning, use only non-chemical cleaning agents which do not damage light-alloy, non-ferrous, steel, gray cast iron and elastomers. Clean the engine only at places where there is an appropriate oil separator (environmental protection). Before using the H.P. cleaner or steam jet, read the respective operating instructions, paying particular attention to safety instructions. For cleaning externally with the H.P. jet, use only a flat-jet nozzle.

Carry out external cleaning as follows: Disable engine start (G000.000.01).

To loosen dirt: Spray on a thin coating of cleaning agent and allow 1 to 5 minutes, depending on the degree of contamination, for it to react.

To remove dirt: Use the H.P. jet to spray off the loosened dirt. Note: During exterior engine cleaning with a high-pressure cleaner or steam jet, the jet pressure must not exceed 100 bar (1450 PSI).

Do not go any closer than 20 cm (8 inches) to the object that is being sprayed. The temperature of the cleaning agent must not rise above a max. of 80 °C (176 °F). Note: Moisture penetrating electrical components (temperature transmitter, pressure transmitter, terminal) may lead t o malfunctions and engine failure.

Release engine start (G000.000.03).

15345/20 E 00–05

Section Page

Task Description

G 8

G018.101.03 Crankcase Ventilation, Oil Sep arator Check Release clamps, fit rubber sleeve on pipe.

Release clamps, fit rubber sleeves on vent lines.

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Fit 4 hex screws. Remove oil separator, clamps, washers and spacer sleeves.

Release clamp, turn guide sleeve to withdraw guide sleeve from oil separator and dispose of oil separator.

Disposal of Hazardous Materials Fluids and lubricants (e.g. oils, greases, treated engine coolant, fuels), cleaning agents and numerous auxiliary materials are an environmental hazard and therefore constitute hazardous materials. When disposing of these hazardous materials, always follow the manufacturer’s instructions, general environmental protection regulations and local legal specifications. Under no circumstances must even small amounts of hazardous materials be allowed to drain into water, or be discarded or disposed of outdoors. Leaked hazardous materials must immediately be absorbed with suitable bonding agents and disposed of in accordance with regulations in appropriate vessels. The contents of these containers must be specified.

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Note: Before installing oil separator, check whether O-ring is installed in oil separator.

Coat guide sleeve and O-ring (see arrow) with ethanol. Press guide sleeve as far as it will go into new oil separator and tighten clamp.

Coat guide sleeve and rubber sleeve with ethanol. Insert guide sleeve (see arrow) into rubber sleeve. Install oil separator, clamp, washer, spacer sleeve and hex screw on bracket, but tighten only lightly.

Align oil separator and fit remaining rubber sleeves on the respective connections. Tighten all clamps.

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G030.001.01 Engine Barring Tool Installation Special tools: Engine barring tool No. F6 555 766 Disable engine start (G000.000.01). Remove cover from flywheel housing. Engage engine barring tool (1) with ring gear (2) and attach to flywheel housing.

G030.001.03 Engine Barring Tool Removal Remove engine barring tool from flywheel housing. Screw cover to flywheel housing. Release engine start (G000.000.03).

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G055.000.01 Valve Gear Oil Supply Check WARNING With the engine running, hot oil emerges at the rocker arm bearings under high pressure. Risk of eye injury and burning! Run engine only when cylinder head covers are installed.

Shut down engine (G000.000.23). Disable engine start (G000.000.01). Remove cylinder head cover (G055.101.01). Check that the rocker arms and the cylinder head cover (inside) are coated with oil. Install cylinder head cover (G055.101.03). Release engine start (G000.000.03).

G055.000.03 Valve Gear Lubrication Note: The oil chambers must be filled with oil during initial operation, extended out-of-service periods and after cleaning valve gear.

Disable engine start (G000.000.01). Remove cylinder head cover (G055.101.01). Fill oil chambers of the valve bridges with oil. Fill oil chambers of the rocker arms and adjusting screws with oil. Install cylinder head cover (G055.101.03). Release engine start (G000.000.03).

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G055.050.01 Valve Clearance Check Special tools: – Valve clearance adjusting gauge: – Engine barring tool:

Y2 0010 128 F6 555 766

Note: Check with the valve closed and when coolant temperature does not exceed 40 C. 

Disable engine start (G000.000.01). Remove cylinder head cover (G055.101.01). Install engine barring tool (G030.001.01).

Checking valve clearance in two crankshaft positions Bar crankshaft with barring tool in engine direction of rotation until marking TDC-A1 and arrow on flywheel housing are aligned.

Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC, cylinder A1) as per the diagram shown. The crankshaft must be turned in the engine direction of rotation. If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. 1 = Firing TDC for cylinder A1 If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC. 2 = Overlap TDC for cylinder A1 X = Exhaust valve O = Inlet valve

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G 14

Inlet valves: long rocker arm. Exhaust valves: short rocker arm. Valve clearance (A055.050.01). Use feeler gauge to check distance between valve bridge and rocker arm. If deviation from specified value is more than 0.05 mm, adjust valve clearance (G055.050.03). Note: It must be possible to just pull the feeler gauge through the gap.

Remove engine barring tool (G030.001.03). Install cylinder head cover (G055.101.03). Release engine start (G000.000.03).

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G055.050.03 Valve Clearance Adjustment (Valve Bridge with Adjusting Screw M16 (Locknut 24 AF)) Note: Before starting adjustment, it is essential to check whether the valve bridges are provided with adjusting screw M16 (locknut 24 AF) or adjusting screws M12 (locknut 19 AF). Then select the appropriate Task Description.

Special tools: – Valve clearance adjusting gauge: – Retaining device: – Engine barring tool:

Y2 0010 128 F6 557 950 F6 555 766

Adjust with the valve closed and when coolant temperature does not exceed 40 C: 

Note: Before valve clearance is adjusted, it is essential that the valve bridge be checked.


Adjusting valve clearance in two crankshaft positions. Bar crankshaft with barring tool in engine direction of rotation until marking TDC-A1 and arrow on flywheel housing are aligned.

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Checking valve bridge adjustment Use feeler gauge to determine distance between valve bridge and rocker arm. Note: It must be possible to just pull the feeler gauge through the gap.

Place feeler gauge with determined value between valve bridge and valve stem (B). Using a second feeler gauge, measure distance between opposite valve stem and valve bridge (A). A feeler gauge thicker / thinner by more than 0.05 mm must not fit. The valve bridge must be adjusted if deviation from determined value (B) to (A) valve stem end to valve bridge is greater than 0.05 mm.

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Adjusting valve bridge

CAUTION To release the locknut, the valve bridge must be held firmly with the retaining device, otherwise the valves will be deformed. Install retaining device. Insert locating pin of retaining device into oil bore of valve bridge. Note: The locating pin can be inserted into the valve bridge oil bore only when the valves are closed / unloaded.

Release locknut.

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Withdraw locating pin of retaining device from oil bore of valve bridge.

Place a feeler gauge of determined distance between valve bridge and valve stem (A) and (B), e.g. 0.20 mm. The valve bridge must be adjusted so that both feeler gauges can just be pulled through. Hold adjusting screw securely in position with Allen key and fit locknut by hand on valve bridge. Insert locating pin of retaining device into oil bore of valve bridge. Note: The locknut and adjusting screw must be free to move.

Use torque wrench to tighten locknut, holding adjusting screw firmly with Allen key. The adjusting screw must not turn. Tightening torque = 90 Nm + 9 Nm Lubricant = Engine oil Withdraw locating pin of retaining device from oil bore of valve bridge.

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Again check valve bridge adjustment. Remove retaining device.

CAUTION Before barring the engine, the retaining device must be removed, otherwise with a secured valve bridge the valve gear or retaining device will be damaged.

Valve clearance adjustment Inlet valves: long rocker arm. Exhaust valves: short rocker arm. Valve clearance, see (A055.050.01). Release locknut (1) and slightly unscrew adjusting screw (2) with Allen key. Insert feeler gauge between valve bridge and rocker arm. Set adjusting screw so that feeler gauge just passes through gap when locknut is tightened. Tighten locknut with torque wrench, holding adjusting screw firm. Note: The locknut and adjusting screw must be free to move.

Tightening torque = 90 Nm + 9 Nm Lubricant = Engine oil Recheck valve clearance. Remove engine barring tool (G030.001.03). Install cylinder head cover (G055.101.03). Release engine start (G000.000.03).

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G055.050.03 Valve Clearance Adjustment (Valve Bridge with Adjusting Screw M12 (Locknut 19 AF)) Note: Before starting adjustment, it is essential to check whether the valve bridges are provided with adjusting screw M16 (locknut 24 AF) or adjusting screws M12 (locknut 19 AF). Then select the appropriate Task Description.

Special tools: – Valve clearance adjusting gauge: – Engine barring tool:

Y2 0010 128 F6 555 766

Adjust with the valve does not exceed 40 C: closed and when coolant temperature 

Note: Before valve clearance is adjusted, it is essential that the valve bridge be checked.


Adjusting valve clearance in two crankshaft positions Bar crankshaft with barring tool in engine direction of rotation until marking TDC-A1 and arrow on flywheel housing are aligned.


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Checking valve bridge adjustment Use feeler gauge to determine distance between valve bridge and rocker arm. Note: It must be possible to just pull the feeler gauge through the gap.

Place feeler gauge with determined value between valve bridge and valve stem (B). Using a second feeler gauge, measure distance between opposite valve stem and valve bridge (A). A feeler gauge thicker / thinner by more than 0.05 mm must not fit. The valve bridge must be adjusted if deviation from determined value (B) to (A) valve stem end to valve bridge is greater than 0.05 mm.

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Adjusting valve bridge

CAUTION When releasing the locknut, the valve bridge must be held firmly, as otherwise the valves will be bent. Hold valve bridge (1) firmly in position with open-end wrench and release locknut (2).

Place a feeler gauge of determined distance between valve bridge and valve stem (A) and (B), e.g. 0.20 mm. The valve bridge must be adjusted so that both feeler gauges can just be pulled through. Hold adjusting screw securely in position with Allen key and fit locknut by hand on valve bridge. Note: The locknut and adjusting screw must be free to move.

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Using torque wrench, tighten locknut (2); for this purpose hold valve bridge (1) in position with open-end wrench. Tightening torque = 35 Nm + 5 Nm Lubricant = Engine oil

Again check valve bridge adjustment.

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G 24

Valve clearance adjustment Inlet valves: long rocker arm. Exhaust valves: short rocker arm. Valve clearance, see (A055.050.01). Release locknut (1) and slightly unscrew adjusting screw (2) with Allen key. Insert feeler gauge between valve bridge and rocker arm. Set adjusting screw so that feeler gauge just passes through gap when locknut is tightened. Tighten locknut with torque wrench, holding adjusting screw firm. Note: The locknut and adjusting screw must be free to move.

Tightening torque = 90 Nm + 9 Nm Lubricant = Engine oil Recheck valve clearance. Remove engine barring tool (G030.001.03). Install cylinder head cover (G055.101.03). Release engine start (G000.000.03).

G055.101.01 Cylinder Head Cover Removal WARNING With the engine running, hot oil emerges at the rocker arm bearings under high pressure. Risk of eye injury and burning! Run engine only when cylinder head covers are installed.

Disable engine start (G000.000.01). Remove screws. Remove cylinder head cover from cylinder head.

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G055.101.03 Cylinder Head Cover Installation Clean mating faces. Check that profile gasket in cylinder head cover is in perfect condition, replace if necessary. Place cylinder head cover on cylinder head. Insert screws with washers and tighten with torque wrench. Tightening torque = 42 Nm Lubricant = Engine oil Release engine start (G000.000.03).

G073.051.07 High-Pressure Pump, Relief Bor e Obstruction Check Check relief bore for oil and fuel discharge (visual inspection). Clean the bore if it is contaminated. Note: Replace H.P. fuel pump if oil and/or fuel emerges from the relief bore.

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G 26

G075.051.01 Injector Removal WARNING Fuels are combustible. Fire hazard! When working on the fuel system: no naked flame no electrical sparks do not smoke do not spill fuel. Note: The fuel injectors can only be replaced completely, as the injection nozzle can only be replaced at MTU.

Special tools: – Extractor sleeve for injector: – Extractor:

F3 0377 769 F6557991

Disable engine start (G000.000.01). Shut off fuel supply to engine (G364.000.01). Remove cylinder head cover (G055.101.01). Remove fuel return line on cylinder head and on fuel collecting line. Note: Fuel must not penetrate the cylinder chamber.

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Release the cable terminal threaded connection on the injector and remove cable terminals.

Remove screw (1) together with hold-down clamp (2).

Unscrew H.P. fuel line (2) from injector (1) and connector (limiting valve) (3) and remove H.P. line. Note: The H.P. line must not be bent.

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Task Description

Place extractor sleeve section 1 (4) on injector (1). Fit section 2 (2) over section 1 and turn to correct position – see next illustration. Secure section 2 with hex nut (3).

Starting point for section 2 (2) is position “a” (2 o’clock) End point is position “b” (12 o’clock).

Screw threaded rod (3) into extractor sleeve (5) and secure with hex nut (4). Place extractor (2) on cylinder head. Turn nut (1) clockwise to withdraw injector. Remove special tool. Remove injector manually.

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Remove CE support ring (1) from injector or use wire hook to remove from cylinder head. Remove O-rings (2) from injector. Cover all connections and bores, or seal with suitable plugs. Note: Fuel must not penetrate the cylinder.

G075.051.05 Injector Replacement WARNING Fuels are combustible. Fire hazard! When working on the fuel system: no naked flame no electrical sparks do not smoke do not spill fuel.

Remove injectors (G075.051.01). Install injectors (G075.051.09). Note: The fuel injectors for replacement can be ordered from MTU.

G075.051.09 Injector Installation WARNING Fuels are combustible. Fire hazard! When working on the fuel system: no naked flame no electrical sparks do not smoke do not spill fuel.

Special tools: – Press-fitting lever for injector: – Press-fitting sleeve for injector: – Lever:

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F6 557 952 F3 0378 403 F6 555 197

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Coat new O-rings with petroleum jelly and fit on injector.

Check sealing surface on cylinder head (heat protection sleeve) for contamination, clean if necessary. Fit new CE Ring (2) with grease on injector (1).

Ensure that CE ring is correctly positioned.

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Note: Before installation, remove all plugs and covers.

Insert fuel injector (1) into cylinder head, ensuring the H.P. line connection is correctly aligned. Fit press-fitting sleeve (2).

Lock press-fitting tool (1) between pushrods. Release palm grip (3) and move pressure element (2) to correct position for press-fitting sleeve. Secure palm grip and press injector (4) with press-fitting tool into cylinder head. Remove press-fitting tool.

Install hold-down clamp (2), positioning correctly, and fit hex screw (1) by hand.

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Task Description

Tighten screw of hold-down clamp with torque wrench. Tightening torque: 5 Nm to 10 Nm Lubricant = Engine oil

Coat new O-ring (2) with petroleum jelly and fit on H.P. line (3). Install H.P. line (3) at injector (1) and connector (limiting valve) (4). Note: The H.P. line must not be bent. Ensure that the installation position is correct.

Using torque wrench, tighten H.P. line (2) at injector (1) and connector (limiting valve) (3). Tightening torque: 5 Nm to 10 Nm Lubricant = Engine oil Note: The H.P. line must not be bent. Ensure that the installation position is correct.

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Tighten hex screw of hold-down clamp with torque wrench. Tightening torque: 100 Nm + 10 Nm Lubricant = Engine oil

Using torque wrench, tighten threaded connection of H.P. line at injector (1) and connector (limiting valve) (2). Tightening torque: 100 Nm + 10 Nm Lubricant = Engine oil Note: The H.P. line must not be bent. Ensure that the installation position is correct.

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Fit cable terminals below the screws on injector and tighten. Tightening torque: 1.0 Nm +/– 0.2 Nm Install cylinder head cover (G055.101.03).

Attach fuel return line between cylinder head and manifold and tighten. Open fuel supply to engine (G364.000.03). Release engine start (G000.000.03).

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G080.000.03 Fuel System Filling WARNING Fuels are combustible. Fire hazard! When working on the fuel system: no naked flame no electrical sparks do not smoke do not spill fuel.

Special tools: Filling device: B8 0144 852 On initial operation/restart or after a fuel filter change, the L.P. fuel system must be refilled. Disable engine start (G000.000.01). Fill L.P. fuel system. Remove flushing line (1) from the H.P. pump (3) and release from filter block (2). Connect the fuel return hose of the filling device to the H.P. pump (3). Connect the filling device fuel supply to connection (P) of the filter block. NOTE: When filling, a fuel pressure of between 0.5 and 1.5 bar must be achieved.

The fuel system is filled by the hand pump until bubble-free fuel is seen to emerge in the fuel return hose.

Filling device Fuel supply (1) Fuel return (2)

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G 36

Remove fuel return hose from the H.P. pump (3). Screw flushing line (1) onto the H.P. pump (3) and filter block (2) and tighten. Remove the filling device fuel supply from connection (P) of the filter block. Seal filling connection (P) with blanking plug and tighten. Release engine start (G000.000.03). The H.P. system is filled when the engine is started.


G080.000.05 Fuel System, Fuel Delivery Pump Supply Check Connect pressure gauge before fuel delivery pump. Run engine at full load and read off pressure gauge. Specified value, see (A000.000.21). Remove pressure gauge.

G083.051.03 Fuel Duplex Filter Replacement WARNING Fuels are combustible. Fire hazard! When working on the fuel system: no naked flame no electrical sparks do not smoke do not spill fuel.

Special tools: Strap wrench F3 0006 199

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Remove filter and dispose of in accordance with local regulations. Clean sealing surface at connector. Check sealing ring of new filter and moisten with fuel. Install filter and tighten by hand. Replace second filter in same way.


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G083.101.01 Fuel Pref ilter Primi ng Fuel prefilter not supplied by MTU. See Operating Instructions of Plant Manufacturer.

G083.101.03 Fuel Prefilter, Water and Conta minants Drainin g Fuel prefilter not supplied by MTU. See Operating Instructions of Plant Manufacturer.

G083.101.09 Fuel Prefilter, Element and Gask et Replacement WARNING Fuels are combustible. Fire hazard! When working on the fuel system: no naked flame no electrical sparks do not smoke do not spill fuel.

Fuel prefilter not supplied by MTU. See Operating Instructions of Plant Manufacturer.

G083.101.15 Fuel Prefi lter Clean ing WARNING Fuels are combustible. Fire hazard! When working on the fuel system: No open flame, no electrical sparks. Do not spill fuel.

Close fuel supply. Remove nuts from filter head. Remove filter bowl and drain fuel into a suitable container. Remove securing nut for filter element and remove filter element from below.

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Using a clean brush, flush out filter element in clean fuel. Flush out filter bowl with clean fuel. Insert filter insert in filter bowl and secure with the nut. Insert new sealing ring in groove in filter head. Mount filter bowl taking care not to damage sealing ring. Tighten nuts diagonally and evenly. Fuel supply opening.

G101.011.01 Exhaust Turbocharger, Engine Operation in Event of Turbocharger Failure In the event of turbocharger failure, determine the cause and assess whether the engine can continue in operation without risk. If, in the event of turbocharger failure (e.g. if rotor is seized), the engine must continue in operation, run the engine only under partial load. Run the engine in this condition only until it is possible to replace or repair the turbocharger.

G101.011.05 Exhaust Turbocharger Connections Check Check exhaust connections for leaks.

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Check oil supply and return lines for leaks.

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G120.000.03 Intake Air System , Intake Si de Leak and Damage Check Check intake side of engine for condition and leaks with the engine running.

G120.000.05 Intake Air System, Intake Depression Check Connect U-pipe pressure gauges to turbocharger air intake housings. Run engine at full load and read off indicated pressures. Specified value, see (A000.000.21). Remove U-pipe pressure gauges.

G120.000.07 Intake Ai r Syst em Che ck Check that cover is removed. Check for cleanliness. Disable engine start (G000.000.01). Remove guard and loose material on intake housing or air filter. Release band clamp. Remove air filter from intake housing. Mount new air filter on intake housing. Tighten band clamp. Release engine start (G000.000.03).

G121.051.01 Air Fil ter Rep lacement Disable engine start (G000.000.01). Remove guard and loose material on intake housing or air filter. Remove contamination indicator (4). Release clamp (2). Remove air filter (3) and dispose of in accordance with local regulations. Clean connection on air flow control flap housing (1). Install new air filter with clamp. Install contamination indicator with reset signal ring (G121.052.01). Release engine start (G000.000.03).

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G121.052.01 Air Filter, Contamination Indicator Positio n Check Check Check position of signal ring (1) (visual check). If signal ring is fully visible, replace air filter (G121.051.01).

Reset Press reset button (2) to return signal ring to normal position.

G124.051.01 Charge Air Manifold , Drain Wa ter Discha rge and Obstru ction Chec k WARNING Engine noise above 85 dB(A). Risk of damage to hearing! Wear ear protectors.

Engine coolant is hot and under pressure. Risk of injury! Wear protective gloves.

Coolant discharge check If the coolant is continuously discharged and the coolant level falling, the intercooler is leaking. If a leaking intercooler cannot be repaired immediately, before starting the engine: – Remove injection nozzles (G075.051.01). – Bar engine manually (G000.000.05). – Bar engine with starting system (G000.000.07) and blow out combustion chambers. Note: If the intercooler is leaking, activate engine only in an emergency.

Obstruction check Note: Check drain bore on engine A and B sides.

With the engine running, oil-containing air must emerge at the drain bore.

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G124.051.03 Charge Air Manifold Drain Cleaning CAUTION Compressed air is air compressed under pressure. Risk of injury! If compressed air is used for blowing out or blow-drying components, always wear protective goggles or safety mask. Compressed air must not be aimed at parts of the body. The pressure must not exceed 3.0 bar.

Disable engine start (G000.000.01). Clean drain bore, blow out with compressed air and check for obstructions. Note: Clean and check drain bore on engine A and B sides.


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G 44

G140.000.01 Exhaust Syste m Chec k Check engine exhaust system (visual inspection) for leaks and damage.

G140.000.03 Exhaust System Security Check When the engine is cold, check tightness of securing screws by torque wrench application.

G140.000.05 Exhaust System, Exhaust Gas Colour Check Exhaust gases light grey: good combustion. Exhaust gases black: incomplete combustion. Exhaust gases blue: excessive engine oil in combustion chamber. Exhaust gases white: unburnt fuel.

G140.000.07 Exhaust Syste m Chec k Check that cover is removed. Check for cleanliness.

G140.000.09 Exhaust System, Exhaust Backpressure Check Connect U-pipe pressure gauge to exhaust manifold. Run engine at full load and read off indicated pressures. Specified value, see (A000.000.21). Remove U-pipe pressure gauges.

G140.000.11 Exhaust System Drain Obstruction Check Check and drain exhaust system. (If drain is provided.)

G146.000.01 Exhaust System , Security and Exha ust Manifo ld Insulat ion Check s Check tightness of the exhaust system securing screws (after engine) by torque wrench application and the insulation for damage by visual inspection.

G172.051.09 Starter Con dition Che ck Disable engine start (G000.000.01). Check starter for mechanical damage. Check security of starter securing screws. Check security and condition of all cable connections. Check all electric cables for damage. Release engine start (G000.000.03).

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G180.000.01 Engine Oi l Lev el Che ck Checking before starting engine Withdraw dipstick from guide tube and wipe. Carry out oil level check. Engine oil must be between Min. and Max. marks. If necessary, top up oil to Max. mark. Insert dipstick in guide tube.

Checking after engine shutdown Remove the oil dipstick from the guide tube 5 minutes after engine shutdown. Engine oil must be between Min. and Max. marks. If necessary, top up oil to Max. mark. Insert dipstick in guide tube.

G180.000.03 Engine Oil Sy stem Filli ng Note: Always use MTU-approved engine oil, see MTU Fluids and Lubricants Specification.

Turn cover counterclockwise until the cover of the oil filler neck can be removed. Pour engine oil in at oil filler neck up to Max. mark on oil filler neck. Start engine and run at idle for approx. 1 to 2 minutes. Shut down engine and after approx. 5 minutes withdraw dipstick from guide tube and wipe. Carry out oil level check. Engine oil must be between Min. and Max. marks. If necessary, top up oil to Max. mark. Note: Do not fill engine oil above the Max. mark.

Insert dipstick in guide tube. Reinstall oil filler neck cover.

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G180.000.04 Engine Oil Sample Extraction and Analysis DANGER Engine oil is hot and can contain combustion residues which are harmful to health. Risk of injury! Wear protective gloves. Avoid extended and intensive contact with skin. Do not inhale oil vapour.

Open shut-off cock with engine running and engine at operating temperature. Drain approx. 2 litres of engine oil into a container in order to flush out the oil sludge in the shut-off cock. Drain approx. 1 litre of engine oil coolant into a clean container. Using equipment and chemicals from the MTU Test Kit, inspect the engine oil for dispersion capability (spot test), coolant content and fuel dilution – see Publication for MTU Test Kit.


G180.000.05 Engine Oil Change Disable engine start (G000.000.01). Drain engine oil (G180.000.07). Replace engine oil filter (G183.052.03). Pour in new engine oil (G180.000.03). Release engine start (G000.000.03). Note: After each engine oil change and filter replacement, bar the engine with the starting system (G000.000.07).

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G180.000.07 Engine Oil Dra ining DANGER Engine oil is hot and can contain combustion residues which are harmful to health. Risk of injury! Wear protective gloves. Avoid extended and intensive contact with skin. Do not inhale oil vapour.

Note: Drain engine oil with the engine at operating temperature.

Provide a suitable container in which to collect and dispose of the engine oil. Drain engine oil from the oil pan at the oil drain plug. Install oil drain plug with a new sealing ring.

Drain remaining oil from equipment carrier. Install oil drain plug with a new sealing ring.

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G 48


G180.000.09 Corrosion Inhibitor Oil Filling Note: Always use only approved corrosion inhibitor oil – see MTU Fluids and Lubricants Specifications.

Fill engine with corrosion inhibitor oil in same way as engine oil (G180.000.03).

G180.000.11 Corrosion Inhibitor Oil Draining DANGER Engine oil is hot and can contain combustion residues which are harmful to health. Risk of injury! Wear protective gloves. Avoid extended and intensive contact with skin. Do not inhale oil vapour.

Drain corrosion inhibitor oil in same way as engine oil (G180.000.07). Note: Drain the corrosion inhibitor oil with the engine at operating temperature.

G183.052.03 Engine Oil Filter Replacement DANGER Engine oil is hot and can contain combustion residues which are harmful to health. Risk of injury! Wear protective gloves. Avoid extended and intensive contact with skin. Do not inhale oil vapour.

Special tools: Oil filter key F3 0379 104

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Disable engine start (G000.000.01). Use oil filter key to unscrew. Drain remaining oil out of the filters into a container. Clean sealing surface at connector. Check sealing ring of new engine oil filter and coat with oil. Install new engine oil filter and tighten by hand. Replace other engine oil filters in same way. Release engine start (G000.000.03).


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G183.101.01 Centrifugal Oil Filter Cleaning DANGER Engine oil is hot and can contain combustion residues which are harmful to health. Risk of injury! Wear protective gloves. Avoid extended and intensive contact with skin. Do not inhale oil vapour.

Disable engine start (G000.000.01). Release nut. Release band clamp.

Remove band clamp. Remove housing cover. Remove sealing ring.

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Carefully remove complete rotor from housing. Drain oil.

Note: The rotor must not be clamped in a vice.

Release knurled nut on rotor cap. Press out rotor lower section downwards.

Carefully remove rotor cap from standpipe. Remove sealing ring.

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Task Description

G 52

CAUTION Compressed air is air compressed under pressure. Risk of injury! If compressed air is used for blowing out or blow-drying components, always wear protective goggles or safety mask. Compressed air must not be aimed at parts of the body. The pressure must not exceed 3.0 bar.

Remove insertion sleeve. Assess the layer thickness and weight of the oil residues on the sleeve and compare to the values noted during the previous check. Note: Layer thickness max 20 mm (approx. 1800 gr.)

If the two values deviate greatly, the oil must be changed. Perform the next oil change earlier than scheduled. Clean rotor cap, standpipe and rotor base. Wash components, blow out with compressed air. Insert new insertion sleeve.

Assemble rotor cap and standpipe. Insert new sealing ring and fit on rotor lower section. Tighten knurled nut.

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Task Description

Section

G

Page

53

Insert rotor in housing lower section. Fit new sealing ring. Mount housing cover. Tighten nut. Tighten band clamp. Release engine start (G000.000.03). When the engine is again started, check the centrifugal oil filters for leaks.


15345/20 E 00–05

Section Page

Task Description

G 54

G202.000.01 Engine Coolant System Filling WARNING Coolant is hot and under pressure. Risk of injury! Wear protective gloves.

Open breather valve (G208.101.01), so that the air can escape from the engine when the coolant system is filled.

Note: Always use only treated coolant in accordance with MTU Fluids and Lubricant Specifications. Never pour cold coolant into a hot engine. If, in an emergency, untreated water is used to top up the coolant system, the coolant concentration must be checked and rectified at the earliest opportunity.

Connect suitable hose to the drain valve (arrow). Open drain valve and pour in engine coolant via the hose. Close drain valve. Check engine coolant level (G202.000.03). Close breather valve (G208.101.03). Run engine a number of minutes at idling speed. Check engine coolant level (G202.000.03).

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Task Description

Section

G

Page

55

G202.000.03 Engine Coolant Level Check Note: The Min. coolant level is automatically monitored by the engine control system.

Via level sensor Switch on engine control system (G500.000.01) and check indicator.

WARNING Coolant is hot and under pressure. Risk of injury! Wear protective gloves.

Note: Always use only treated coolant in accordance with MTU Fluids and Lubricant Specifications. Never pour cold coolant into a hot engine. If, in an emergency, untreated water is used to top up the coolant system, the coolant concentration must be checked and rectified at the earliest opportunity.

Open breather valve of coolant expansion tank (G208.101.01). If fluid is too low, add only treated coolant – see (G202.000.01). Close breather valve (G208.101.03).

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Section Page

Task Description

G 56

G202.000.05 Engine Coolant Sample Extraction and Analysis WARNING Coolant is hot and under pressure. Risk of injury! Wear protective gloves.

Disable engine start (G000.000.01). Open drain valve. Drain a small quantity of coolant to flush the drain point. Drain approx. 1 litre of engine coolant into a clean container. Close drain valve. Check engine coolant level (G202.000.03). Using the equipment and chemicals in the MTU Test Kit, examine the coolant for: – antifreeze – corrosion inhibitor – pH value See MTU Test Kit instructions. Change engine coolant according to the coolant operating times in the Fluids and Lubricants Specification A001061. Release engine start (G000.000.03).

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Task Description

Section

G

Page

57

G202.000.07 Drain Eng ine Co olant WARNING Coolant is hot and under pressure. Risk of injury! Wear protective gloves.

Disable engine start (G000.000.01). Note: Drain engine coolant when engine has cooled.

Open breather valve (G208.101.01). Provide a suitable container to collect and dispose of the coolant. Open lower drain valve on coolant inlet elbow and drain coolant. Drain residual coolant from engine via the upper drain point on crankcase (A and B sides). Seal all drain points. Close breather valve (G208.101.03). Dispose of engine coolant.


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Section Page

Task Description

G 58

G202.000.09 Engine Co olant Cha nge WARNING Coolant is hot and under pressure. Risk of injury! Wear protective gloves.

Drain engine coolant (G202.000.07). Fill engine coolant system (G202.000.01).


G202.051.01 Engine Coolant Pump Relief Bore Check Check relief bore for oil and coolant discharge (visual inspection). Clean the relief bore if it is dirty. Note: If oil and / or coolant emerge from the relief bore, repair the engine coolant pump.

G202.400.01 Engine Coolant Preheating Switch on preheating unit. Check function of coolant circulating pump. Preheat engine coolant to preheat temperature (A000.000.21).

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Task Description

Section

G

Page

59

G202.401.01 Engine Coolant Preheating Unit Initial Op eration Engine coolant preheating unit not supplied by MTU. Carry out tasks as specified by Manufacturer.

G202.401.03 Engine Coolant Preheating Unit, Switching On Switch on preheating unit. Check function of coolant circulating pump. Carry out tasks as specified by Manufacturer.

G202.401.05 Engine Coolant Preheating Unit, Switch ing Off Switch off preheating unit. Carry out tasks as specified by Manufacturer.

G202.651.01 Engine Coolant Sy stem, Vent Line Obs truction Check

CAUTION Compressed air is air compressed under pressure. Risk of injury! If compressed air is used for blowing out or blow-drying components, always wear protective goggles or safety mask. Compressed air must not be aimed at parts of the body. The pressure must not exceed 3.0 bar.

Remove vent lines and blow out with compressed air. Install vent lines.

G203.000.01 Charge Air Coolant System Filling Note: Always use treated engine coolant corresponding to MTU Fluids and Lubricants Specification.

Open breather valve (G208.101.01). Pour in treated engine coolant via filler neck. Check charge air coolant level (G202.000.03). Close breather valve (G208.101.03). Run engine a number of minutes at idling speed. Check charge air coolant level (G202.000.03).

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Section Page

Task Description

G 60

G203.000.03 Charge Air Coolant Level Check Note: The “Min.” coolant level is automatically monitored by the Engine Control System.

Via level sensor Switch on engine control system and check display. Manual coolant level checking see Alternator Manufacturer’s operating instructions.

WARNING Coolant is hot and under pressure. Risk of injury! Wear protective gloves.

Open breather valve of coolant expansion tank (G208.101.01). Coolant expansion tank is not supplied by MTU. In event of drop in coolant level only fill with treated engine coolant. Note: Never pour cold coolant into a hot engine. If, in an emergency, untreated water is used to top up the coolant system, the coolant concentration must be checked and rectified at the earliest opportunity.

Close breather valve (G208.101.03).

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Task Description

Section

G

Page

61

G203.000.05 Charge Air Coolant Draining WARNING Coolant is hot and under pressure. Risk of injury! Wear protective gloves.

Disable engine start (G000.000.01). Note: Drain engine coolant when engine has cooled.

Open breather valve (G208.101.01). Provide a suitable container to collect and dispose of the coolant. Drain coolant via drain points from cooling system – see Alternator Manufacturer’s Operating Instructions. Seal all drain points. Dispose of coolant.


G203.000.07 Charge Air Coola nt Sample Extraction and Analysis Disable engine start (G000.000.01). Open blanking plug. By means of the blanking union, drain approx. 1 litre coolant into a clean container. Close blanking plug. Check charge air coolant level (G203.000.03). Using the equipment and chemicals in the MTU Test Kit, examine the coolant for: – antifreeze – corrosion inhibitor – pH value See MTU Test Kit instructions. Change engine coolant according to the coolant operating times in the Fluids and Lubricants Specification A001061. Release engine start (G000.000.03).

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Section Page

Task Description

G 62

G203.051.01 Charge Air Coolant Pump Relief Bore Check Check relief bore for oil and coolant discharge (visual inspection). Clean the relief bore if it is dirty. Note: If oil and / or coolant emerge from the relief bore, repair the charge air coolant pump.

G203.551.01 Charge Air Coolan t System, Vent Line Obs truction Check Vent lines not supplied by MTU. Carry out tasks as specified by Manufacturer.

G205.051.01 Engine Coolant Coole r, External Eleme nt Contamin ation Chec k Coolant cooler is not supplied by MTU. Carry out tasks as specified by Manufacturer.

G205.051.03 Charge Air Coolant Coole r, External Elemen t Contamina tion Check Coolant cooler is not supplied by MTU. Carry out tasks as specified by Manufacturer.

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Task Description

Section

G

Page

63

G208.101.01 Breather Valve Opening WARNING Coolant is hot and under pressure. Risk of injury! Wear protective gloves.

Disable engine start (G000.000.01). Turn breather valve counterclockwise to first stop. Allow pressure to escape. Continue to turn breather valve counterclockwise and remove.

G208.101.03 Breather Valve Closing Check that breather valve is in perfect condition. Clean sealing surfaces. Fit breather valve and turn clockwise as far as it will go. Release engine start (G000.000.03).

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Section Page

Task Description

G 64

G213.051.01 Generator Drive , Drive Belt Con dition an d Tension Check DANGER Unguarded rotating and moving engine components can cause injury. Risk of fatal injury! After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine. Before barring or starting the engine, ensure that nobody is in the danger zone.

Special tools: V-ribbed belt tension tester

Condition check Disable engine start (G000.000.01). Remove guard plate. Check V-ribbed belts for cracks, oil, overheating and wear; clean or replace as necessary. NOTE: Solvents such as petroleum or benzol must not be used. Sharp-edged objects are not cleaning agents.

Damage pattern of V-ribbed belts. Normal wear. One or two cracks in the rib, measuring approx. 25 mm (1 inch), usually appear after long-term use; the V-ribbed belts can continue to be used.

F2130001 0a

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Task Description

Section

G

Page

65

The V-ribbed belts must be replaced if the ribs are broken around the entire circumference.

F2130002 0a

The V-ribbed belt must be replaced immediately if the ribbed material has broken through and the ribs are broken around the entire circumference.

F2130003 0a

Tension check Position the V-ribbed belt tension tester on the V-ribbed belt midway between the belt pulleys. Read off the value from the scale.

Settings New V-ribbed belts: 57–70 kg (125–155 lbs) Used V-ribbed belts: 57–70 kg (125–155 lbs)

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Section Page

Task Description

G 66

If the measured value does not correspond to the specified set value, V-ribbed belt tension must be corrected. Release locknut (2) and securing screws (1). Secure V-ribbed belt with clamping nut (3). Check V-ribbed belt tension. Tighten locknut (2). Tighten securing screws (1). Install guard plate. Release engine start (G000.000.03).

G213.051.05 Generator Driv e Belt Installation / Replacement Disable engine start (G000.000.01). Remove guard plate. Release securing screws (1). Release locknut (2) and clamping nut (3) so that both V-ribbed belts can be removed. Check that V-ribbed belt pulleys are clean; clean if necessary. Fit new V-ribbed belts. Secure V-ribbed belt with clamping nut (3). Set V-ribbed belt tension, see under (G213.051.01). Tighten locknut (2). Tighten securing screws (1). Install guard plate. Release engine start (G000.000.03). Note: After the engine has run for 30 minutes, again check V-ribbed belt tension; readjust if necessary. After the engine has run for 8 hours, again check V-ribbed belt tension; readjust if necessary.

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Task Description

Section

G

Page

67

G213.051.08 Generator Condition Check Disable engine start (G000.000.01). Remove guard plate. Check generator for mechanical damage. Check security and condition of all cable connections. Check all electric cables for damage. Install guard plate. Release engine start (G000.000.03).

G231.051.01 Engine Mount Security Check Check tightness of all securing screws by torque wrench application.

G231.051.03 Engine Mount Resilient Element Check Check resilient mounts for cracks and deformation (visual inspection). Replace cracked rubber elements. Note: Wipe rubber surfaces with dry cloth only, never clean with organic detergents.

G250.000.01 Drive System (Driving End) Security Check Disable engine start (G000.000.01). Remove guard plates from PTO system, driving end. Check tightness of securing screws of PTO system, driving end, by torque wrench application. Install guard plate (driving end). Release engine start (G000.000.03).

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Section Page

Task Description

G 68

G252.051.01 Coupling Cond ition Check Disable engine start (G000.000.01). Coupling is not supplied by MTU. Carry out tasks specified by Manufacturer. Release engine start (G000.000.03).

G303.000.01 Compressed Air System Condensate Draining Open drain valves on compressed air system and allow condensate to drain. Note: The pressure drop on the pressure gauge must not be more than approx. 1 bar.

Close drain valves. Drain condensate from compressed air tank in accordance with manufacturer’s specifications.

G303.000.03 Compressed Air System, Op erating Pressure Check Open shut-off valve before pressure gauge. Check compressed air at pressure gauge. Always fill compressed air tank to maximum pressure. Note: Examine compressed air systems regularly; clean and subject them to a pressure test. Observe the local safety regulations.

G307.001.01 Protective Device Che ck Check that all guards are correctly installed on the generator and PTO systems, driving end and free end. Guard plates on PTO system, driving end.

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Task Description

Section

G

Page

69

G309.001.01 Battery Check WARNING Battery acid is highly caustic and may splash into eyes. During filling or charging, explosive gases may develop. Metal objects between battery terminals cause short-circuiting. Risk of explosion, burning and short-circuiting! No naked flames. No electrical sparks. Do not smoke. Wear rubber gloves, protective goggles and protective clothing. Before starting work, provide clean water for washing. If battery filling gets into eyes, rinse immediately with water and seek medical attention. Do not place metal objects on battery.

The battery is not supplied by MTU. Carry out tasks specified by manufacturer.

G309.001.03 Battery Filling Fill battery with electrolyte or alkaline solution. Carry out tasks specified by manufacturer.

G309.001.05 Battery Charge State Check

Check fluid viscosity and electrolyte level. Carry out tasks specified by manufacturer.

G364.050.01 Fuel Supply Check WARNING Fuels are combustible. Fire hazard! When working on the fuel system: no naked flame no electrical sparks do not smoke do not spill fuel.

Check fuel supply in fuel tank, top up if necessary. Note: A full fuel tank reduces condensation and the growth of bacteria.

G364.200.01 Fuel Supply System, Shut-Off Valve Closing Close shut-off valve in supply line before fuel prefilter.

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Section Page

Task Description

G 70

G364.200.03 Fuel Supply System, Shut-Off Valve Opening Open shut-off valve in supply line before fuel prefilter.

G364.200.05 Fuel Supply System – Fill ing Intake Line to En gine Clean fuel system and fill with clean fuel.

G365.000.01 Exhaust System Condensate Draini ng system is not supplied by MTU. Carry out Exhaust tasks specified by Manufacturer.

G365.000.03 Exhaust System Drain Obstruction Check Exhaust system not supplied by MTU.

G500.000.01 Engine Control System Switching On Move power supply master switch from “Off” to “On”.

G500.000.03 Engine Control System Switching Off Move power supply master switch from “On” to “Off”.

G500.000.07 Engine Control System Initial Operatio n Contact MTU Service. G500.000.09 Engine Wiring Che ck Disable engine start (G000.000.01). Check all plug-in connection(s) for security and damage at: – Speed, pressure and temperature transmitters – Level sensor – Fuel prefilter Check all mechanical fixtures and electrical connections. – – – – –

Injection pumps Battery Turbocharger control Starter Generator

Note: When checking the electrical connection, it is essential to ensure that no ground short is created.


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Task Description

Section

G

Page

71

G510.000.01 Monitoring System, Equipment Function Check Check operation of level sensor on engine coolant expansion tank. The temperature sensor, pressure sensor and speed sensor are continuously monitored with the Integrated Test System (ITS) in the Engine Control System. If a monitoring unit fails, a warning is given. In event of a fault signal, replace respective component.

Remove speed sensor (crankshaft) Note: The speed sensor is an electronic component. Appropriate care is required for removal.

Separate electrical plug-in connection. Remove securing screw. Withdraw speed sensor (arrow). Remove O-rings.

Check speed sensor (crankshaft) Visually check speed sensor for damage, replace as necessary. Use an ohmmeter to measure resistance between Pin A and Pin B. Required resistance = 135 ohms ± 20 ohms In event of deviation from specified value, replace speed sensor.

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Section Page

Task Description

G 72

Special tools: Reference mandrel:

Install speed sensor (crankshaft) Note: The speed sensor is an electronic component. Appropriate care is required for removal.

Check that support bore in flywheel housing is clean and clean if necessary. Determine depth of support bore. For this purpose, carefully insert reference mandrel (1) into support bore until it contacts the graduated disc.

Measure projection “X” of reference mandrel over mating face of speed sensor and subtract from total length “L” of reference mandrel. Depth of support bore from mating face of speed sensor to graduated disc: T = L – X

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Task Description

Section

G

Page

73

Fit O-rings (1) on speed sensor (2) and coat with petroleum jelly.

Check gap clearance “S” between graduated disc and speed sensor: S = 1 mm to 2 mm For this purpose measure installation length “E” of speed sensor and compare with depth of support bore. Installation length “E” must be smaller by dimension “S” than installation depth “T”. If necessary, fit shims to achieve correct gap clearance.

Note: Before installing, check speed sensor for particular cleanness.

Insert speed sensor into support bore and press in up to mating face on flywheel housing (arrow). Tighten speed sensor with securing screw. Connect electronic plug-in connection on speed sensor.

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Section Page

Task Description

G 74

Remove pressure and temperature sensors Note: Sensors are electronic components. Appropriate care is required for removal. Store sensors so that they are protected from dirt and mechanical damage.

Use an open-end wrench to unscrew sensor. Attach suitable dust caps to screw-in thread of sensors. Store sensors so that they are protected from dirt and mechanical damage. Seal removal bores with suitable plugs.

Check pressure sensor (crankcase) Visually check pressure sensor for damage, replace as necessary. Carry out DC voltage test on pressure sensor. – Pin A = Earth – Pin B = Voltage output – Pin C = Voltage input Input voltage at 25 °= C 5.00 DC V Specified output voltage = 2.5 V DC 0.1 V DC In event of deviation from specified value, replace pressure sensor. Note: These values apply only when the engine is shut down or the pressure sensor is removed.

Check speed sensor Visually check pressure sensor for damage, replace as necessary. Carry out DC voltage test on pressure sensor. – Pin A = Earth – Pin B = Voltage output – Pin C = Voltage input Input voltage at 25 °= C 5.00 DC V Engine oil pressure sensor (1): Specified output voltage = 0.5 V DC 0.1 V DC Charge air pressure sensor (2): Specified output voltage = 1 V DC 0.1 V DC In event of deviation from specified value, replace pressure sensor. Note: These values apply only when the engine is shut down or the pressure sensor is removed.

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Task Description

Section

G

Page

75

Check pressure sensor (fuel high pressure) Visually check pressure sensor for damage, replace as necessary. Carry out DC voltage test on sensor. – Pin A = Earth – Pin B = Voltage input – Pin C = Voltage output Input voltage at 25 °= C

5.00 DC V 

Specified output voltage = 0.5 V DC 0.1 V DC In event of deviation from specified value, replace sensor. Note: These values apply only when the engine is shut down or the pressure sensor is removed.

Check temperature sensor (engine coolant circuit, fuel, charge air coolant circuit, charge air, engine oil) Visually check pressure sensor for damage, replace as necessary. Measure resistance between Pin A and Pin B with an ohmmeter at different bath temperatures. Specified resistance at 0 °C = from 8500 ohms to 14000 ohms Specified resistance at 25 °C = from 2613 ohms to 2992 ohms Specified resistance at 100 °C = from 155 ohms to 190 ohms In event of deviation from specified values, replace sensor.

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Section Page

Task Description

G 76

Install pressure and temperature sensors Note: Sensors are electronic components. It is therefore necessary to take due care and ensure cleanness during installation.

Remove blanking plug. Check sealing surface and installation bore (thread) for particular cleanness, and clean if necessary. Screw in sensor with new sealing ring and tighten with torque wrench. Tightening torque: – H.P. fuel sensor – Charge air pressure sensor – Crankcase pressure sensor – Engine oil pressure sensor

70 Nm 30 Nm 20 Nm 20 Nm

– Temperature sensor – Lubricant:

16 Nm engine oil

Note: After starting engine, visually inspect sensor connections for leaks.

If leaks are found, slightly tighten sensor connections. If correct sealing cannot be achieved in this way, remove sensor and replace gasket. Switch on engine control system (G500.000.01). Release engine start (G000.000.03).

G510.070.01 Monitoring Equipment Lamp Test The monitoring system is not supplied by MTU. Carry out tasks as specified by Manufacturer.

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Section

Preservation

K

Contents

K000.000.01

Preservation Preface –

K000.000.03

Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.

K000.000.05

Represervation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.

K000.000.07

Depreservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.

K000.000.09

Description of services

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . .

Section

K

Preservation

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Preservation

Section Page

K 1

K000.000.01 Preservation – Pr eface Low operating and maintenance costs as well as operational reliability and availability depend on maintenance and servicing being carried out in compliance with our specifications and instructions. These instructions differentiate between preservation, represervation and depreservation. Preservation must be carried out on – New or overhauled engines after the test stand run – carried out at MTU. Not necessary if to be put into service immediately after completion. – Engines being withdrawn from operation for a period exceeding three months, as soon after the final operating period as possible. Preservation is adequate for storage for a period up to – 12 months under favourable storage conditions. – 6 months under unfavourable storage conditions, e.g. high humidity, salt-laden atmosphere, pronounced temperature fluctuations, etc. On conclusion of the preservation period, carry out represervation at the required intervals. Represervation is adequate for a storage period of up to – 6 months under favourable storage conditions. – 3 months under unfavourable storage conditions, e.g. high humidity, salt-laden atmosphere, pronounced temperature fluctuations, etc. Engines in special packing do not need to be represerved as long as the permissible relative humidity is not exceeded in the packaging enclosure room. – See inspection specification for Special Packing. Only preservation agents approved by the manufacturer may be used for preservation and represervation. – See Fluids and Lubricants Specification. These services may be omitted if – they cannot be completed due to operationally required special equipment (e.g. test stand). – the specified component is not fitted on the diesel engine. Before- and after-operation services on the engine must be carried out in accordance with the Operating Instructions (Section C). NOTE: The operations and tasks required for preservation, represervation and depreservation must be carried out in the recommended sequence. They are specified by 3-digit and 8-digit codes. Task descriptions: 3-digit codes in Section K 8-digit codes in Section G

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Section Page

K 2

Preservation

K000.000.03 Preservation Code No.

Task Description

G000.000.23

Shut d own engine

G000.000.01

Disable engine start

G180.000.07

Drain engine oil

K001

Cleanengine

G180.000.09

Fill corrosion inhibitor oil into engine

K002

Preserve fuel system

G000.000.03 G000.000.09

Release engine start Start engine

K003

Preserve engine coolant system

K004

Perform preservation run

G000.000.23

Shut down engine

G000.000.07

Bar engine with starting system and

K005

– spray corrosion inhibitor oil into air manifolds

G000.000.01

Disable engine start

K006

Spray corrosion inhibitor oil onto turbocharger compressor wheels

–

Connect fuel suction line to fuel system

G180.000.11

Draw off corrosion inhibitor oil f rom engine

K007

Seal engine exhaust system

K008

Seal engine air system

K009

Preserve engine externally

K000.000.05 Represervation Code No.

Task Description

K001

Cleanengine

G000.000.05

Bar engine manually, and

K005

– spray corrosion inhibitor oil into air manifolds

K006


K009


K000.000.07 Depreservation Code No.

Task Description

K001

Cleanengine

G055.101.01

Remove cylinder head covers

G000.000.07

Turn engine on starter, and

K011

– check valvegear

G055.101.03

Install cylinder head covers

G180.000.11

Draw off corrosion inhibitor oil (residue) from engine

K012

Remove seals from engine air system

K013

Remove seals from engine exhaust system

–

For other services see Operating Instructions

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Preservation

Section Page

K 3

K000.000.09 Description of Ser vices K001

Cleanengine

Clean engine externally and check for corrosion. If necessary, remove rust spots and renew paint. NOTE: Do not use organic detergents to clean rubber or synthetic components. Wipe with a dry cloth only.

K002

Preserve fuel system

Connect the fuel delivery pump suction line to a separate tank, which should be filled with – Injection pump testing oil, to DIN ISO 4113 or – Diesel fuel with 10% corrosion inhibitor oil, for internal preservation. If possible, preserve the fuel system when the engine is hot. (Preservation is carried out during the preservation run, 004)

K003

Preserve engine coolant system

NOTE: Engine coolant systems are usually filled with prepared engine coolant and, therefore, protected from corrosion.

Fill engine coolant system with coolant containing 2% corrosion inhibitor oil or 50% antifreeze. The coolant preserves the engine during the preservation run. The coolant should be allowed to remain in the engine to provide protection against corrosion. Only drain the coolant at ambient temperatures – Below 0 °C for coolant / corrosion inhibitor oil emulsions – Below –40 °C for coolant / antifreeze emulsions

K004 Perform preservation run Run the engine approximately 20 minutes at idling speed. K005

Spray corrosion inhibitor oil into air manifolds

Remove plugs from air manifolds. Turn engine on starter. Spray corrosion inhibitor oil into air manifolds. Insert plugs into air manifolds. – Use only sealing rings which are in perfect condition.

K006


Disconnect air pipework from turbochargers. Spray compressor wheels and compressor housing with corrosion inhibitor oil while rotating the compressor wheels. Reconnect air pipework.

K007

Seal engine exhaust system

Cover the exhaust outlets at the turbocharger with blanking plates so that they are sealed against air and moisture penetration. NOTE: In order to ensure that these plates are not overlooked when the engine is returned to service, they must be shaped in such a way as to project beyond the flanges at a certain point. Paint the projections bright red and fold them back.

K008

Seal engine air system

Cover the air filter with plastic sheet.

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Section Page

K009

K 4

Preservation


Spray or brush preservation agent on all exposed metalwork. NOTE: Do not apply grease to the sealing lips of radial-lip oil seals. Seal all openings in pipework, housings and turbochargers, with suitable, plugs or plates.

K010

Spray V-belt pulleys with corrosion inhibitor oil

Spray corrosion inhibitor oil onto belt running surfaces on generator, crankshaft PTO, fan wheel PTO and tension roller.

K011

Check and preserve valve gear

Check valve gear and fuel injection components for moisture, corrosion or other evidence of damage. Spray corrosion inhibitor oil into housing and onto valve gear and fuel injection system components.

K012

Remove seals from engine air system

Remove plastic sheet from air filters.

K013

Remove seals from engine exhaust system

Remove blanking plates from exhaust outlets. Note: When removing the plates, ensure that no foreign particles fall into the engine.

Reconnect bellows.

15345/20 E 00–05

Transportation Locking Device

Section

T

Contents

T036.051.01

Crankshafttransportationlockingdevice

T231.001.01

Enginemounttransportationlockingdevice

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. .

Section

T


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Section

T

Page

1

T036.051.01 Crankshaft Transportation Locking Device Applicable to: 030.00160

General The transportation locking devices protect the crankshaft mounts against damage caused by impacts and vibrations during engine transportation. Transportation locking device – must be left in place until just before engine installation. – must, in the meantime, be removed only for engine barring (e.g. during preservation work) and immediately reinstalled. – must always be installed before the engine is transported.

Transportation locking device removal Remove transportation locking devices from driving end.

Store the transportation locking devices (including fixtures) together with this documentation for possible reinstallation at a later date.

Transportation locking device installation Transportation locking device at driving end Secure 2x plates (2) with screws (5) and washers (6) together with blanking plate (1) to the side openings of the flywheel housing. – Tightening torque: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 . . . Nm . . + 25 Nm – Lubricant: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine . . . . . .oil Screw in nut (4) to thread end of the screw (3). Place 2x retainers (7) through the opening in the plate (2) and secure with screws (3). Tighten screws (3) alternately. – Tightening torque: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 . . Nm . . . + 3 Nm – Lubricant: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine . . . . . .oil Fit nuts (4) on plate (2) and lock in position. Stick warning sign on blanking plate (1).

Attach this documentation to the engine where it can clearly be seen.

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15345/20 E 00–05


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T231.001.01 Engine mount transportation locking device Applicable to: 230.00002

General These transportation locking devices block the engine mounts. The transportation locking devices protect the engine mounts against damage caused by impacts and vibrations during engine transportation. Transportation locking devices – Do not remove until the engine has been aligned and secured on the machinery foundation, but in all cases before the engine is put into operation. – The locking devices must always be installed before the engine is transported.

Operation of the engine with engine mount locking devices in place is impermissible. The transportation locking device must only be released when the mounts are fully loaded.

Transportation locking device removal Release nuts (7) and remove screws (9) from base plate (5). Check buffer clearance via control grooves (6) with feeler gauge. – Specified value: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 . . . mm ... If buffer clearance adjustment is necessary: Remove cover caps (1). Release securing nut (3). Screw central buffer (4) on hexagon (2) clockwise to the lower stop position. Back off central buffer (4) counterclockwise and adjust to distance “H” = 3.0 mm ± 0.3 mm. Tighten securing nut (3), holding central buffer (4) in position on hexagon (2). – Tightening torque: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .580 . . . Nm . . ±50Nm – Lubricant: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine . . . . . .oil Fit cover caps (1). Store screws, nuts and washers together with these instructions for any possible future installation.

Transportation locking device installation Note: Before the transportation locking devices are fitted, the engine mounts must be subjected to the load of the engine weight for at least 48 hrs owing to settlement of the rubber elements.

Screw in and tighten screws (9) with nuts (7) and washers (8) into base plate (5). Attach these instructions to an engine carrier.

15345/20 E 00–05

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15345/20 E 00–05

Keyword Index

A Abnormal turbocharger running noises, Troubleshooting, Section E, 4 After shutdown, C000.000.11, Section C,

4

Air filter replacement, G121.051.01, Section G,

41

Air filter, contamination indicator position check, G121.052.01, Section G, Application, D000.000.05, Section D,

42

1

Attachments security check, G000.000.27, Section G,

4

Attachments, hoses and hose connections check, G000.000.29, Section G,

4

B Barring engine manually, G000.000.05, Section G,

1

Barring engine with starting system, G000.000.07, Section G, 2 Battery charge state check, G309.001.05, Section G,

69

Battery check, G309.001.01, Section G, 69 Battery filling, G309.001.03, Section G,

69

Breather valve closing, G208.101.03, Section G, 63 Breather valve opening, G208.101.01, Section G,

63

C Centrifugal oil filter cleaning, G183.101.01, Section G, 50 Charge air coolant cooler, external element contamination check, G205.051.01, Section G, Charge air coolant draining, G203.000.05, Section G,

62

61

Charge air coolant level check, G203.000.03, Section G, 60 Charge air coolant pump relief bore check, Troubleshooting, Section E, 62 Charge air coolant sample extraction and analysis, G180.000.04, Section G, 61 Charge air coolant system filling, G203.000.01, Section G,

59

Charge air coolant system, vent line obstruction check, G202.651.01, Section G, Charge air manifold drain cleaning, G124.051.03, Section G,

62

43

Charge air manifold, drain water discharge and obstruction check, G124.051.01, Section G, Charge air pressure too low, Troubleshooting, Section E, 5 Charge air temperature too high, Troubleshooting, Section E, 4 Cleaning engine externally, G000.000.39, Section G,

7

Compressed air system condensate draining, G303.000.01, Section G, 68 Compressed air system, operating pressure check, G303.000.03, Section G, Compression pressure too low, Troubleshooting, Section E, Coolant capacity, A202.000.01, Section A,

3

6

Coolant discharge at intercooler relief bore, Troubleshooting, Section E, 5 Coolant loss, Troubleshooting, Section E,

9

Corrosion inhibitor oil draining, G180.000.11, Section G, Corrosion inhibitor oil filling, G180.000.09, Section G,

15345/20 E 00–05

48

48

68

42

Section

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1

Section

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2

Keyword Index

Coupling condition check, G252.051.01, Section G,

68

Crankcase ventilation, oil separator check, G018.101.03, Section G, 8 Crankshaft transportation locking device, T036.051.01, Section T, 1 Cylinder chamber endoscopic examination, G000.000.33, Section G, Cylinder head cover installation, G055.101.03, Section G,

5

25

Cylinder head cover removal, G055.101.01, Section G, 24

D Depreservation, K000.000.07, Section K,

2

Description of services, K000.000.09, Section K, Drain engine coolant, G202.000.07, Section G,

3

57

Drive system (driving end) security check, G250.000.01, Section G,

67

E Emergency shutdown, G000.000.25, Section G, 4 Engine and exhaust noise, A000.000.25, Section A,

5

Engine and external lines leak check, G000.000.21, Section G, Engine barring tool installation, G030.001.01, Section G, Engine barring tool removal, G030.001.03, Section G,

3

11

11

Engine control system initial operation, G500.000.07, Section G,

70

Engine control system switching off, G500.000.01, Section G, 70 Engine control system switching on, G500.000.01, Section G, 70 Engine coolant change, G202.000.09, Section G,

58

Engine coolant cooler, external element contamination check, G205.051.01, Section G, Engine coolant level check, G202.000.03, Section G,

62

55

Engine coolant level rising, Troubleshooting, Section E, 9 Engine coolant preheating, G202.400.01, Section G,

58

Engine coolant preheating unit initial operation, G202.401.01, Section G,

59

Engine coolant preheating unit, switching off, G202.401.03, Section G,

59

Engine coolant preheating unit, switching on, G202.401.03, Section G,

59

Engine coolant pressure too low, Troubleshooting, Section E,

9

Engine coolant pump leaking at relief bore, Troubleshooting, Section E, 9 Engine coolant pump relief bore check, Troubleshooting, Section E, 58 Engine coolant sample extraction and analysis, G180.000.04, Section G, Engine coolant system filling, G202.000.01, Section G,

56

54

Engine coolant system, vent line obstruction check, G202.651.01, Section G, 59 Engine coolant temperature too high, Troubleshooting, Section E, Engine coolant temperature too low, Troubleshooting, Section E,

8

8

Engine does not reach full-load speed, Troubleshooting, Section E, 2 Engine does not turn when starter is actuated, Troubleshooting, Section E, 1 Engine fires unevenly, Troubleshooting, Section E,

2

15345/20 E 00–05

Keyword Index

Engine layout, A000.000.01, Section A, 1 Engine model designation, A000.000.03, Section A,

2

Engine mount resilient element check, G231.051.03, Section G,

67

Engine mount security check, G231.051.01, Section G, 67 Engine mount transportation locking device, T000.000.02, Section T, 3 Engine oil change, G180.000.05, Section G,

46

Engine oil consumption abnormally high, Troubleshooting, Section E, 7 47

Engine oil draining, G180.000.07, Section G, Engine oil filter replacement, G183.052.03, Section G,

48

Engine oil level abnormally high, Troubleshooting, Section E, 7 Engine oil level check, G180.000.01, Section G,

45

Engine oil pressure too high, Troubleshooting, Section E,

8

Engine oil pressure too low, Troubleshooting, Section E, 8 Engine oil sample extraction and analysis, G180.000.04, Section G, Engine oil system filling, G180.000.03, Section G,

45

Engine oil temperature too high, Troubleshooting, Section E, 7 Engine power, A000.000.19, Section A, 4 Engine pressure checks, G000.000.15, Section G, 3 Engine running noise check, G000.000.19, Section G, Engine shutdown, G000.000.23, Section G,

3

4

Engine side and cylinder designations, A000.000.05, Section A, Engine speed check, G000.000.13, Section G, 3 Engine speed not steady, Troubleshooting, Section E, Engine start disabling, G000.000.01, Section G, Engine start release, G000.000.03, Section G, Engine starting, G000.000.09, Section G,

3

3

1

1

2

Engine temperature checks, G000.000.17, Section G, 3 Engine transportation, C000.000.17, Section C, 4 Engine turns but does not fire, Troubleshooting, Section E, 1 Engine warm-up procedure, G000.000.11, Section G, Engine weight, A000.000.13, Section A,

3

3

Engine wiring check, G500.000.09, Section G,

70

Exhaust gases black, Troubleshooting, Section E, 5 Exhaust gases blue, Troubleshooting, Section E, 5 Exhaust gases white, Troubleshooting, Section E, 6 Exhaust system check G140.000.01, Section G, 44 G140.000.07, Section G, 44 Exhaust system condensate draining, G365.000.01, Section G, 70 Exhaust system drain obstruction check G140.000.11, Section G, 44 G365.000.03, Section G, 70 Exhaust system security check, G140.000.03, Section G,

15345/20 E 00–05

44

46

Section

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Section

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4

Keyword Index

Exhaust system, exhaust backpressure check, G140.000.09, Section G, Exhaust system, exhaust gas colour check, G140.000.05, Section G,

44

44

Exhaust system, security and exhaust manifold insulation checks, G146.000.01, Section G, 44 Exhaust turbocharger connections check, G101.011.05, Section G,

39

Exhaust turbocharger, engine operation in event of turbocharger failure, G101.011.01, Section G,

39

F Fuel duplex filter replacement, G083.051.03, Section G, Fuel prefilter cleaning, G083.101.15, Section G, 38 Fuel prefilter priming, G083.101.01, Section G,

36

38

Fuel prefilter, element and gasket replacement, G083.101.09, Section G,

38

Fuel prefilter, water and contaminants draining, G083.101.03, Section G,

38

Fuel pressure too high, Troubleshooting, Section E,

4

Fuel pressure too low, Troubleshooting, Section E, 3, 4 Fuel supply check, G364.050.01, Section G, 69 Fuel supply system – filling intake line to engine, G364.200.05, Section G,

70

Fuel supply system, shut-off valve closing, G364.200.01, Section G, 69 Fuel supply system, shut-off valve opening, G364.200.03, Section G, 70 Fuel system filling, G080.000.03, Section G,

35

Fuel system, fuel delivery pump supply check, G080.000.05, Section G,

36

G General, Troubleshooting, Section E, 1 Generator condition check, G213.051.08, Section G, 67 Generator drive belt installation / replacement, G213.051.05, Section G,

66

Generator drive, drive belt condition and tension check, G213.051.01, Section G,

64

H H.P. pump leaking at relief bore, Troubleshooting, Section E, 4 High-pressure pump, relief bore obstruction check, G073.051.07, Section G,

25

I Initial operation, C000.000.05, Section C, 3 Injector installation, G075.051.09, Section G, 29 Injector removal, G075.051.01, Section G, 26 Injector replacement, G075.051.05, Section G,

29

Intake air system check, G120.000.07, Section G,

41

Intake air system, intake depression check, G120.000.05, Section G,

41

Intake air system, intake side leak and damage check, G120.000.03, Section G,

41

15345/20 E 00–05

Keyword Index

Section

?

Page

5

M Main engine dimensions, A000.000.09, Section A, 3 Main engine specifications, A000.000.17, Section A, 4 Maintenance echelon W6, D000.000.15, Section D,

4

Maintenance frequency chart, D000.000.07, Section D, 2 Maintenance schedule, D000.000.11, Section D,

2

Maintenance schedule – preface, D000.000.01, Section D, Maintenance system, D000.000.03, Section D,

1

1

Monitoring equipment lamp test, G510.070.01, Section G,

76

Monitoring system, equipment function check, G510.000.01, Section G, 71

O Oil capacity, A180.000.01, Section A,

6

Operating instructions – preface, C000.000.01, Section C, 1 Operational checks –maintenance echelon W1–, C000.000.07, Section C,

3

Operational data, A000.000.21, Section A, 5 Out-of-service period, C000.000.13, Section C, 4 Out-of-service periods, D000.000.17, Section D,

P

Power supply faulty, Troubleshooting, Section E,

4

6

Preheat temperature too low, Troubleshooting, Section E,

10

Preparations for initial operation, C000.000.03, Section C,

2

Preservation, K000.000.03, Section K,

2

Preservation – Preface, K000.000.01, Section K,

1

Protective device check, G307.001.01, Section G,

68

R Represervation, K000.000.05, Section K,

2

S Shutdown, C000.000.09, Section C, 4 Starter condition check, G172.051.09, Section G, 44

T Timing data (valve clearance adjusted), A050.000.01, Section A,

6

V Valve clearance adjustment (valve bridge with adjusting screw M12 (locknut 19 AF)), G055.050.03, Section G, 20

15345/20 E 00–05

Section

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6

Keyword Index

Valve clearance adjustment (valve bridge with adjusting screw M16 (locknut 24 AF)), G055.050.03, Section G, 15 Valve clearance check, G055.050.01, Section G, Valve clearances, A055.050.01, Section A,

13

6

Valve gear lubrication, G055.000.03, Section G,

12

Valve gear oil supply check, G055.000.01, Section G,

12

15345/20 E 00–05

OPERATING INSTRUCTION MTU 16V 4000

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