MS150093 01e PDF
MS150093 01e PDF
MS150093 01e PDF
Diesel engine
20 V 4000 G23 with 6 exhaust turbochargers
20 V 4000 G43 with 6 exhaust turbochargers
20 V 4000 G63 with 6 exhaust turbochargers
20 V 4000 G63L with 6 exhaust turbochargers
20 V 4000 G83 with 6 exhaust turbochargers
20 V 4000 G83L with 6 exhaust turbochargers
MS150093/01E
Printed in Germany
© 2012 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Table of Contents
1 Safety 3.7 Stop engine in manual mode (testing
mode) 46
1.1 General conditions 5 3.8 Emergency stop 47
1.2 Personnel and organizational requirements 6 3.9 After stopping the engine – Engine remains
1.3 Transport 7 ready for operation 48
1.4 Crankshaft transport locking device 8 3.10 After stopping the engine – putting the
1.5 Explosion hazard when removing engine out of service 49
inspection port cover on engine 11 3.11 Plant cleaning 50
1.6 Safety regulations for maintenance and
repair work 12
1.7 Auxiliary materials, fluids and lubricants,
fire prevention and environmental 4 Maintenance
protection 15
4.1 Maintenance task reference table [QL1] 51
1.8 Conventions for safety instructions in the
text 17
5 Troubleshooting
2 Product Summary 5.1 Troubleshooting 52
5.2 Engine governor ADEC (ECU 7) for Series
2.1 Engine Layout 18
4000 genset engines – Fault messages 55
2.2 Overview of sensors, actuators and
injectors 19
2.3 Engine – Main dimensions 23
2.4 Firing order 24 6 Task Description
2.5 Final compression pressure 25
2.6 Engine side and cylinder designations 26 6.1 Engine 104
2.7 20V 4000 Gx3 engine data: Continuous 6.1.1 Engine – Barring manually 104
6.1.2 Engine – Barring with starting system 105
operation, variable 3B, optimized fuel
6.1.3 Engine – Test run 106
consumption 27
2.8 20V 4000 Gx3 engine data: Continuous 6.2 Cylinder Liner 107
operation, variable 3B, optimized exhaust 6.2.1 Cylinder liner – Endoscopic examination 107
emissions ("TA-Luft") 32 6.2.2 Cylinder liner – Instructions and comments on
2.9 20 V 4000 Gx3 engine data: Standby endoscopic and visual examination 109
operation 3D, optimized fuel consumption,
6.3 Crankcase Breather 111
6ETC 35
6.3.1 Crankcase breather – Oil mist fine separator
replacement 111
installation 117
months) 40
3.2 Putting the engine into operation after 6.5 Injection Pump / HP Pump 118
scheduled out-of-service-period 41 6.5.1 HP pump – Filling with engine oil 118
3.3 Start engine in manual mode (testing
mode) 42 6.6 Injection Valve / Injector 119
6.6.1 Injector – Replacement 119
3.4 Safety system – Override 43
6.6.2 Injector – Removal and installation 120
3.5 Operational checks 44
3.6 Starting the engine in emergency situations 6.7 Fuel System 125
(override mode) 45 6.7.1 Fuel system – Venting 125
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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Personnel requirements
All work on the engine shall be carried out by trained and qualified personnel only.
The specified legal minimum age must be observed.
The operator must specify the responsibilities of the operating, maintenance and repair personnel.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair
and transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on
explaining safety-relevant instructions.
This is particularly important in the case of personnel who only occasionally perform work on or around
the engine. This personnel must be instructed repeatedly.
For the identification and layout of the spare parts during maintenance or repair work, take photos or use
the spare parts catalog.
Transport
Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.
Always use the lifting eyes on the engine when transporting an engine separately.
Only use transport and lifting devices approved by MTU.
The engine/genset must only be transported in installation position: maximum permissible diagonal pull
10°.
Remove any loose parts on the genset.
Raise the engine/genset slowly. The lifting ropes or chains must not make contact with the engine or its
components. Readjust lifting device as necessary.
Pay attention to the center of gravity of the engine/genset.
For special packaging with aluminium foil: Suspend the engine/genset by the lifting eyes on the bearing
pedestal or transport by means of handling equipment (forklift truck) capable of bearing the load.
Fit the crankshaft transportation lock on the engine and fit the engine mount locking devices prior to
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transport.
Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip‐
ping and tipping when driving up or down inclines and ramps.
For installation and removal of the transport locking device, follow the instructions
below:
1. The transport locking device must remain installed as long as possible during engine installation in order
to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both sides according
to the instructions.
3. If the engine is to be moved together with the generator, the transport locking device for the generator
must also be installed.
4. Always use the screws supplied with or installed in the transport locking device to secure it on the en‐
gine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the generator
is already mounted on the engine, ensure that the transport locking device of the generator is also re‐
moved.
6. Attach these instructions, clearly visible, to the engine.
Note: Attach plates (2) only to the upper part of the openings.
1. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel
housing and tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
2. Screw nut (3) onto screws (4) up to the end of the thread.
3. The long end of retainers (1) must face downwards. Push retainers (1) with the round front face through
the plate openings (2).
Note: The retainers (1) must lock the flywheel only, not the ring gear.
4. Install screws (4) into the bores of retainers (1) until the retainers (1) are locked in position.
5. Tighten screws (4) alternately with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
6. Screw on nuts (3) of both screws (4) at plates (2) and secure.
DANGER
Explosion hazard due to oil vapors.
Risk of serious injury – danger to life!
• Allow the engine to cool down before opening the crankcase!
• Avoid open flames, electrical sparks and ignition sources.
Safety instructions
u Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion
due to oil vapors).
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Observe special cleanness when conducting maintenance and repair work on the assembly or system.
After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐
bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards
have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.
When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires –
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐
cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.
Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to
the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their
use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
not smoke.
Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.
Compressed air
Observe special safety precautions when working with compressed air:
• Pay special attention to the pressure level in the compressed air network and pressure vessel.
• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐
mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection.
• Hose couplings and connections must be securely attached.
• Wear goggles when blowing off components or blowing away chips.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before equipment or tool is to be replaced.
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Carry out leak test in accordance with the specifications.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
DANGER
In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
WARNING
In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
CAUTION
In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
1. Read and familiarize yourself with all safety notices before starting up or repairing the product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
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010 Crankcase and add-on 080 Fuel system (low pres‐ 180 Lube oil system / lube
components sure) oil circuit
020 Gear train 100 Exhaust turbocharger 200 Coolant system
030 Running gear 110 Intercooler 210 Power supply
040 Cylinder head 120 Air intake/air supply 230 Mounting/support
050 Valve gear 140 Exhaust system 250 PTO systems, driving
070 Fuel system (high pres‐ 170 Starting equipment end and free end (cou‐
sure) pling)
500 Engine governor
1 Temperature sensors 2 Sensor B34 (P-Fuel after 3 M8 (HP fuel pump ac‐
for single exhaust gas filter) tuator)
B4.1 to B4.10 (engine
side A)
The injectors (Y39.1 to Y39.10, engine side A) are underneath the cylinder head covers of the cylinder.
Injector replacement and necessary activities (→ Page 119).
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Firing order
Num‐ Firing order
ber of
cylin‐
ders
8V A1-B4-A4-A2-B3-A3-B2-B1
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 20V 20V 20V 20V 20V
4000G23 4000G63 4000G63L 4000G83 4000G83L
Application group 3B 3B 3B 3B 3B
Intake air tempera‐ °C 25 25 25 25 25
ture
Charge-air coolant °C 55 55 55 55 55
temperature
Raw-water inlet °C - - - - -
temperature
Barometric pres‐ mbar 1000 1000 1000 1000 1000
sure
Site altitude above m 100 100 100 100 100
sea level
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylin‐ 20 20 20 20 20
ders
Rated engine A rpm 1500 1500 1500 1800 1800
speed
Continuous power A kW 2200 2420 2590 2740 3010
ISO 3046 (10%
overload capability,
design power DIN
6280, ISO 8528)
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warning
Coolant tempera‐ L °C 104 104 104 104 104
ture after engine,
shutdown
Coolant antifreeze L % 50 50 50 50 50
content, max.
Pressure loss in off- L bar 0.7 0.7 0.7 0.7 0.7
engine cooling sys‐
tem, max.
FUEL SYSTEM
Number of cylin‐ 20 20 20 20 20
ders
Fuel pressure at L bar -0.1 -0.1 -0.1 -0.1 -0.1
engine inlet con‐
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CAPACITIES
Number of cylin‐ 20 20 20 20 20
ders
Engine coolant ca‐ R Liters 205 205 205 205 205
pacity, engine side
(without cooling
system)
Charge-air coolant, R Liters 30 30 30 30 30
engine side
Engine oil, total, for R Liters 390 390 390 390 390
initial filling (stand‐
ard oil system) (op‐
tion: max. operating
inclinations)
Oil pan capacity at L Liters 245 245 245 245 245
dipstick mark “min.”
(standard oil sys‐
tem) (option: max.
operating inclina‐
tions)
Oil pan capacity at L Liters 340 340 340 340 340
dipstick mark
“max.” (standard oil
system) (option:
max. operating in‐
clinations)
Number of cylin‐ 20 20 20 20 20
ders
Engine weight, dry R kg 9290 9290 9290 9290 9290
(basic engine con‐
figuration acc. to
scope of delivery
specification)
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 20V 20V 20V
4000G23 4000G63 4000G63
L
Application group 3B 3B 3B
Intake air temperature °C 25 25 25
Charge-air coolant temperature °C 55 55 55
Barometric pressure mbar 1000 1000 1000
Site altitude above sea level m 100 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 20 20 20
Rated engine speed A rpm 1500 1500 1500
Continuous power ISO 3046 (10% overload capabil‐ A kW 2200 2420 2590
ity, design power DIN 6280, ISO 8528)
Fuel stop power ISO 3046 kW 2420 2662 2849
Number of cylinders 20 20 20
Number of cylinders 20 20 20
Cylinder arrangement: V-angle Degrees 90 90 90
Bore mm 170 170 170
Stroke mm 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77
Total displacement Liters 95.4 95.4 95.4
FUEL SYSTEM
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Number of cylinders 20 20 20
Fuel pressure at engine inlet connection, min. (when L bar -0.1 -0.1 -0.1
engine is starting)
Fuel pressure at supply connection to engine (when L bar 1.5 1.5 1.5
engine is starting), max.
CAPACITIES
Number of cylinders 20 20 20
Engine coolant capacity, engine side (without cool‐ R Liters 205 205 205
ing system)
Charge-air coolant, engine side R Liters 30 30 30
Engine oil, total, for initial filling (standard oil system) R Liters 390 390 390
(option: max. operating inclinations)
Oil change quantity, max. (standard oil system) (op‐ R Liters
tion: max. operating inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil L Liters 245 245 245
system) (option: max. operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil L Liters 340 340 340
system) (option: max. operating inclinations)
ACOUSTICS
Number of cylinders 20 20 20
Engine surface noise with attenuated intake noise R dB(A) 105 106 107
(filter) - DL (free-field sound power level Lp, 1 m dis‐
tance, ISO 6798, +2dB(A) tolerance)
Engine surface noise with attenuated intake noise R dB(A) 124 125 125
(filter) - DL (sound power level LW, ISO 6798, +2dB
(A) tolerance)
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Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
r Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 20V 20V 20V 20V 20V 20V
4000G23 4000G43 4000G63 4000G63 4000G83 4000G83
L L
Application group 3D 3D 3D 3D 3D 3D
Intake air tem‐ °C 25 25 25 25 25 25
perature
Charge-air cool‐ °C 55 55 55 55 55 55
ant temperature
Barometric pres‐ mbar 1000 1000 1000 1000 1000 1000
sure
Site altitude m 100 100 100 100 100 100
above sea level
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylin‐ 20 20 20 20 20 20
ders
Rated engine A rpm 1500 1800 1500 1500 1800 1800
speed
Fuel stop power A kW 2420 2740 2670 2850 3010 3490
ISO 3046
shutdown
CAPACITIES
Number of cylin‐ 20 20 20 20 20 20
ders
Engine coolant R Liters 205 205 205 205 205 205
capacity, engine
side (without
cooling system)
Charge-air cool‐ R Liters 30 30 30 30 30 30
ant, engine side
Engine oil, total, R Liters 390 390 390 390 390 390
for initial filling
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ACOUSTICS
Number of cylin‐ 20 20 20 20 20 20
ders
Engine surface R dB(A) 104 106 106 106 108 108
noise with atte‐
nuated intake
noise (filter) - BL
(free-field sound
power level Lp, 1
m distance, ISO
6798, +2dB(A)
tolerance)
Engine surface R dB(A) 123 125 125 125 126 127
noise with atte‐
nuated intake
noise (filter) - BL
(sound power
level LW, ISO
6798, +2dB (A)
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tolerance)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Preconditions
☑ Engine is stopped and starting disabled.
Preconditions
☑ Generator (if provided) not connected to network.
☑ External start interlock is not activated.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Task
Operating mode selector Change to manual mode.
switch (if provided)
Preheating pump (if provid‐ Switch ON.
ed)
CAUTION
Safety functions and engine shutdown alarms will be disregarded.
Serious damage to plant!
• Initiate emergency start only in emergency situations.
CAUTION
Inadmissible operational condition.
Major material damage!
• Use override function only in hazardous situations to ensure full capability in case of engine mal‐
functions.
Preparation
Note: This function is only available when a pushbutton is provided.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Operational checks
Item Measure
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine oil Check engine oil level (→ Page 142)
Engine under load Check engine/plant and piping for leaks, repair leaky pipes with the engine
stopped (exhaust lines and turbocharger turbine housings may be red-hot.
Engine at nominal speed
If the maximum exhaust temperatures are not exceeded, no restrictions in
engine operation are required)
Check for abnormal running noises and vibration.
Fuel prefilter Check reading on differential pressure gauge to ensure that maximum
permissible value is not exceeded (→ Page 128).
Exhaust system Check exhaust color (→ Page 52).
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 134).
Air filter Check signal ring position of contamination indicator (→ Page 138).
Replace air filter (→ Page 135) if the signal ring is completely visible in the
contamination indicator control window.
Engine coolant pump Check relief bore (→ Page 153).
Charge-air coolant pump Check relief bore (→ Page 161).
Compressed-air system (if Check operating pressure on pressure gauge;
installed)
Always fill compressed-air tank to max. pressure;
Drain condensate from compressed-air tank, pressure drop must not ex‐
ceed 1 bar.
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CAUTION
Safety functions and engine shutdown alarms will be disregarded.
Serious damage to plant!
• Initiate emergency start only in emergency situations.
Preparation
Item Task
Operating mode switch Set to emergency mode.
Preconditions
☑ Generator (if provided) not connected to network.
☑ Engine is running in manual mode.
CAUTION
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
• Before stopping the engine, operate it at idle speed until operating temperatures decrease and
stable values are indicated.
CAUTION
An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) is available.
Preconditions
☑ Engine is stopped and starting disabled.
☑ Operating voltage is not present.
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
WARNING
Water jet.
Risk of injury and scalding!
• Do not direct water jet at persons.
• Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• Observe manufacturer's instructions.
• Wear protective clothing, gloves, and goggles / safety mask.
NOTICE
Dry with compressed air.
Damage to component!
• Never aim compressed air directly at electronic components.
Plant cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐
tection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.
3. During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must
be observed. The temperature of the cleaning medium must not exceed 80 °C.
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4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable fashion.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
Note: Never aim compressed air directly at electronic components.
e) Dry engine.
004 – SS T-Fuel
ZKP-Number: 2.0122.932
Limit value 2
Cause Corrective action
Fuel temperature too high; u Contact Service.
engine shutdown.
019 – HI T-Exhaust A
ZKP-Number: 2.0126.931
Limit value 1
Cause Corrective action
Exhaust gas temperature (A- 1. Check cabling (→ Page 165).
side) too high. 2. Contact Service.
020 – SS T-Exhaust A
ZKP-Number: 2.0126.932
Limit value 2
Cause Corrective action
Exhaust gas temperature (A- 1. Check cabling (→ Page 165).
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021 – HI T-Exhaust B
ZKP-Number: 2.0127.931
Limit value 1
Cause Corrective action
Exhaust gas temperature (B- 1. Check cabling (→ Page 165).
side) too high. 2. Contact Service.
33 – HI P-Diff-Fuel
ZKP-Number: 20.114.931
Limit value 1
Cause Corrective action
Fuel filter differential pressure u Replace fuel filter (→ Page 126).
too high.
34 – SS P-Diff-Fuel
ZKP-Number: 20.114.932
Limit value 2
Cause Corrective action
Fuel filter differential pressure u Replace fuel filter (→ Page 126).
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too high.
ZKP-Number: 2.0125.932
Limit value 2
Cause Corrective action
Lube oil temperature too high; 1. Reduce power.
engine shutdown. 2. Check engine oil level (→ Page 142).
058 – SS P-Coolant
ZKP-Number: 2.0101.922
Limit value 2
Cause Corrective action
Coolant pressure too low; engine 1. Automatic engine shutdown.
shutdown or reduction of fuel 2. Check coolant level (→ Page 147).
injection.
59 – SS T-Coolant L3
ZKP-Number: 20.120.933
Limit value 3
Cause Corrective action
Coolant temperature too high/ 1. Allow engine to cool down;
low 2. Check coolant cooler, clean if necessary.
3. Contact Service.
60 – SS T-Coolant L4
ZKP-Number: 20.120.934
Limit value 4
Cause Corrective action
Coolant temperature too high/ 1. Allow engine to cool down;
low 2. Check coolant cooler, clean if necessary.
3. Contact Service.
063 – HI P-Crankcase
ZKP-Number: 2.0106.931
Limit value 1
Cause Corrective action
TIM-ID: 0000008506 - 001
065 – LO P-Fuel
ZKP-Number: 2.0102.921
Limit value 1
Cause Corrective action
Fuel supply pressure too low. 1. Check fuel lines for leaks.
2. Clean fuel prefilter (→ Page 127).
3. Flush fuel prefilter (→ Page 130).
4. Replace filter element of fuel prefilter (→ Page 132).
5. Replace fuel filter (→ Page 126).
066 – SS P-Fuel
ZKP-Number: 2.0102.922
Limit value 2
Cause Corrective action
Fuel supply pressure too low; 1. Check fuel lines for leaks.
engine shutdown. 2. Clean fuel prefilter (→ Page 127).
3. Flush fuel prefilter (→ Page 130).
4. Replace filter element of fuel prefilter (→ Page 132).
5. Replace fuel filter (→ Page 126).
067 – HI T-Coolant
ZKP-Number: 2.0120.931
Limit value 1
Cause Corrective action
Coolant temperature too high. u Reduce power.
068 – SS T-Coolant
ZKP-Number: 2.0120.932
TIM-ID: 0000008506 - 001
Limit value 2
Cause Corrective action
Coolant temperature too high; 1. Allow engine to cool down;
engine shutdown. 2. Check coolant cooler, clean if necessary.
3. Restart engine (→ Page 42).
4. Contact Service.
085 – HI T-Recirculation
ZKP-Number: 2.0128.931
Limit value 1
Cause Corrective action
Recirculation temperature too u Reduce power.
high.
086 – HI T-Recirculation
ZKP-Number: 2.0128.932
Limit value 2
Cause Corrective action
TIM-ID: 0000008506 - 001
093 – SS T-Preheat
ZKP-Number: 2.1090.922
Limit value 2
Cause Corrective action
Preheating temperature too low; u Check preheater.
coolant temperature too low for
engine start ; engine start
interlock.
094 – LO T-Preheat
ZKP-Number: 2.1090.921
Limit value 1
Cause Corrective action
Preheating temperature too low; u Check preheater.
coolant temperature too low for
engine start.
TIM-ID: 0000008506 - 001
Limit value 2
Cause Corrective action
Supply voltage too high. 1. Check ECU supply voltage.
2. Contact Service.
201 – SD T-Coolant
ZKP-Number: 1.8004.570
202 – SD T-Fuel
ZKP-Number: 1.8004.572
206 – SD T-Exhaust A
ZKP-Number: 1.8004.576
207 – SD T-Exhaust B
ZKP-Number: 18.004.577
ZKP-Number: 1.8004.566
212 – SD P-Coolant
ZKP-Number: 1.8004.564
214 – SD P-CrankCase
ZKP-Number: 1.8004.568
215 – SD P-HD
ZKP-Number: 1.8004.567
ZKP-Number: 1.8004.575
ZKP-Number: 1.8004.620
ZKP-Number: 1.3011.129
240 – SD P-Fuel
ZKP-Number: 1.8004.565
241 – SD T-Umblasen
ZKP-Number: 1.8004.581
break.
ZKP-Number: 1.8004.501
Time-of-flight measuring fault of u Replace injector concerned if the fault message appears
injector: time-of flight measured frequently (→ Page 119).
value extremely low or extremely
high.
Time-of-flight measuring fault of u Replace injector concerned if the fault message appears
injector: time-of flight measured frequently (→ Page 119).
value extremely low or extremely
high.
Time-of-flight measuring fault of u Replace injector concerned if the fault message appears
injector: time-of flight measured frequently (→ Page 119).
value extremely low or extremely
high.
371 – AL Wiring TO 1
ZKP-Number: 1.8004.634
372 – AL Wiring TO 2
ZKP-Number: 1.8004.635
373 – AL Wiring TO 3
ZKP-Number: 1.8004.636
374 – AL Wiring TO 4
ZKP-Number: 1.8004.637
ZKP-Number: 2.0129.931
Limit value 1
Cause Corrective action
Redundant coolant temperature 1. Check cabling.
reading too high. 2. Contact Service.
410 – LO U-PDU
ZKP-Number: 2.0141.921
Limit value 1
Cause Corrective action
Injector voltage too low. 1. Check cabling.
2. Check power supply.
3. Contact Service.
412 – HI U-PDU
ZKP-Number: 2.0141.931
Limit value 1
Cause Corrective action
TIM-ID: 0000008506 - 001
421 – AL L2 Aux 1
ZKP-Number: 2.0160.922
Limit value 2
Cause Corrective action
Input signal of Aux 1 has u Determine and rectify reason for limit value violation.
exceeded/not attained limit value
2, depending on configuration.
428 – AL L1 T-Aux 1
ZKP-Number: 2.0130.921
Limit value 1
Cause Corrective action
Temperature signal of Aux 1 has u Determine and rectify reason for limit value violation.
exceeded / not attained limit
value 1, depending on
configuration.
440 – AL L1 P-Aux 1
ZKP-Number: 2.0110.921
Limit value 1
Cause Corrective action
Pressure signal of Aux 1 has u Determine and rectify reason for limit value violation.
exceeded / not attained limit
value 1, depending on
configuration.
442 – AL L2 P-Aux 1
ZKP-Number: 2.0110.931
Limit value 2
Cause Corrective action
Pressure signal of Aux 1 has u Determine and rectify reason for limit value violation.
exceeded / not attained limit
value 2, depending on
configuration.
444 – SD U-PDU
ZKP-Number: 1.8004.578
464 – SD P-AUX 1
ZKP-Number: 1.8004.589
467 – AL L2 T-Aux 1
ZKP-Number: 2.0130.922
Limit value 2
Cause Corrective action
Temperature signal of Aux 1 has u Determine and rectify reason for limit value violation.
exceeded / not attained limit
TIM-ID: 0000008506 - 001
value 2, depending on
configuration.
468 – SD T-AUX 1
ZKP-Number: 1.8004.579
470 – SD T-ECU
ZKP-Number: 1.8004.587
472 – Al Stop SD
ZKP-Number: 2.8006.593
474 – AL Wiring FO
TIM-ID: 0000008506 - 001
ZKP-Number: 2.8006.655
482 – SD T-Exhaust C
ZKP-Number: 18.004.596
Exhaust temperature sensor on u Check sensor and cabling (B4.23), replace as necessary.
A-side faulty; short circuit or wire
break.
484 – HI T-Exhaust C
ZKP-Number: 20.133.931
Limit value 1
485 – SS T-Exhaust C
ZKP-Number: 20.133.932
Limit value 2
Cause Corrective action
Exhaust gas temperature (C- 1. Reduce power.
side) too high. 2. Contact Service.
486 – HI T-Exhaust D
ZKP-Number: 20.134.931
Limit value 1
Cause Corrective action
Exhaust gas temperature (D- 1. Reduce power.
side) too high. 2. Contact Service.
487 – SS T-Exhaust D
ZKP-Number: 20.134.932
Limit value 2
Cause Corrective action
Exhaust gas temperature (D- 1. Reduce power.
TIM-ID: 0000008506 - 001
ZKP-Number: 14.500.907
Limit value 2
Cause Corrective action
Redundant engine overspeed. 1. Acknowledge alarm.
2. Attempt to restart engine.
Preconditions
☑ Engine is stopped and starting disabled.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – Danger to life!
• Before barring the engine, ensure that nobody is in the danger zone.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preconditions
☑ Engine is stopped and starting disabled
Preparatory steps
1. Remove cylinder head cover (→ Page 117).
2. Remove injector (→ Page 120).
Cylinder liners with a large number of black lines around the running surface
have limited service life and should be replaced.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Preconditions
☑ Engine is stopped and starting disabled.
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine coolant temperature is max. 40 °C.
☑ Valves are closed.
Preparatory steps
1. Remove cylinder head cover (→ Page 117).
2. Install barring device (→ Page 104).
3. The TDC marking (1) (if fitted) on the fly‐
wheel must not be used for reference.
TIM-ID: 0000000922 - 008
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.
5. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2)
to prevent it from turning.
Name Size Type Lubricant Value/Standard
Locknut M16 x 1.5 Tightening torque (Engine oil) 90 Nm +9 Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Final steps
1. Remove barring device (→ Page 104).
2. Install cylinder head cover (→ Page 117).
Preconditions
☑ Engine is stopped and starting disabled.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Oils/oil vapors are combustible.
Risk of fire!
• No open flames, no electric sparks. Do not smoke. Avoid ignition sources.
CAUTION
Fuel system high-pressure pump not filled with engine oil.
Damage to components, major material damage!
• Make sure that the high-pressure fuel pump is filled with engine oil before installation or initial
operation.
Filling HP pump
1. Remove plug screw (1).
2. Use pump oiler to fill HP pump with engine
oil until engine oil emerges.
3. Insert plug screw (1).
TIM-ID: 0000001640 - 009
Replacing injector
u Remove injector and install new injector (→ Page 120).
TIM-ID: 0000000022 - 013
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Preparatory steps
1. Shut off fuel supply to engine.
2. Remove cylinder head cover (→ Page 117).
Removing injector
1. Disconnect cable connector on injector.
10. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the specified
initial tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
Note: Ensure special cleanness.
11. Coat thread and sealing cone of adapter (3) with engine oil.
12. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
Name Size Type Lubricant Value/Standard
Adapter Preload torque (Engine oil) 5 Nm to 10 Nm
13. Tighten screw (2) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Tightening torque 100 Nm + 10 Nm
14. Tighten adapter (3) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Adapter Tightening torque 100 Nm + 10 Nm
15. Install return line (7).
Note: Ensure special cleanness.
16. Coat thread and sealing cone of HP line (5) with engine oil.
Note: Two HP line versions (single- and double-walled) with different torques as described below.
17. Mount single-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening se‐
TIM-ID: 0000000925 - 006
quence:
1 Rail (6)
2 Adapter (4)
Name Size Type Lubricant Value/Standard
Union nut / thrust Tightening torque 30 Nm + 5 Nm
screw
Final steps
1. Install cylinder head cover (→ Page 117).
2. Open fuel supply to engine.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
3. Bar engine with starting system to blow out combustion chambers (→ Page 105).
4. Install injectors (→ Page 120).
Preconditions
☑ Engine is stopped and starting disabled.
Preconditions
☑ Engine is stopped and starting disabled.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine is at operating temperature.
☑ MTU fluids and lubricants specifications (A001061/..) are available.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Version without semirotary hand pump: Drain the engine oil through the drain plug(s)
on the oil pan.
1. Provide a suitable container in which to collect the engine oil.
2. Remove drain plug(s) and drain engine oil.
3. Install drain plug(s) with new sealing ring.
6. Tighten drain plugs (2) and (3) with torque wrench to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm
Preconditions
☑ Engine shut down and starting disabled.
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
• Dilution by fuel.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
TIM-ID: 0000000934 - 008
24. Tighten cover nut (2) with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 5 Nm to 7 Nm
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheating unit.
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 147) and top up coolant as required.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
tions).
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 155) and top up coolant as required.
TIM-ID: 0000019867 - 001
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preconditions
☑ Engine is stopped and starting disabled.
☑ Guard is removed.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
3. Tighten screw (2) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10x1.5 Tightening torque 60 Nm +5 Nm
4. Tighten screw (1) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10x1.5 Tightening torque 42 Nm
5. Install protective cover.
TIM-ID: 0000000945 - 006
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
8. Tighten screw (2) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10x1.5 Tightening torque 60 Nm +5 Nm
9. Tighten screw (1) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10x1.5 Tightening torque 42 Nm
TIM-ID: 0000022970 - 004
Preconditions
☑ Engine is stopped and starting disabled.
Preconditions
☑ Engine is stopped and starting disabled.
Preconditions
☑ Engine is stopped and starting disabled.
Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the
contacts could be bent.
Preconditions
☑ Engine is stopped and starting disabled.
Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the
contacts could be bent.
Preconditions
☑ Engine is stopped and starting disabled.
CAUTION
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given
engine is installed.
Service
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you
- either during operation, for preventive maintenance, corrective work in case of malfunction or changed
operating conditions, or for spare parts supply.
Your contact at Headquarters: Service-support@mtu-online.com
Feeler gauge
Part No.: Y20098771
Qty.: 1
Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page
113)
Filter wrench
Part No.: F30379104
DCL-ID: 0000005896 - 002
Qty.: 1
Used in: 6.8.1 Fuel filter – Replacement (→ Page 126)
Qty.:
Used in: 6.14.1 Engine oil filter – Replacement (→ Page 144)
Milling cutter
Part No.: F30452739
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 120)
Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 6.4.2 Valve clearance – Check and adjustment (→ Page
113)
Qty.: 1
DCL-ID: 0000005896 - 002
Rigid endoscope
Part No.: Y20097353
Qty.: 1
Used in: 6.2.1 Cylinder liner – Endoscopic examination (→ Page
107)
G W
General conditions 5 Wiring - engine
– Check 165
H
Hotline 174
HP pump
– Filling with engine oil 118
I
Injector
– Removal and installation 120
– Replacement 119
Inspection port cover
– Explosion hazard 11
M
Maintenance work
– Safety regulations 12
MTU contact persons 174
O
Operational checks 44
P
Personnel and organizational requirements 6
Plant
– Cleaning 50
Putting the engine into operation after extended out-of-
service periods (>3 months) 40
Putting the engine into operation after scheduled out-of-
service-period 41
R
Repair work
– Safety regulations 12
DCL-ID: 0000005896 - 002
S
Safety instructions 17
Safety regulations 12
Safety system
– Override 43
Service partners 174
Spare parts service 174
Start engine in manual mode (testing mode) 42
Starting the engine in emergency situations (override
mode) 45