Operating Instructions: Diesel Engine 16 V 4000 Rx3 X
Operating Instructions: Diesel Engine 16 V 4000 Rx3 X
Operating Instructions: Diesel Engine 16 V 4000 Rx3 X
Diesel engine
16 V 4000 Rx3 x
MS15042/00E
Engine model kW/cyl. Application group
16V4000R43 137.5 kW/cyl. 2A, continuous operation, unrestricted
16V 4000 R43L 150 kW/cyl. 2A, continuous operation, unrestricted
16V4000R43R 125 kW/cyl. 2A, continuous operation, unrestricted
Table 1: Applicability
7.15 Oil Filtration / Cooling 121 7.19 Drive, Power Generation and Safety
7.15.1 Engine oil filter – Replacement 121 Systems 147
7.15.2 Checking oil indicator filter 122 7.19.1 Generator – Greasing antifriction bearing 147
7.15.3 Centrifugal oil filter – Cleaning and filter- 7.19.2 Generator – Cleaning intake air grille 148
sleeve replacement 124
7.20 Wiring (General) for Engine/Gearbox/Unit 149
7.16 Coolant Circuit, General, High-Temperature 7.20.1 Еngine cabling ‒ Check 149
Circuit 126
7.16.1 Engine coolant – Level check 126
7.21 Accessories for (Electronic) Engine
7.16.2 Engine coolant – Change 127 Governor / Control System 150
7.16.3 Engine coolant – Draining 128 7.21.1 CDC parameters – Reset with DiaSys® 150
7.16.4 Replenishing engine coolant 129 7.21.2 Engine governor and connectors – Cleaning 151
7.16.5 Engine coolant pump – Relief bore check 132 7.21.3 Engine governor plug connections – Check 152
7.16.6 Engine coolant – Sample extraction and
analysis 133
8 Appendix A
7.16.7 Preheating unit – Overview 134
7.16.8 Preheater unit – Removal 136 8.1 Abbreviations 153
7.16.9 Preheater unit – Installation 137 8.2 MTU contact persons/service partners 155
7.17 Low-Temperature Circuit 138
7.17.1 Charge-air coolant – Level check 138 9 Appendix B
7.17.2 Charge-air coolant – Change 139
7.17.3 Charge-air coolant – Draining 140 9.1 Special Tools 156
9.2 Index 162
General information
This product may pose a risk of injury or damage in the following cases:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices
Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine management/parameters)
• In compliance with all safety regulations and in accordance with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re-
sulting from improper, non-intended use.
Changes or modifications
Unauthorized changes to the product represent a contravention of its intended use and compromise
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safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and 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: Refer to installation drawing.
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
transport.
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Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip-
ping and tipping when driving up or down inclines and ramps.
For installation and removal of the transport locking device, follow the in-
structions below:
1. The transport locking device must remain installed on both engine sides as long as possible during en-
gine installation in order to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both engine 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 genera-
tor is already installed on the engine, ensure that the transport locking device of the generator is also
removed.
Note: Screw plate (6) onto the upper part of the openings only.
1. Fasten the plates (6) with screws (4) and washers (5) at the lateral openings on both sides of the fly-
wheel 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. Fit locknut (2) on screws (1) up to the end of the thread.
3. The long side of retainer (3) must point downwards. Insert retainer (3) through the openings of plate (6).
Note: Retainer (3) must tension only the flywheel, not the ring gear.
4. Insert screw (1) in bores of retainer (3) until retainer (3) is locked in position.
Note: Screw (1) must be tightened alternately on both sides of the flywheel housing.
5. Tighten screw (1) to specified tightening torque .
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
6. Fit locknut (2) of screw (1) on plate (6) and tighten.
Operation
Do not stay in the operating room when the product is running unless absolutely necessary and then as
briefly as possible.
Keep a safe distance away from the product whenever possible. Do not touch the product unless ex-
pressly instructed to do so.
Do not inhale exhaust gases emitted by the product.
Ensure that the following requirements have been fulfilled before starting the product:
• Ear protectors are worn.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
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agent.
Welding work
Do not perform welding on the product or its attachments. Cover the product when performing welding
work in the vicinity.
Before commencing welding work:
• Switch off the master power supply switch.
• Disconnect the battery.
• Disconnect electronic and genset grounds.
Do not perform maintenance or repair work on the product when welding is in progress in its vicinity.
Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use the product as a grounding terminal.
Do not route the welding cable over or near the wiring harnesses of the product. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .
Observe the safety requirements of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte (battery acid) to come into contact with skin or clothing.
Wear goggles and protective gloves.
Do not place tools on the battery.
Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.
Noise
Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.
Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A).
Used oil
Used oil contains combustion residues that are harmful to health.
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 (hazard class AI, AII and B) out of
containers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products to be connected must either be designed for that pressure, or, if the permis-
sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
• 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 device is disconnected from the supply
line, or before device 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.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
CAUTION
In the event of a situation involving potential danger.
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.
Safety notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.
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Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 16
Rated engine speed A rpm 1800
UIC rated power (fuel stop power ISO 3046) A kW 2200
Consumption
Number of cylinders 16
Specific fuel consumption (be) - 100% BL (+5%; EN 590; 42.8MJ/kg) R g/kWh 206
Fuel system
Number of cylinders 16
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3
Fuel pressure at engine inlet connection, min. (when engine is running) L bar -0.3
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 1.5
Capacities
Number of cylinders 16
Engine coolant, engine side (without cooling equipment) R Liters 235
Charge-air coolant, engine side R Liters 70
Engine oil capacity, initial filling (standard oil system) (Option: max. operating R Liters 330
inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 180
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 255
operating inclinations)
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Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 16
Nominal engine speed A rpm 1800
UIC rated speed (fuel stop power as per ISO 3046) A kW 2400
Consumption
Number of cylinders 16
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Specific fuel consumption (be) - 100% BL (+5%; EN 590; 42.8MJ/kg) G g/kWh 207
Lube oil consumption after 100 h run time (B = hourly fuel consumption) R % of B 0.3
Air/exhaust gas
Number of cylinders 16
Charge-air pressure before cylinder R bar abs 4.1
Exhaust temperature after exhaust turbocharger R °C –
Number of cylinders 16
Lube oil operating temperature before engine, from R °C 60
Lube oil operating temperature before engine, to R °C 95
Lube oil operating pressure before engine (measuring block) R bar 5.7
Lube oil operating pressure before engine, warning R bar –
Lube oil pressure before engine, shutdown L bar –
Lube oil operating pressure (low idle) (measuring point: before engine) R bar 2.7
Capacities
Number of cylinders 16
Engine coolant capacity, engine side (without cooling equipment) R Liters 235
Charge-air coolant, engine side R Liters 70
Engine oil capacity, initial filling (standard oil system) (option: max. operating R Liters 330
inclinations)
Oil pan capacity, dipstick mark min. (standard oil system) (option: max. oper- L Liters 180
ating inclinations)
Oil pan capacity, dipstick mark max. (standard oil system) (option: max. oper- L Liters 255
ating inclinations)
Weights/main dimensions
Number of cylinders 16
Engine dry weight (with standard accessories installed, without clutch) R kg 7930
Acoustics
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Number of cylinders 16
Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- R dB(A) 118
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise, without intake noise - BL (free-field sound-pressure level R dB(A) 106
Lp, 1m distance, ISO 6798)
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 16
Rated engine speed A rpm 1800
UIC rated power (fuel stop power ISO 3046) A kW 2000
CONSUMPTION
Number of cylinders 16
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Specific fuel consumption (be) - 100% BL (+5%; EN 590; 42.8MJ/kg) R g/kWh 207
Number of cylinders 16
Lube oil operating temperature before engine, from R °C 60
Lube oil operating temperature before engine, to R °C 95
Lube oil operating pressure before engine (measurement block) R bar 5.7
Lube oil operating pressure before engine, warning R bar -
Lube oil operating pressure before engine, shutdown L bar -
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.7
CAPACITIES
Number of cylinders 16
Engine coolant capacity, engine side (without cooling equipment) R Liters 235
Charge-air coolant, engine side R Liters 70
Engine oil capacity, initial filling (standard oil system) (Option: max. operating R Liters 330
inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 180
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 255
operating inclinations)
ACOUSTICS
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Number of cylinders 16
Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- R dB(A) 115
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise w/o intake noise - BL (free-field sound pressure level Lp, R dB(A) 105
1m distance, ISO 6798, +2dB(A) tolerance)
Item Dimension
Length (A) 8 V approx. 2129 mm
Length (A) 12 V approx. 2497 mm
Length (A) 16 V approx. 3192 mm
Length (A) 20 V approx. 3591 mm
Width (B) 8 V approx. 1399 mm
Width (B) 12, 16, 20 V approx. 1562 mm
Height (C) 8 V approx. 1988 mm
Height (C) 12, 16, 20 V approx. 2013 mm
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Putting the engine into operation after extended out-of-service periods (>3
months)
Item Action
Engine Depreservation (→ MTU Preservation and Represervation Specifications
A001070/..).
Valve drive Lubricate valve gear (→ Page 85).
Lube oil system Check engine oil level (→ Page 117).
Bar engine with starting equipment (→ Page 77).
Fuel system Vent (→ Page 99).
Coolant circuit Out-of-service period more than 1 year: Change engine coolant (→ Page 127)
Change charge-air coolant (→ Page 139).
Coolant circuit Check engine coolant level (→ Page 126).
Check charge-air coolant level (→ Page 138).
Coolant circuit Preheat engine coolant with coolant preheater (if applicable).
Engine control system Check plug connections (→ Page 152).
Engine Control System Switch on.
HP fuel pump Only for engines without oil priming pump:
Fill HP fuel pump with fresh engine oil (→ Page 92).
Startup
Item Action
Lube oil system Check engine oil level (→ Page 117).
Coolant circuit Check engine coolant level (→ Page 126);
Check charge-air coolant level (→ Page 138).
Coolant circuit Heat coolant with coolant preheater (if available; see manufacturer's docu-
mentation).
Engine control system Put into operation (see manufacturer's documentation).
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DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the en-
gine's danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Action
Operating mode switch (if Switch to manual mode.
applicable)
Coolant preheater If engine coolant temperature is ≤ 25 °C: Switch on preheater.
NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical
stresses.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and
constant levels are indicated.
Preparations
Item Action
Engine Run engine at idling speed under zero load.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
• Never direct water jet at people.
• Wear protective clothing, protective gloves and safety goggles/face mask.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors
or ECUs.
Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).
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. For external cleaning of the plant with water or steam-jet cleaners:
• 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.
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W1207 Check valve clearance, adjust if necessary. ATTENTION! First (→ Page 86)
adjustment after 1,000 operating hours.
W1463 Check general condition of engine mounting (visual inspection). (→ Page 145)
W1481 Replace intermediate fuel filter or filter element of intermediate (→ Page 103)
fuel filter.
Fault message:
Brief description of the reported fault.
Cause:
More detailed description of the cause of the fault message.
Remedial action:
Measures for the vehicle operator. If several measures are specified for a single fault message, car-
ry them out in the listed order until the fault is eliminated.
4 – SS T-Fuel L2
Red alarm; power reduction ≥ 20%; forced idle
Cause Corrective action
Fuel temperature too high. 1. Acknowledge alarm.
2. Request towing locomotive if required.
5 – HI T-Charge Air
Yellow alarm; warning
Cause Corrective action
Charge-air temperature too high. 1. Reduce power.
2. If fault code number 9 is signaled at the same time, then it has
priority.
6 – SS T-Charge Air L2
Yellow alarm; power limitation < 20%;
Cause Corrective action
Charge-air temperature too high. 1. Reduce power.
2. If fault code number 9 is signaled at the same time, then it has
priority.
9 – HI T-Coolant Intercooler
Yellow alarm; warning
Cause Corrective action
Coolant temperature in 1. Reduce power.
intercooler too high. 2. Check engine lines for leaks. Check coolant cooler for leaks,
contamination and operation.
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10 – SS T-Coolant Intercooler L2
Yellow alarm; power limitation < 20%;
Cause Corrective action
Coolant temperature in 1. Reduce power.
intercooler too high. 2. Check engine lines for leaks. Check coolant cooler for leaks,
contamination and operation.
3. Contact Service.
16 – SS P-Lube Oil L2
Red alarm; engine stop
Cause Corrective action
Lube oil pressure too low. 1. Check oil level, top up as necessary (→ Page 117).
2. Acknowledge alarm.
3. Restart engine (→ Page 38).
4. Request towing locomotive if required.
19 – HI T-Exhaust A
Red alarm; engine stop
Cause Corrective action
Exhaust gas temperature (A- 1. Reduce power.
side) too high. 2. Check air filter.
3. Request towing locomotive if required.
20 – SS T-Exhaust A
Red alarm; power reduction ≥ 20%
Cause Corrective action
Exhaust gas temperature (A- 1. Reduce power.
side) too high. 2. Check air filter.
3. Request towing locomotive if required.
21 – HI T-Exhaust B
Yellow alarm; warning
Cause Corrective action
Exhaust gas temperature (B- 1. Reduce power.
side) too high. 2. Check air filter.
3. Request towing locomotive if required.
22 – SS T-Exhaust B
Red alarm; power reduction ≥ 20%
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30 – SS Engine Overspeed L2
Red alarm; engine stop
Cause Corrective action
Engine speed too high. 1. Acknowledge alarm.
2. Request towing locomotive if required.
31 – HI ETC1 Overspeed L1
Yellow alarm; power limitation > 20%
Cause Corrective action
ETC1 (A-side) speed too high. 1. Reduce power.
2. Check air filter.
3. Request towing locomotive if required.
32 – SS ETC1 Overspeed L2
Red alarm; power reduction ≥ 20%
Cause Corrective action
ETC1 (A-side) speed too high. 1. Reduce power.
2. Check air filter.
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36 – HI ETC2 Overspeed L1
Yellow alarm; power limitation > 20%
Cause Corrective action
ETC2 (B-side) speed too high. 1. Reduce power.
2. Check air filter.
3. Request towing locomotive if required.
51 – HI T-Lube Oil
Yellow alarm; warning
Cause Corrective action
Lube oil temperature too high. 1. Reduce power.
2. If fault code number 67 is signaled at the same time, then it has
priority.
52 – SS T-Lube Oil L2
Red alarm; power reduction ≥ 20%
Cause Corrective action
Lube oil temperature too high. 1. Reduce power.
2. If fault code number 67 is signaled at the same time, then it has
priority.
59 – SS T-Coolant L3
Red alarm; forced idle
Cause Corrective action
Coolant temperature too high. 1. Activate fan emergency operating mode if required.
2. Allow engine to cool down.
3. Check engine coolant cooler, clean if dirty.
4. Acknowledge alarm.
5. Restart engine (→ Page 38).
6. Request towing locomotive if required.
60 – SS T-Coolant L4
Red alarm; engine stop
Cause Corrective action
Coolant temperature too high. 1. Allow engine to cool down.
2. Check engine coolant cooler, clean if dirty.
3. Acknowledge alarm.
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64 – SS P-Crankcase L2
Red alarm; engine stop
Cause Corrective action
Crankcase pressure too high. 1. Request towing locomotive if required.
2. Contact Service.
65 – LO P-Fuel
Yellow alarm; warning
Cause Corrective action
Fuel pressure before HP pump 1. Check fuel lines for leakage.
too low. 2. Drain fuel prefilter (→ Page 101).
3. Replace filter element of fuel prefilter (→ Page 102).
4. Replace fuel filter and, if required, intermediate fuel filter
(→ Page 100).
66 – SS P-Fuel L2
No alarm, fault is registered.
Cause Corrective action
Fuel pressure before HP pump 1. Check fuel lines for leakage.
too low. Possibly only reduced 2. Drain fuel prefilter (→ Page 101).
power is available. 3. Replace filter element of fuel prefilter (→ Page 102).
4. Replace fuel filter and, if required, intermediate fuel filter
(→ Page 100).
67 – HI T-Coolant L1
Yellow alarm; warning
Cause Corrective action
Coolant temperature too high. 1. Reduce power.
2. Check engine coolant cooler, clean if dirty.
68 – SS T-Coolant L2
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90 – SS No Idling Speed
Yellow alarm; warning
Cause Corrective action
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92 – SS No Starter Speed
Yellow alarm; warning
Cause Corrective action
Starter speed not reached; 1. Initiate new starting attempt.
termination of starting 2. Check voltage at starter power supply.
sequence; starter does not turn 3. Request towing locomotive if required.
or turns slowly.
93 – SS T-Preheat
No alarm, fault is registered.
Cause Corrective action
Preheating temperature too low; 1. Extend preheating period.
coolant temperature too low for 2. Check preheating unit.
engine start. Significantly
increased engine wear. Engine
start might be inhibited by the
locomotive control system.
Engine may be started in
emergency situations only.
94 – LO T-Preheat
Yellow alarm; warning
Cause Corrective action
Preheating temperature too low; 1. Extend preheating period.
coolant temperature too low for 2. Check preheating unit.
engine start. Excessive engine
wear. Engine start might be
inhibited by the locomotive
control system. Engine may be
started in emergency situations
only.
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122 – HI T-ECU
Yellow alarm; warning
Cause Corrective action
Electronic unit temperature too 1. Reduce power.
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valid.
201 – SD T-Coolant
Yellow alarm; power limitation < 20%;
Cause Corrective action
Coolant temperature sensor u Check sensor B6 and wiring, replace as necessary
faulty; short circuit or wire (→ Page 149).
break.
206 – SD T-Exhaust A
Yellow alarm; warning
Cause Corrective action
Exhaust temperature sensor on u Check sensor B4.21 and wiring, replace as necessary
A-side faulty; short circuit or (→ Page 149).
wire break.
207 – SD T-Exhaust B
Yellow alarm; warning
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214 – SD P-Crankcase
Yellow alarm; warning
Cause Corrective action
Crankcase pressure sensor u Check sensor B50 and wiring, replace as necessary
faulty; short circuit or wire (→ Page 149).
break.
240 – SD P-Fuel
Yellow alarm; warning
Cause Corrective action
Fuel pressure sensor after fuel u Check sensor B34 and wiring, replace as necessary
main filter defective; short (→ Page 149).
circuit or wire break.
410 – LO U-PDU L1
Yellow alarm; warning
Cause Corrective action
Injector voltage too low. 1. Check wiring (→ Page 149).
2. Check supply.
412 – HI U-PDU L2 L1
Yellow alarm; warning
Cause Corrective action
Injector voltage too high. 1. Check wiring (→ Page 149).
2. Check supply.
444 – SD U-PDU
Yellow alarm; warning
Cause Corrective action
Injector power stage sensor u Replace engine governor.
defect; internal fault in engine
governor.
470 – SD T-ECU
Yellow alarm; warning
Cause Corrective action
Temperature sensor for engine u Check sensor and wiring, replace as necessary (→ Page 149).
governor faulty; short circuit or
wire break.
474 – AL Wiring FO
Yellow alarm; warning
Cause Corrective action
Line break or short circuit at FO u Check wiring (→ Page 149).
channel.
battery-charging generator.
The operating voltage of the u Instruct the operator only to disconnect the power supply when
engine governor was switched of the engine has stopped.
with the engine running. This
may lead to overpressure in the
HP fuel system, which might
cause damage to the engine.
601 – SD ETC1+ETC2
Red alarm; power reduction ≥ 20%
Cause Corrective action
Exhaust temperature sensor on u Check sensor and wiring (B44.1 and B44.2), replace as
A and B sides defective; short necessary.
circuit or wire break.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Preparatory steps
1. Remove cylinder head cover (→ Page 90).
2. Remove injector (→ Page 94).
• On the entire circumference, apart from light areas of discoloration Cylinder liner must be replaced,
(do not impair operation) clearly darker stripes that start at the top contact Service.
piston ring
• Heat discoloration in the direction of stroke and honing pattern
damage
• Heat discoloration of piston rings
Final steps
1. Install injector (→ Page 94).
2. Install cylinder head cover (→ Page 90).
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.
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.
Preparatory steps
1. Remove cylinder head cover (→ Page 90).
2. Install barring device (→ Page 75).
Note: The OT mark (if fitted) on the flywheel must
not be used for reference.
3. Rotate crankshaft with barring device in en-
gine direction of rotation until "OT / A1"
mark and pointer are aligned.
Final steps
1. Remove barring device (→ Page 75).
2. Install cylinder head cover (→ Page 90).
TIM-ID: 0000000922 - 013
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
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/explosive.
Risk of fire and explosion!
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.
NOTICE
HP fuel pump not filled with engine oil.
Damage to components, major material damage!
• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into 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. Install plug screw (1).
Injector – Replacement
u Remove injector and install new one (→ Page 94).
TIM-ID: 0000042329 - 002
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 90).
Removing injector
1. Disconnect connectors on injector.
TIM-ID: 0000000925 - 014
10. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the speci-
fied 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 (Engine oil) 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 (Engine oil) 100 Nm + 10 Nm
Note: Ensure special cleanness.
15. Coat thread and sealing cone of HP line (5) with engine oil.
16. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening
sequence:
1 Adapter (4)
TIM-ID: 0000000925 - 014
2 Rail (6)
Name Size Type Lubricant Value/Standard
Union nut / thrust Tightening torque (Engine oil) 40 Nm + 5 Nm
screw
Final steps
1. Install cylinder head cover (→ Page 90).
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.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
screws (6).
12. Close vent plug (4) when fuel emerges.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
5. Tighten clamp (11) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque (Assembly compound 15 Nm +2 Nm
(Ultra-Therm MTU))
6. Install insulation mat on bellows (12).
7. Install protective cover (1) with washers (9) and screws (8) and tighten with torque wrench to the speci-
fied tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Tightening torque (Assembly compound 60 Nm +6 Nm
(Ultra-Therm MTU))
8. Install heat shield (2) with spacer (5), washers (3,7) and screws (4,6).
TIM-ID: 0000013059 - 006
WARNING
Chemical substances.
Risk of irritation or burning of eyes, skin and airways!
• Observe information provided in the relevant safety data sheet.
• Wear protective gear as specified in the relevant safety data sheet.
NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.
NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
Preparatory steps
1. Remove air filter (→ Page 114).
2. Remove bellows.
3. Seal all openings with suitable covers.
TIM-ID: 0000048620 - 002
Final steps
1. Install compressor housing (1).
TIM-ID: 0000048620 - 002
4. Position clamp (2) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 15 Nm + 2 Nm
5. Install air intake.
Note: Install new gasket.
6. Install charge-air pipe to compressor housing.
7. Tighten screws.
8. Install bellows.
9. Install air filter (→ Page 114).
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
Visual inspection
1. Use inspection lamp to check cleaned filter
element for damage.
2. Fit new filter element if old one is damaged
(→ Page 113).
TIM-ID: 0000005423 - 006
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: Draining oil at drain plug(s) on 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.
5. Tighten drain (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
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.
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
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
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
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 gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.
Removing strainer
1. Clean oil indicator filter before dismantling
it.
2. Remove screws (1).
3. Take off cover (2) and O-ring (3).
4. Remove strainer (5) from the filter housing
and allow oil to drip into container.
TIM-ID: 0000036227 - 005
Checking strainer
Item Findings Action
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Notify 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 - 005
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 gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
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.
Preparatory steps
1. Provide a suitable receptacle to catch the coolant.
2. Switch off preheating unit.
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.
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn the valve cover (1) on the coolant ex-
pansion tank counterclockwise to the stop
and allow pressure to escape.
2. Continue to turn valve cover (1) counter-
clockwise and remove.
TIM-ID: 0000006724 - 007
be topped up.
15. Disconnect pump and hose.
Final steps
1. Start the engine and run it under zero load for several minutes.
2. Check coolant level (→ Page 126) and top up coolant as required.
TIM-ID: 0000006724 - 007
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.
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
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
1 Preheating unit
WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.
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
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!
WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
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.
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• 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.
TIM-ID: 0000000940 - 007
be topped up.
15. Remove pump and hose.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 138) and top up coolant as necessary.
TIM-ID: 0000000940 - 007
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
NOTICE
Contamination of engine mounts made of natural rubber with fuel or oil.
Engine mounts swell. Risk of shorter service life or destruction of the mounts!
• Cover engine mounts when working with fuel or oil.
• Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them.
5. Tighten nut (3) to the specified tightening torque. When doing so, lock the central buffer (2) to prevent
it turning.
Name Size Type Lubricant Value/Standard
Nut M27 x 2 Tightening torque (Engine oil) 580 Nm +50 Nm
6. Fit protective cap (1).
TIM-ID: 0000015376 - 008
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Note: Always use test connectors to enter the connectors. Never use test leads for this purpose. Otherwise
the contacts could be bent.
NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.
GND Ground
HP High pressure
HI High Alarm: Measured value higher than 1st maximum
limit
HIHI High High Alarm: Measured value higher than 2nd maximum
limit
HT High Temperature
ID Identification number
Caps
UT Unterer Totpunkt Bottom dead center (BDC)
WZK Tool Catalog
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 person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Endoscope
Part No.: Y20097353
Qty.: 1
Used in: 7.2.1 Cylinder liner – Endoscopic examination
(→ Page 79)
Qty.: 1
Used in: 7.9.1 Exhaust turbocharger – Turbine housing check
(→ Page 104)
DCL-ID: 0000035416 - 001
Feeler gauge
Part No.: Y20010128
Qty.: 1
Used in: 7.18.1 Engine mounts – Resilient element check
(→ Page 145)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.8.1 Fuel filter – Replacement (→ Page 100)
Qty.: 1
Used in: 7.8.4 Intermediate fuel filter – Replacement
(→ Page 103)
Qty.:
Used in: 7.15.1 Engine oil filter – Replacement (→ Page 121)
Grease gun
Part No.:
Qty.:
Used in: 7.19.1 Generator – Greasing antifriction bearing
(→ Page 147)
DCL-ID: 0000035416 - 001
Milling cutter
Part No.: F30452739
Qty.: 1
Used in: 7.6.2 Injector – Removal and installation (→ Page 94)
Ratchet
Part No.: F30027341
Qty.: 1
Used in: 7.14.2 Engine oil – Change (→ Page 118)
DCL-ID: 0000035416 - 001
Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 7.6.2 Injector – Removal and installation (→ Page 94)
Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
Used in: 7.4.2 Valve clearance – Check and adjustment
(→ Page 86)
DCL-ID: 0000035416 - 001
Vacuum cleaner
Part No.:
Qty.:
Used in: 7.19.2 Generator – Cleaning intake air grille
(→ Page 148)
Vernier caliper
Part No.: Y20001743
Qty.: 1
Used in: 7.18.1 Engine mounts – Resilient element check
(→ Page 145)
DCL-ID: 0000035416 - 001
P
W
PAU
– Fault message indication 47 Wiring
Plant – Check
– Cleaning 41 – On engine 149
Preheater unit
– Installation 137
– Removal 136
Preheating unit
– Overview 134