Operating Instructions
Operating Instructions
Diesel engine
12 V 4000 C10, C10R, C11, C11R
12 V 4000 C20, C20R, C21, C21R
16 V 4000 C10, C11, C11R
16 V 4000 C20, C20R, C21, C21L
MS150049/02E
Nameplate
Engine identification is provided by the engine serial number on the nameplate.
The nameplate is located on the engine.
General information
This engine or plant may 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 or plant is intended solely for use in accordance with contractual agreements and the pur‐
pose envisaged for it on delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ engine data)
• With fluids and lubricants approved by MTU in accordance with the (→ MTU Fluids and Lubricants
Specifications)
• With spare parts approved by MTU in accordance with the associated (→ Spare Parts Catalog)
• In the original as-delivered configuration or in a configuration approved by MTU in writing (engine and
engine control/parameters)
• In compliance with all safety instructions and in adherence to all warning notices in these Operating
Instructions
• In compliance with the maintenance and repair instructions contained in these Operating Instructions,
in particular with regard to the specified tightening torques
• Appointing only qualified personnel to carry out work related to initial startup, operation, maintenance
and repair
• Contracting only workshops authorized by MTU to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in engine/plant operation.MTU will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the engine or plant represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
TIM-ID: 0000000860 - 018
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies.
MTU will accept no liability or warranty claims for any damage caused by the use of other spare parts.
Personnel requirements
All work on the engine or plant shall be carried out by trained and qualified personnel only:
• Training at the MTU Training Center
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair
and transport.
Transport
Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.
Always use the lifting eyes on the engine when transporting an engine separately.
Only use transport and lifting devices approved by MTU.
The engine/genset must only be transported in installation position: maximum permissible diagonal pull
10°.
Remove any loose parts on the genset.
Raise the engine/genset slowly. 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
TIM-ID: 0000002618 - 006
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.
Note: The transport locking device on both sides protects the crankshaft bearings from shocks and possible
vibration damage during engine transport.
For installation and removal of the transport locking device, follow the instructions
below:
1. The transport locking device on both sides must remain installed as long as possible during engine in‐
stallation in order to avoid damage.
2. Prior to every engine transport (without generator) , the transport locking device on both sides must be
installed 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 (→ Page 11).
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 this documentation to a highly visible area of the engine.
1. Secure plate (1) with screws (5) and washers (4) together with cover plate (7) 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) 250Nm +25Nm
2. Screw locknut (2) onto screws (3) up to the end of the thread.
3. Insert holder (8) through opening in plate (1) and secure with screw (3).
4. Tighten screws (3) alternately with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30Nm +3Nm
5. Place locknuts (2) of screw (3) in position on both sides of plate (1) and lock.
6. Fit sign (6) to mark the engine as "Fitted with transport locking device".
Note: The transport locking device on the engine protects the crankshaft bearings from shocks and vibration
damage during genset transport.
The following must be taken into account when removing/installing the transport
locking device:
1. The transport locking device must remain installed as long as possible during genset installation in order
to avoid damage.
2. Prior to every genset transport, the transport locking device must be reinstalled on the engine and gener‐
ator according to the instructions.
3. Always use the screws supplied with or installed in the transport locking device to secure it on the en‐
gine.
4. Starting or barring the engine is allowed only with the transport locking device removed from engine and
generator.
4. Install the two screws with washers to secure the diaphragm coupling to the flywheel.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 250Nm +25Nm
Engine operation
The following conditions must be fulfilled before starting the engine or plant:
• Wear ear protection.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com‐
ponents are placed on stable surfaces.
Observe special cleanness when conducting maintenance and repair work on the engine or plant. After
completion of maintenance and repair work, make sure that no loose objects are in/on the assembly or
plant (e.g. cloths and cable ties)
Welding work
Never carry out welding work on the assembly or plant, or attached units. Cover the engine or plant when
welding in its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the engine or plant while weld‐
ing is going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.
Do not use the engine or plant as ground terminal.
Do not route the welding lead over or near the wiring harnesses of the engine or plant. The welding cur‐
rent may otherwise induce an interference voltage in the wiring harnesses which could conceivably dam‐
age the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work. In particular, check the
function of the engine emergency stop feature.
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 or plant in a clean condition. Do not leave cloths soaked with fluids and
lubricants on the engine or plant. Do not store combustible materials near the engine or plant.
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).
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:
• 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.
• Wear goggles when blowing off components or blowing away chips.
• 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.
• Pay special attention to the pressure level in the compressed air network or pressure vessel.
• Assemblies or plants to be connected 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 couplings and connections must be securely attached.
• 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 the equipment or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• 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.
protective clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately.
• Rinse injured parts of the body thoroughly with clean water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.
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 hazardous situations.
Consequences: Minor or moderate injuries
• 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 messages 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 messages
1. Read and familiarize yourself with all safety message before starting up or repairing the product.
2. Pass on all safety messages to operating, maintenance, repair and transport personnel.
TIM-ID: 0000000881 - 020
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.
y Configuration status: 0, 1
Explanation
Abbr. Meaning
DL Reference value: Continuous power
BL Reference 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 set‐
ting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 12V 12V 12V 12V
4000 4000 4000 4000
C10 C10R C11 C11R
Application group 5A, 5B 5A, 5B 5A, 5B 5A, 5B
Intake air temperature °C 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 12 12 12 12
Rated engine speed A rpm - - 1900 1900
Continuous power (without fan) (fuel A kW - - 1286 1193
stop power)
TIM-ID: 0000040201 - 001
FUEL SYSTEM
Number of cylinders 12 12 12 12
Fuel temperature before pump, max. L °C 60 - 60 60
CAPACITIES
Number of cylinders 12 12 12 12
Engine coolant capacity, engine side R Liters 127 - 127 127
(without cooling equipment)
TIM-ID: 0000040201 - 001
Explanation
Abbr. Meaning
DL Reference value: Continuous power
BL Reference 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 set‐
ting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 16 V 16 V 16 V
4000 4000 4000
C10 C11 C11R
Application group 5A, 5B 5A, 5B 5A, 5B
Intake air temperature °C 25 25 25
Barometric pressure mbar 1000 1000 1000
Site altitude above sea level m 100 100 100
POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 16 16 16
Rated engine speed A rpm - 1900 1800
Continuous power (without fan) (fuel stop A kW - 1715 1600
power)
FUEL SYSTEM
Number of cylinders 16 16 16
Fuel temperature before pump, max. L °C 60 60 60
CAPACITIES
Number of cylinders 16 16 16
Engine coolant capacity, engine side (without R Liters 164 164 164
cooling equipment)
TIM-ID: 0000040208 - 001
Explanation
Abbr. Meaning
DL Reference value: Continuous power
BL Reference 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 set‐
ting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 12V 12V 12V 12V
4000 4000 4000 4000
C20 C20R C21 C21R
Application group 5A, 5B 5A, 5B 5A, 5B 5A, 5B
Intake air temperature °C 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 12 12 12 12
Rated engine speed A rpm 1900 1900 1900 1900
Continuous power (without fan) (fuel A kW 1500 - 1510 1398
stop power)
FUEL SYSTEM
Number of cylinders 12 12 12 12
Fuel temperature before pump, max. L °C 60 - 60 60
CAPACITIES
Number of cylinders 12 12 12 12
Engine coolant capacity, engine side R Liters 160 - 127 127
(without cooling equipment)
TIM-ID: 0000040210 - 001
Explanation
Abbr. Meaning
DL Reference value: Continuous power
BL Reference 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 set‐
ting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 16 V 16 V 16 V 16 V
4000 4000 4000 4000
C20 C20R C21 C21L
Application group 5A, 5B 5A, 5B 5A, 5B 5A, 5B
Intake air temperature °C 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 16 16 16 16
Rated engine speed A rpm 1900 1900 1900 1900
Continuous power (without fan) (fuel A kW 2013 1864 1864 2013
stop power)
FUEL SYSTEM
Number of cylinders 16 16 16 16
Fuel temperature before pump, max. L °C 60 - 60 60
CAPACITIES
Number of cylinders 16 16 16 16
Engine coolant capacity, engine side R Liters 164 - 164 164
(without cooling equipment)
TIM-ID: 0000040213 - 001
Firing order
Number of cylin‐ Firing order
ders
8V A1-B4-A4-A2-B3-A3-B2-B1
12V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
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
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting the engine into operation after extended out-of-service-periods (>3 months)
Item Action
Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).
Valve gear Lubricate valve gear every ≥ 6 months (→ Page 84).
Lube oil system Check engine oil level (→ Page 103);
Bar engine with startingsystem (→ Page 73).
Fuel system Vent (→ Page 97).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 113).
Change charge-air coolant (→ Page 121).
Coolant circuit Check engine coolant level (→ Page 112);
Check charge-air coolant level (→ Page 120).
Coolant circuit Preheat coolant with preheating unit, if fitted.
DDEC Check plug-in connections (→ Page 143).
Preconditions
☑ Engine is stopped and starting disabled.
Startup
Item Action
Lube oil system Check engine oil level (→ Page 103).
Coolant circuit Check engine coolant level (→ Page 112);
Check charge-air coolant level (→ Page 120).
Coolant circuit Preheat coolant with coolant preheating unit (if applicable).
Engine control system Put into operation.
TIM-ID: 0000002683 - 005
Preconditions
☑ Engine is not under load.
☑ External start interlock is not activated.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Action
Operating mode switch (if Switch to manual mode.
applicable)
Coolant preheating unit (if Switch ON.
applicable).
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 Action
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine operation Visually inspect engine and attached components for condition and leaks;
Check for abnormal running noise, exhaust discoloration and vibrations
(→ Page 49).
Battery-charging generator Check for dirt, clean as necessary (→ Page 130).
HP pump Check relief bore (→ Page 90).
HT coolant pump Check relief bore (→ Page 117).
LT coolant pump Check relief bore (→ Page 126).
TIM-ID: 0000002261 - 002
Preconditions
☑ Engine is not under load.
☑ 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.
Preparation
Item Action
Engine Operate engine at idling speed for approx. 5 minutes.
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are 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.
TIM-ID: 0000010171 - 024
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.
The DDEC engine governor generates alarms which are indicated in different ways depending on the
equipment configuration:
• Two-digit flashing code
• Fault code and text on a display or PC screen
To facilitate troubleshooting without additional auxiliary equipment, the two-digit flash codes can be read
out from the DDEC by means of the vehicle-side alarm lamps CHECK ENGINE LIGHT (yellow) and
STOP ENGINE LIGHT (red).
Two switches (DIAGNOSTIC REQUEST) must be provided in the plant in this case. The first switch is
used for reading out the flash codes of the master DDEC unit, the second one to read out the receiver
DDEC unit. The flash-code signals from master and receiver are transmitted to the same alarm lamps.
Active codes: Inactive codes:
indicated by STOP ENGINE LIGHT (red) indicated by CHECK ENGINE LIGHT (yellow)
Activation of “FLASH-CODES”:
1. Set “IGNITION” switch to ON.C.
2. Actuate “DIAGNOSTIC REQUEST” switch of Master or Receiver.
3. Read-off codes.
4. Identify fault on the basis of the DDC fault code list.
Example:
Active code 23: Inactive code 34:
STOP ENGINE LIGHT lamp CHECK ENGINE LIGHT lamp
flashes: flashes:
Flashing phase 1 Flashing phase 2 Flashing phase 1 Flashing phase 2
ОО ООО ООО ОООО
2 x flash 3 x flash 3 x flash 4 x flash
There is a pause lasting 0.5 seconds between flashing phases 1 and 2. There is a pause of approx. 3
seconds on changing between active and inactive code.
Switch off the “DIAGNOSTIC REQUEST” and “IGNITION” switches to cancel “FLASH-CODE” indication.
The “IGNITION” switch may only be switched back on after a 30 sec. delay.
Precise fault diagnosis is, however, not possible using this method as any one flashing code may be
used to cover several different fault causes.
Detailed diagnosis is possible using the Diagnostic Data Reader (DDR) readout/programming unit.
The Diagnostic Data Reader (DDR) is used to:
• Read out DDEC electronics fault messages
• Change a limited scope of parameters
Active and inactive fault codes can be read out with the DDR via separate menus. Inactive fault codes
TIM-ID: 0000003162 - 002
2. Contact Service.
17 51 3 Throttle sensor, input volt‐ 1. Check cabling.
age too high.
2. Contact Service.
17 72 3 Blower bypass position, in‐ 1. Check cabling.
put voltage too high.
2. Contact Service.
17 354 3 Humidity sensor, electric 1. Check cabling.
circuit defective / high (ver‐
2. Contact Service.
sion 33.0 or later).
2. Contact Service.
39 153 7 VNT vanes do not respond, 1. Check contamination indica‐
(version 29.0 or later). tor signal ring position
(→ Page 102).
2. Contact Service.
41 21 0 Too many SRS (TRS miss‐ Contact Service.
ing).
42 21 1 Too few SRS (SRS miss‐ Contact Service.
ing).
2. Contact Service.
66 99 3 Oil filter differential pressure 1. Check cabling.
sensor, voltage too high.
2. Contact Service.
66 99 4 Oil filter differential pressure 1. Check cabling.
sensor, voltage too low.
2. Contact Service.
66 76 0 Engine knock level above Contact Service.
normal range.
2. Contact Service.
73 77 0 Gas valve position above Contact Service.
normal range.
73 77 1 Gas valve position below Contact Service.
normal range.
73 77 3 Gas valve position input Contact Service.
voltage too high.
Preconditions
☑ Engine shut down 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 the engine, ensure that nobody is in the danger zone.
Preconditions
☑ Engine is stopped and starting disabled
Preparatory steps
1. Remove cylinder head cover (→ Page 89).
2. Remove injector (→ Page 92).
• On the entire circumference, apart from light areas of discoloration Cylinder liner must be re‐
(do not impair operation) clearly darker stripes that start at the top placed; Service must be con‐
piston ring tacted.
• Heat discoloration in the direction of stroke and honing pattern dam‐
age
• Heat discoloration of piston rings
Final steps
1. Install injector (→ Page 92).
2. Install cylinder head cover (→ Page 89).
TIM-ID: 0000003304 - 004
Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves in
the overlap (open) position. They are clearly visible due to the dark color of the
honing groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear
discoloration from TDC to BDC in the running surface and the start of localized
damage to the honing pattern.
Cylinders with a number of black lines around the running surface have limited
service life and should be replaced.
Preconditions
☑ Engine shut down 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.
9. Tighten nut of clamp (4) with torque wrench to specified tightening torque.
Name Size Type Lubricant Value/Standard
Nut Tightening torque (Engine oil) 9Nm +1Nm
10. Push vent hose onto oil separator cover (3) and bolt on.
11. Replace further filter elements (2) in the same way.
TIM-ID: 0000003532 - 003
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• Observe manufacturer's instructions.
• Wear protective clothing, gloves, and goggles / safety mask.
Preconditions
☑ Engine shut down and starting disabled.
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
CAUTION
Unsuitable cleaning tool.
Damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.
Preconditions
☑ Engine shut down and starting disabled.
Preconditions
☑ Engine is stopped and starting disabled.
Preconditions
☑ Engine shut down and starting disabled.
☑ Engine coolant temperature is max. 40°C.
☑ Valves are closed.
Preparatory steps
1. Remove cylinder head cover (→ Page 89).
2. Install barring device (→ Page 72).
3. Rotate crankshaft with barring device in en‐
gine direction of rotation until "TDC-A1"
mark and pointer are aligned.
TIM-ID: 0000004357 - 007
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
Nut M16 x 1.5 Tightening torque (Engine oil) 90Nm +9Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Preconditions
☑ Engine is stopped and starting disabled.
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.
Replacing injector
u Remove injector and install new injector (→ Page 92).
TIM-ID: 0000000022 - 013
Preconditions
☑ Engine shut down and starting disabled.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
CAUTION
Removal of all injectors.
Damage to component!
• Ensure that the high-pressure fuel accumulator is secured on the engine through two HP lines.
CAUTION
Cable damage during operation.
Fire hazard!
• Twist cables when installing.
• Ensure that cables do not touch components.
Preparatory steps
1. Close off fuel supply to engine.
2. Remove cylinder head cover (→ Page 89).
TIM-ID: 0000000952 - 009
Installing injector
1. Prior to installation, remove all blanking
plugs.
2. Coat injector with assembly paste in the
area of the nozzle retaining nut.
3. Fit new O-rings on injector and coat with
grease.
4. Fit new sealing ring with grease on injector,
observe installation position of sealing ring.
12. Fit hold-down clamp (1) in correct position by hand. Tighten screw (2) with torque wrench to the specified
initial tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Preload torque (Engine oil) 5Nm to 10Nm
TIM-ID: 0000000952 - 009
13. Fit O-rings (4) and (6) on high-pressure fuel line (5) and coat with grease.
14. Tighten high-pressure fuel line (5) to the specified initial tightening torque.
Name Size Type Lubricant Value/Standard
HP line Preload torque (Engine oil) 5Nm to 10Nm
15. Tighten screw (2) to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw M12 Tightening torque 100Nm + 10Nm
19. Insert cable lugs (arrows) underneath the screws on the injector and tighten screws with torque wrench
to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 1.5Nm
Final steps
1. Install cylinder head cover (→ Page 89).
2. Open up fuel supply to engine.
Preconditions
☑ Engine shut down 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 shut down 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.
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Preconditions
☑ Engine is stopped and starting disabled.
Preconditions
☑ Engine shut down and starting disabled.
DANGER
Cleaner is an explosive and poisonous substance.
Danger to life, major material damage!
• Avoid open flames, electrical sparks and ignition sources.
• Wear goggles/facial protection.
• Only work in a well-ventilated room.
• Do not smoke.
Preconditions
☑ Engine is stopped and starting disabled.
Preconditions
☑ Engine shut down 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.
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.
• Fuel dilution.
Preconditions
☑ Engine shut down 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.
CAUTION
Unsuitable cleaning tool.
Damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.
Removing strainer
1. Clean oil indicator filter before disassem‐
bling it.
2. Remove screws (1).
3. Take off cover (2) with O-ring (3).
4. Remove strainer (5) from housing and allow
oil to drip into container.
TIM-ID: 0000036227 - 002
Checking strainer
Item Findings Action
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Contact Service.
Strainer Damaged Fit new part
Square-section ring Damaged Fit new part
O-ring Damaged Fit new part
Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Insert strainer into housing.
3. Fill housing with new engine oil.
4. Coat O-ring (3) with engine oil and fit in filter housing.
5. Fit cover (2) and secure with screws (1) and washers.
TIM-ID: 0000036227 - 002
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.
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 shut down 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 a suitable receptacle to catch the coolant.
2. Switch off preheating unit.
Final steps
u Switch on preheater.
TIM-ID: 0000000936 - 004
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 of filler neck on coolant
expansion tank counterclockwise to first
stop and allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
TIM-ID: 0000006715 - 002
Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 112) and top up engine 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
☑ 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.
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 (A001061/..)).
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.
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 of coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Turn breather valve counterclockwise and
remove.
TIM-ID: 0000007013 - 003
Final steps
TIM-ID: 0000007013 - 003
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 120) 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
☑ Engine is stopped and starting disabled.
☑ Guard is removed.
Preconditions
☑ Engine shut down and starting disabled.
Preconditions
☑ Engine shut down and starting disabled.
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Heavy object.
Risk of crushing!
• Use appropriate lifting devices and appliances.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Heavy object.
Risk of crushing!
• Use appropriate lifting devices and appliances.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
Preconditions
☑ Engine shut down and starting disabled.
Preparatory steps
1. Remove protective cover.
2. Check belt condition visually (→ Page 128).
Result: Measure for drive replacement (→ Page 138).
Initial assembly at MTU Initial operation with fan Belt tension adjustment
- 60Hz ± 1Hz 52Hz ± 1Hz
TIM-ID: 0000040791 - 002
Preconditions
☑ Engine is stopped and starting disabled.
Preparatory steps
1. Remove protective cover.
2. Remove fan.
Preconditions
☑ Engine is stopped and starting disabled.
WARNING
Compressed-air pipes may still be under pressure, although the shut-off valve is closed.
Risk of injury!
• Before starting work, release pressure from pipework.
Checking compressor
1. Check oil supply line (3) and connections
for condition and leaks.
2. Check coolant lines (1) and connections for
condition and leaks.
3. Check air intake line (2) and connections
for condition and leaks.
4. Check compressor (4) for leaks.
5. If damage or leaks are found, contact Serv‐
ice.
TIM-ID: 0000007722 - 002
Preconditions
☑ Engine is stopped and starting disabled.
Preconditions
☑ Engine is stopped and starting disabled.
DANGER
Cleaner is an explosive and poisonous substance.
Danger to life, major material damage!
• Avoid open flames, electrical sparks and ignition sources.
• Wear goggles/facial protection.
• Only work in a well-ventilated room.
• Do not smoke.
Preconditions
☑ Engine is stopped and starting disabled.
DT Diagnostic Tool
ECM Electronic Control Module Electronic control unit of the DDEC system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EE‐ Electrically Erasable Programmable Read
PROM Only Memory
EFPA Electronic Foot Pedal Assembly
EGR Exhaust Gas Recirculation
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you
– either during operation, for preventive maintenance, corrective work in case of malfunction or changed
operating conditions, or for spare parts supply.
Your contact at Headquarters: Service-support@mtu-online.com
Barring device
Part No.: F6555766
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 72)
Qty.: 1
Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page
74)
Endoscope
Part No.: Y20097353
Qty.: 1
Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page
74)
DCL-ID: 0000017488 - 004
Filling device
Part No.: B80144852
Qty.: 1
Used in: 7.8.1 Fuel system – Venting (→ Page 97)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.9.1 Fuel filter – Replacement (→ Page 98)
Qty.: 1
Used in: 7.14.1 Engine oil filter – Replacement (→ Page 107)
Qty.: 1
Used in: 7.14.3 Centrifugal oil filter – Cleaning and filter sleeve
replacement (→ Page 110)
Qty.: 1
Used in: 7.15.6 Coolant filter – Replacement (→ Page 118)
Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 7.13.2 Engine oil – Change (→ Page 104)
DCL-ID: 0000017488 - 004
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 7.19.3 Battery-charging generator – Removal and in‐
stallation (→ Page 131)
Qty.: 1
Used in: 7.19.4 Battery-charging generator – Drive belt and belt
tensioner replacement (→ Page 133)
Qty.: 1
Used in: 7.19.5 Battery-charging generator – Drive belt tension
adjustment (→ Page 135)
Slotted screwdriver
Part No.: F30452578
Qty.: 1
Used in: 7.7.2 Injector – Removal and installation (→ Page 92)
DCL-ID: 0000017488 - 004
Qty.: 1
Used in: 7.19.3 Battery-charging generator – Removal and in‐
stallation (→ Page 131)
O
Oil indicator filter
– Check 108
Operation
– Safety regulations 13
Operational checks 43
Organizational requirements 6
P
Personnel requirements 6
Plant
– Cleaning 46
Provisions 5
Putting the engine into operation
– Preparation after scheduled out-of-service-period
41
Putting the engine into operation after extended out-of-
service periods (>3 months) 40
R
Repair work
DCL-ID: 0000017488 - 004
S
Safety messages
– Standards 19
Safety regulations 13, 14
Sensors, actuators and injectors – Overview 23
Service indicator
– Check 102
Service partners 147
Spare parts service 147