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Operating Instructions

Diesel engine 12 V 2000 G25, G25 TB 12 V 2000 G45, G45 TB 12 V 2000 G65, G65 TB 12 V 2000 G85, G85 TB 16 V 2000 G25, G25 TB 16 V 2000 G45, G45 TB 16 V 2000 G65, G65 TB 16 V 2000 G85, G85 TB 18 V 2000 G25, G25 TB 18 V 2000 G45, G45 TB 18 V 2000 G65, G65 TB 18 V 2000 G85, G85 TB Application group 3A
MS15018/01E

Printed in Germany 2012 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro filming and storage or processing on electronic systems including data bases and online services. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments.

Table of Contents
1 Safety 1.1 1.2 1.3 1.4 General conditions Personnel and organizational requirements Transport Safety regulations for maintenance and repair work 1.5 Auxiliary materials, fluids and lubricants, fire prevention and environmental protection 1.6 Conventions for safety instructions in the text 5 6 7 8 6 Task Description 11 13 6.1 Engine
6.1.1 Engine Barring manually 6.1.2 Engine Barring with starting system 6.1.3 Engine Test run 6.2.1 Cylinder liner Endoscopic examination 6.2.2 Cylinder liner Instructions and comments on endoscopic and visual examination 6.3.1 Crankcase breather Oil separator element replacement, diaphragm check and replacement 6.3.2 Crankcase breather Wire mesh cleaning 6.4.1 Valve clearance Check and adjustment 6.4.2 Cylinder head cover Removal and installation 6.5.1 Injection pump Removal and installation 6.5.2 Injection pump Removal 6.5.3 Injection pump Installation 6.6.1 6.6.2 6.6.3 6.6.4 Injector Replacement Injector Removal and installation Injector Removal Injector Installation

5 Troubleshooting 5.1 Troubleshooting 5.2 Fault indication on SAM display Genset applications 37 40

65

65 66 67 68 70

2 Product Summary 2.1 2.2 2.3 2.4 Engine - Overview Engine Main dimensions Engine side and cylinder designations Technical Data 14 16 17 18
18 22 26

6.2 Cylinder Liner

68

6.3 Crankcase Breather

72
72 74

2.4.1 12/16/18 V 2000 Gx5 engine data, optimized fuel consumption 2.4.2 12/16/18 V 2000 Gx5-TB engine data, optimized fuel consumption 2.4.3 Firing order

6.4 Valve Drive

75

75 78

3 Operation 3.1 Putting the engine into operation after extended out-of-service periods (>3 months) 3.2 Putting the engine into operation after scheduled out-of-service-period 3.3 Start engine in manual mode (testing mode) 3.4 Safety system Override 3.5 Operational checks 3.6 Stop engine in manual mode (testing mode) 3.7 Emergency stop 3.8 After stopping the engine Engine remains ready for operation 3.9 After stopping the engine putting the engine out of service

6.5 Injection Pump / HP Pump

79

79 82 83 84 85 89 91

27 28 29 30 31 32 33 34 35

6.6 Injection Valve / Injector

84

6.7 Fuel System

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6.7.1 Fuel injection line Pressure pipe neck replacement 6.7.2 Fuel pressure maintaining valve Removal and installation 6.7.3 Fuel Draining 6.7.4 Fuel system Venting 6.8.1 Fuel filter Replacement 6.8.2 Fuel prefilter cleaning 6.8.3 Fuel prefilter Differential pressure gauge check and adjustment 6.8.4 Fuel prefilter Draining 6.8.5 Fuel prefilter Flushing

93
93 95 96 98

6.8 Fuel Filter

100

100 101 102 103 104

4 Maintenance 4.1 Maintenance task reference table [QL1] 36

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6.8.6 Fuel prefilter Filter element replacement

106

6.17.2 Cooler Cleaning cooler elements

128

6.9 Charge-Air Cooling General, Left-Hand Side

6.9.1 Intercooler Checking condensate drains for coolant discharge and obstructions

108
108

6.18 Battery-Charging Generator

6.10 Air Filter

6.10.1 Air filter Replacement 6.10.2 Air filter Removal and installation 6.11.1 Service indicator Signal ring position check 6.12.1 Air starter Manual operation 6.13.1 Engine oil Level check 6.13.2 Engine oil Change

109

109 110 111 112 113 114 115

6.18.1 Drive belt Condition check 6.18.2 Battery-charging generator drive Drive-belt check and adjustment 6.18.3 Battery-charging generator drive Drive belt replacement 6.19.1 Fan drive Drive-belt check and adjustment 6.19.2 Fan drive Drive belt replacement 6.20.1 Engine wiring Check 6.20.2 Sensors and actuators

129

129 130 132

6.19 Fan Drive

133

6.11 Air Intake

111 112 113

133 136 138 139

6.12 Starting Equipment

6.20 Cabling

138

6.13 Lube Oil System, Lube Oil Circuit

6.21 Accessories for (Electronic) Engine Governor / Control System

6.14 Oil Filtration / Cooling

6.14.1 Engine oil filter Replacement

115

6.15 Coolant Circuit, General, HighTemperature Circuit


6.15.1 6.15.2 6.15.3 6.15.4 6.15.5 6.16.1 6.16.2 6.16.3 6.16.4

6.21.1 Engine governor and connectors Cleaning 6.21.2 Engine governor Checking plug-in connections 6.21.3 ECU 7 engine governor Removal and installation

140

140 141 142

Engine coolant Filling Engine coolant Draining Engine coolant Change Engine coolant Level check Coolant pump Relief bore check Charge-air coolant Filling Charge-air coolant Draining Charge-air coolant Change Charge-air coolant Level check

116

116 118 119 120 121 122 124 125 126

7 Appendix A 7.1 Abbreviations 7.2 MTU contacts/service partners 143 146

6.16 Low-Temperature Circuit

122

8 Appendix B 8.1 8.2 8.3 8.4 Special Tools Consumables Spare Parts Index 147 155 158 161

6.17 Coolant System

6.17.1 Cooler Checking cooler elements externally for dirt

127
127

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1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com pulsory regulations regarding accident prevention and environmental protection must be observed. This state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may nevertheless present a risk of injury or damage in the following cases: Incorrect use Operation, maintenance and repair by unqualified personnel Modifications or conversions Noncompliance with the Safety Instructions

Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user alone. Correct use also includes observation of and compliance with the maintenance specifications.

Modifications or conversions
Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.

Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided in such case.

Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.

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MS15018/01E 2012-05 | Safety | 5

1.2 Personnel and organizational requirements


Personnel requirements
All work on the engine shall be carried out by trained and qualified personnel only. The specified legal minimum age must be observed. The operator must specify the responsibilities of the operating, maintenance and repair personnel.

Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta tion. Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair and transport personnel at all times. Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on explaining safety-relevant instructions. This is particularly important in the case of personnel who only occasionally perform work on or around the engine. This personnel must be instructed repeatedly. For the identification and layout of the spare parts during maintenance or repair work, take photos or use the spare parts catalog.

Working clothes and protective equipment


Wear proper protective clothing for all work. Use the necessary protective equipment for the given work to be done.

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1.3 Transport
Transport

Lift the engine only with the lifting eyes provided. Use only the transport and lifting equipment approved by MTU. Take note of the engine center of gravity. The engine must only be transported in installation position, max. permissible diagonal pull 10. In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans port pallet or transport with equipment for heavy loads (forklift truck). Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and engine mounts. Secure the engine against tilting during transport. The engine must be especially secured against slip ping or tilting when going up or down inclines and ramps.

Setting the engine down after transport


Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.
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1.4 Safety regulations for maintenance and repair work


Safety regulations for maintenance and repair work
Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug with a rag to prevent fluids escaping under pressure. Take special care when draining hot fluids Risk of injury. When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated. Allow the engine / system to cool down before starting to work. Observe the maintenance and repair instructions. Never carry out maintenance and repair work with the engine running unless expressly instructed to do so. Secure the engine against accidental starting. Disconnect the battery when electrical starters are fitted. Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic starters are fitted. Disconnect the control equipment from the assembly or system. Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly. Carry out work only on assembles and/or units which are properly secured. Never use lines for climbing. Keep fuel injection lines and connections clean. Always seal connections with caps or covers if a line is removed or opened. Take care not to damage lines, in particular fuel lines, during maintenance and repair work. Ensure that all retainers and dampers are installed correctly. Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con tact with other components. Do not place fuel or oil lines near hot components. Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper ly protected. Note cooling time for components which are heated for installation or removal Risk of burning. When working high on the engine, always use suitable ladders and work platforms. Make sure compo nents are placed on stable surfaces. Observe special cleanness when conducting maintenance and repair work on the assembly or system. After completion of maintenance and repair work, make sure that no loose objects are in/on the assem bly or system. Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards have been reinstalled and that all tools and loose parts have been removed after working on the engine. The following additional instructions apply to starters with beryllium copper pinion: Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de vice as an additional measure. 8 | Safety | MS15018/01E 2012-05

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Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when welding in its vicinity. Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system. Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.

Hydraulic installation and removal


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

Working on electrical/electronic assemblies


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


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

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For conducting light-beam procedures and measurement work, only the following laser devices must be used: Laser devices of classes 1, 2 or 3A. Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.

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1.5 Auxiliary materials, fluids and lubricants, fire prevention and environmental protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit. Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid. When starting the engine with an external power source, connect the ground lead last and remove it first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the ground lead of the engine or to the ground terminal of the starter. Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their use.

Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating danger are drowned. Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).

Environmental protection and disposal


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

Auxiliary materials, fluids and lubricants


Use only fluids and lubricants that have been tested and approved by MTU. The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using them, make sure you have the latest version. The latest version is also available at: http://www.mtu-on line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation. Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions that apply to the product. Take special care when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do not smoke.

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Used oil
Used oil contains harmful combustion residues. Rub barrier cream into hands. Wash hands after contact with used oil. MS15018/01E 2012-05 | Safety | 11

Lead
When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. Adopt suitable measures to avoid the formation of lead dust. Switch on extraction system. Wash hands after contact with lead or lead-containing substances.

Compressed air
Observe special safety precautions when working with compressed air: Pay special attention to the pressure level in the compressed air network and pressure vessel. Assemblies and equipment to be connected must either be designed for this pressure, or, if the per mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose couplings and connections must be securely attached. Wear goggles when blowing off components or blowing away chips. Provide the snout of the air nozzle with a protective disk (e.g. rubber disk). First shut off compressed air lines before compressed air equipment is disconnected from the supply line, or before equipment or tool is to be replaced. Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers, results in a risk of explosion. Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying purposes or to check for leaks, results in a risk of bursting. Carry out leak test in accordance with the specifications.

Paints and lacquers


When carrying out painting work outside the spray stands provided with fume extraction systems, en sure that the area is well ventilated. Make sure that neighboring work areas are not impaired. No open flames. No smoking. Observe fire prevention regulations. Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen
Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. Avoid body contact (eyes, hands). Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask. Make sure that working area is well ventilated. Avoid all knocks and jars to the containers, fixtures or workpieces.

Acids and alkaline solutions


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

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1.6 Conventions for safety instructions in the text


DANGER

In the event of immediate danger. Consequences: Death or serious injury Remedial action

WARNING

In the event of potentially dangerous situations. Consequences: Death or serious injury Remedial action

CAUTION

In the event of dangerous situations. Consequences: Minor injury or material damage Remedial action

NOTICE

In the event of a situation involving potentially adverse effects on the product. Consequences: Material damage. Remedial action Additional product information This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which begin with one of the signal words listed above depending on the severity of the hazard.

Note:

Safety instructions
1. 2. Read and familiarize yourself with all safety notices before starting up or repairing the product. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.

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MS15018/01E 2012-05 | Safety | 13

2 Product Summary
2.1 Engine - Overview
Illustration is applicable to 12/16/18 V 2000 Gxy engines (with water-cooled intercooler)

010 Crankcase and add-on components 020 Gear train 030 Running gear 040 Cylinder head 050 Valve gear 070 Fuel system (high pres sure)

080 Fuel system (low pres sure) 100 Exhaust turbocharger 110 Charge-air cooling 120 Air intake/air supply 140 Exhaust system 170 Starting equipment

Engine model designation


Key to the engine model designations 12/16/18V 2000 Gxy 12/16/18 V 2000 G 14 | Product Summary | MS15018/01E 2012-05 Number of cylinders Cylinder arrangement: V-engine Series Application

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180 Lube oil system / lube oil circuit 200 Coolant system 210 Power generation / sup ply, engine side 220 Cooling air system 230 Mounting/support 500 Monitoring, control and regulation equipment, general electric equip ment

Key to the engine model designations 12/16/18V 2000 Gxy X y Application segment (2, 4, 6, 8) Design index (0,1, 2,...)

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MS15018/01E 2012-05 | Product Summary | 15

2.2 Engine Main dimensions

Engine model 12V 2000 Gxy 16V 2000 Gxy 18V 2000 Gxy

Length (A) approx. 1885 mm approx. 2230 mm approx. 2400 mm

Width (B) approx. 1580 mm approx. 1580 mm approx. 1580 mm

Height (C) approx. 1585 mm approx. 1585 mm approx. 1620 mm

16 | Product Summary | MS15018/01E 2012-05

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2.3 Engine side and cylinder designations


Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated with "A" and those of the right side with "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the en gine's driving end. Other components are numbered in the same way, i.e. starting with No. 1 at the engine's driving end.

1 KGS = free end 2 Right engine side

3 KS = driving end 4 Left engine side

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MS15018/01E 2012-05 | Product Summary | 17

2.4 Technical Data


2.4.1 12/16/18 V 2000 Gx5 engine data, optimized fuel consumption
Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings). Not yet defined value Not applicable Applicable

REFERENCE CONDITIONS
Engine model Application group Intake air temperature Barometric pressure Site altitude above sea level C mbar m 12V 2000 12V 2000 G25 3A 25 1000 100 G65 3A 25 1000 100 16V 2000 18V 2000 G65 3A 25 1000 100 G65 3A 25 1000 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders Rated engine speed A rpm kW Continuous power ISO 3046 (10% over A load capability, design power DIN 6280, ISO 8528) 12 1500 452 12 1500 515 16 1500 655 18 1500 720

GENERAL CONDITIONS (for maximum power)


Number of cylinders Intake air depression (new filter) Intake air depression, max. Exhaust pressure Exhaust pressure, max. A L A L mbar mbar mbar mbar 12 15 50 30 85 12 15 50 30 85 16 15 50 30 85 18 15 50 30 85
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MODEL RELATED DATA (basic design)


Number of cylinders Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) Exhaust piping, non-cooled Working method: four-cycle, diesel, sin gle-acting Combustion method: Direct fuel injection Cooling system: conditioned water 18 | Product Summary | MS15018/01E 2012-05 12 x x x x x 12 x x x x x 16 x x x x x 18 x x x x x

Number of cylinders Direction of rotation: c.c.w. (facing driv ing end) Number of cylinders Cylinder configuration: V angle Bore Stroke Displacement per cylinder Displacement, total Compression ratio Cylinder heads: single-cylinder Cylinder liners: wet, replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (en gine main PTO) Flywheel interface SAE DISC Degrees mm mm liters liters

12 x 12 90 130 150 1.99 23.88 16 x x 2 2 0 18"

12 x 12 90 130 150 1.99 23.88 16 x x 2 2 0 18"

16 x 16 90 130 150 1.99 31.84 16 x x 2 2 0 18"

18 x 18 90 130 150 1.99 35.82 16 x x 2 2 0 18"

COMBUSTION AIR / EXHAUST GAS


Number of cylinders Charge air pressure before cylinder - DL R bar abs 12 2.3 12 2.5 16 2.5 18 2.4

COOLANT SYSTEM (HT circuit)


Number of cylinders Coolant temperature (at engine connec tion: outlet to cooling equipment) Coolant temperature after engine, shut down Coolant antifreeze content, max. Pressure loss in off-engine cooling sys tem, max. A C C C % bar 12 95 97 102 50 0.7 12 95 97 102 50 0.7 16 95 97 102 50 0.7 18 95 97 102 50 0.7

Coolant temperature after engine, alarm R L L L

LUBE-OIL SYSTEM
Number of cylinders
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12 R R R L R C C C C bar 88 98 100 105 6.2

12 88 98 100 105 6.2

16 88 98 100 105 5.5

18 88 98 100 105 6.0

Lube oil operating temperature before engine, from Lube-oil operating temperature before engine, to Lube-oil temperature before engine, alarm Lube-oil temperature before engine, shutdown Lube-oil operating pressure before en gine, from

MS15018/01E 2012-05 | Product Summary | 19

Number of cylinders Lube-oil operating pressure before en gine, to Lube-oil pressure before engine, alarm Lube-oil pressure before engine, shut down R R L bar bar bar

12 7.5 4.4 3.9

12 7.5 4.4 3.9

16 6.5 4.4 3.9

18 8.0 4.4 3.9

FUEL SYSTEM
Number of cylinders Fuel pressure at engine supply connec tion, min. (when engine is starting) Fuel pressure at engine supply connec tion, max. (when engine is starting) L L bar bar 12 -0.3 +0.5 12 -0.3 +0.5 16 -0.3 +0.5 18 -0.3 +0.5

GENERAL OPERATING DATA


Number of cylinders Cold start capability: Air temperature (w/ R o start aid, w/o preheating) - (case A) Coolant preheating: preheating tempera R ture (min.) Firing speed, from Firing speed, to R R C C rpm rpm 12 0** 32 100 120 12 0** 32 100 120 16 0** 32 100 120 18 0** 32 100 120

CAPACITIES
Number of cylinders Engine coolant capacity, engine side (without cooling equipment) Total engine oil capacity at initial filling (standard oil system) (Option: max. op erating inclinations) Oil change capacity, max. (standard oil system) Oil change quantity, max. (standard oil system) (Option: max. operating inclina tions) Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. op erating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. op erating inclinations) R R liters liters 12 90 77 12 90 77 16 110 102 18 120 130

R R

liters liters

N 74

N 74

N 99

N 114

liters

50

50

69

87

WEIGHTS / MAIN DIMENSIONS


Number of cylinders Engine weight, dry (basic engine config R uration acc. to scope of supply specifica tion) 20 | Product Summary | MS15018/01E 2012-05 kg 12 2490 12 2490 16 3100 18 3500

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liters

67

67

92

110

ACOUSTICS
Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R dB(A) dB(A) 12 119 114 12 119 115 16 116 119 18 116 119

Engine surface noise with attenuated in R take noise filter) - DL (sound power level LW, ISO 6798)

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MS15018/01E 2012-05 | Product Summary | 21

2.4.2

12/16/18 V 2000 Gx5-TB engine data, optimized fuel consumption


Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings). Not yet defined value Not applicable Applicable

REFERENCE CONDITIONS
Engine model Application group Intake air temperature Charge-air coolant temperature Raw water inlet temperature Barometric pressure Site altitude above sea level C C C mbar m 12V 2000 12V 2000 16V 2000 18V 2000 G25-TB G65-TB G65-TB G65-TB 3A 25 55 1000 100 3A 25 55 1000 100 3A 25 55 1000 100 3A 25 55 1000 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders Rated engine speed A rpm kW Continuous power ISO 3046 (10% over A load capability, design power DIN 6280, ISO 8528) 12 1500 452 12 1500 515 16 1500 655 18 1500 720

GENERAL CONDITIONS (for maximum power)


Number of cylinders Intake air depression (new filter) Intake air depression, max. Exhaust pressure Exhaust pressure, max. A L A L mbar mbar mbar mbar 12 15 50 30 85 12 15 50 30 85 16 15 50 30 85 18 15 50 30 85
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MODEL RELATED DATA (basic design)


Number of cylinders Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) Exhaust piping, non-cooled Working method: four-cycle, diesel, sin gle-acting Combustion method: Direct fuel injection Cooling system: conditioned water 22 | Product Summary | MS15018/01E 2012-05 12 x x x x x 12 x x x x x 16 x x x x x 18 x x x x x

Number of cylinders Direction of rotation: c.c.w. (facing driv ing end) Number of cylinders Cylinder configuration: V angle Bore Stroke Displacement per cylinder Displacement, total Compression ratio Cylinder heads: single-cylinder Cylinder liners: wet, replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (en gine main PTO) Flywheel interface SAE DISC Degrees mm mm liters liters

12 x 12 90 130 150 1.99 23.88 16 x x 2 2 0 18"

12 x 12 90 130 150 1.99 23.88 16 x x 2 2 0 18"

16 x 16 90 130 150 1.99 31.84 16 x x 2 2 0 18"

18 x 18 90 130 150 1.99 35.82 16 x x 2 2 0 18"

COMBUSTION AIR / EXHAUST GAS


Number of cylinders Charge air pressure before cylinder - DL R bar abs 12 2.3 12 2.5 16 2.5 18 2.4

COOLANT SYSTEM (HT circuit)


Number of cylinders Coolant temperature (at engine connec tion: outlet to cooling equipment) Coolant temperature after engine, shut down Coolant antifreeze content, max. Pressure loss in off-engine cooling sys tem, max. A C C C % bar 12 95 97 102 50 0.7 12 95 97 102 50 0.7 16 95 97 102 50 0.7 18 95 97 102 50 0.7

Coolant temperature after engine, alarm R L L L

COOLANT SYSTEM (LT circuit)


Number of cylinders
TIM-ID: 0000010846 - 001

12 A L L C % bar 55 50 0.7

12 55 50 0.7

16 55 50 0.7

18 55 50 0.7

Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content, max. Pressure loss in off-engine cooling sys tem, max.

MS15018/01E 2012-05 | Product Summary | 23

LUBE-OIL SYSTEM
Number of cylinders Lube oil operating temperature before engine, from Lube-oil operating temperature before engine, to Lube-oil temperature before engine, alarm Lube-oil temperature before engine, shutdown Lube-oil operating pressure before en gine, from Lube-oil operating pressure before en gine, to Lube-oil pressure before engine, alarm Lube-oil pressure before engine, shut down R R R L R R R L C C C C bar bar bar bar 12 88 98 100 105 6.2 7.5 4.4 3.9 12 88 98 100 105 6.2 7.5 4.4 3.9 16 88 98 100 105 5.5 6.5 4.4 3.9 18 88 98 100 105 6.0 8.0 4.4 3.9

FUEL SYSTEM
Number of cylinders Fuel pressure at engine supply connec tion, min. (when engine is starting) Fuel pressure at engine supply connec tion, max. (when engine is starting) L L bar bar 12 -0.3 +0.5 12 -0.3 +0.5 16 -0.3 +0.5 18 -0.3 +0.5

GENERAL OPERATING DATA


Number of cylinders Cold start capability: Air temperature (w/ R o start aid, w/o preheating) - (case A) Coolant preheating: preheating tempera R ture (min.) Firing speed, from Firing speed, to R R C C rpm rpm 12 0** 32 100 120 12 0** 32 100 120 16 0** 32 100 120 18 0** 32 100 120

CAPACITIES
Number of cylinders Engine coolant capacity, engine side (without cooling equipment) Charge-air coolant, engine side Total engine oil capacity at initial filling (standard oil system) (Option: max. op erating inclinations) Oil change capacity, max. (standard oil system) Oil change quantity, max. (standard oil system) (Option: max. operating inclina tions) 24 | Product Summary | MS15018/01E 2012-05 R R R liters liters liters 12 110 20 77 12 110 20 77 16 130 20 102 18 140 20 130
TIM-ID: 0000010846 - 001

R R

liters liters

N 74

N 74

N 99

N 114

Number of cylinders Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. op erating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. op erating inclinations) L liters

12 50

12 50

16 69

18 87

liters

67

67

92

110

WEIGHTS / MAIN DIMENSIONS


Number of cylinders Engine weight, dry (basic engine config R uration acc. to scope of supply specifica tion) kg 12 2570 12 2570 16 3180 18 3580

ACOUSTICS
Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R dB(A) dB(A) 12 119 114 12 119 115 16 116 119 18 116 119

Engine surface noise with attenuated in R take noise filter) - DL (sound power level LW, ISO 6798)

TIM-ID: 0000010846 - 001

MS15018/01E 2012-05 | Product Summary | 25

2.4.3

Firing order
Firing order
12 V 16 V 18 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8

26 | Product Summary | MS15018/01E 2012-05

TIM-ID: 0000002793 - 001

3 Operation
3.1 Putting the engine into operation after extended out-ofservice periods (>3 months)
Preconditions
Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001061/..) are available.

Putting the engine into operation after extended out-of-service-periods (>3 months)
Item Engine Lube oil system Fuel prefilter Fuel prefilter, pressure gauge Fuel system Cooling system Task Depreserve ( MTU Fluids and Lubricants Specifications A001061/..). Check engine oil level ( Page 113); Prime ( Page 104). Align adjustable pointer with position of pressure indicator ( Page 102). Vent ( Page 98). If engine is out of service for more than one year, change engine coolant ( Page 119); Change charge-air coolant ( Page 125). Cooling system Cooling system Engine Governor Monitoring equipment Engine/generator control system Check engine coolant level ( Page 120); Check charge-air coolant level ( Page 126). Preheat coolant with preheating unit. Check plug-in connections ( Page 141). Carry out lamp test (see manufacturer's documentation). Switch ON; Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.

TIM-ID: 0000002190 - 001

MS15018/01E 2012-05 | Operation | 27

3.2 Putting the engine into operation after scheduled out-ofservice-period


Preconditions
Engine is stopped and starting disabled.

Putting the engine into operation


Item Lube oil system Cooling system Cooling system Fuel prefilter Monitoring equipment Engine/generator control system Task Check oil level ( Page 113); Check engine coolant level ( Page 120); Check charge-air coolant level ( Page 126). Preheat coolant with preheating unit. Drain ( Page 103). Carry out lamp test (see manufacturer's documentation). Switch ON; Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPER ATION.

28 | Operation | MS15018/01E 2012-05

TIM-ID: 0000002677 - 001

3.3 Start engine in manual mode (testing mode)


Preconditions
Generator (if provided) not connected to network. External start interlock is not activated.
DANGER

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

WARNING

Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.

Preparation
Item Operating mode selector switch (if provided) Task Change to manual mode.

Preheating pump (if provid Switch ON. ed)

Starting the engine


Item Task Switchgear cabinet, control If coolant temperature is panel etc. (depending on > 40 C (with preheating equipment), or manufacturer) > 5 C (without preheating equipment): Press start button. Automatic starting sequence is performed; Engine speed display instrument indicates increasing crankshaft speed; After the starting sequence is completed, engine is running at rated speed.

Connect generator to network (if provided), run engine to reach operating temperature )
Item
TIM-ID: 0000002226 - 002

Task

Switchgear cabinet, control Close the generator circuit breaker. panel etc. (depending on manufacturer) Engine Apply full load only after engine has reached operating temperature (cool ant temperature approx. 75 C).

MS15018/01E 2012-05 | Operation | 29

3.4 Safety system Override


CAUTION

Safety functions and engine shutdown alarms will be disregarded. Serious damage to plant! Initiate emergency start only in emergency situations.

CAUTION

Inadmissible operational condition. Major material damage! Use override function only in hazardous situations to ensure full capability in case of engine mal functions.

Preparation
Note: This function is only available when a pushbutton is provided.

Bypassing the safety system (Override)


Item Action Switchgear cabinet, control Activate pushbutton for Override input of the ECU. panel etc. (depending on Certain shutdown criteria and/or starting prerequisites are ignored. manufacturer) Switchgear cabinet, control Actuate start button, for further starting sequence, refer to engine start panel etc. (depending on ( Page 29). manufacturer) Control and display panels During operation, check the displayed operational data (speed, tempera ture, pressures). Constantly monitor plant limit values.

30 | Operation | MS15018/01E 2012-05

TIM-ID: 0000000984 - 002

3.5 Operational checks


DANGER

Unguarded rotating and moving engine components. Risk of serious injury danger to life! Take special care when working on a running engine.

WARNING

Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.

Operational checks
Item Control and display panels Engine under load, Engine at nominal speed Fuel prefilter Exhaust system Intercooler Air filter Task Check indicated operating parameters (speed, temperatures, pressures). Check engine/plant and pipework for leaks, rectify any leaks with the en gine stopped; Check for abnormal running noises and vibration. Check whether indicated differential pressure is within the limit ( Page 102). Check exhaust color ( Page 37). Check condensate drain(s) for water discharge and obstruction ( Page 108). Check signal ring position of service indicator ( Page 111). Replace air filter ( Page 109), if the signal ring is completely visible in the red area of the service indicator control window. Coolant pump Compressed-air system (if installed) Check relief bore ( Page 121). Check operating pressure at pressure gauge; Fill compressed-air tank to maximum pressure; Drain condensate from compressed-air tank, pressure drop must not ex ceed 1 bar.

TIM-ID: 0000010120 - 001

MS15018/01E 2012-05 | Operation | 31

3.6 Stop engine in manual mode (testing mode)


Preconditions
Generator (if provided) not connected to network. Engine is running in manual mode.
CAUTION

Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! Before stopping the engine, operate it at idle speed until operating temperatures decrease and stable values are indicated.

Preparing the generator drive (only with generator breaker)


Item Engine Task After opening the generator breaker (if provided), allow to cool down offload for approx. 5 minutes.

Preparing the pump drive (diesel-mechanical/diesel-electric)


Item Engine Task Allow to cool down for approx. 5 minutes at reduced engine speed. Ob serve natural resonance of engine (installation-dependent)!

Stopping the engine


Item Task Switchgear cabinet, control Press stop button. panel etc. (depending on Automatic stopping sequence is performed; manufacturer) Engine is stopped.

After stopping the engine


Item Coolant pump Task Allow to run on for sufficient time after stopping.

32 | Operation | MS15018/01E 2012-05

TIM-ID: 0000002285 - 001

3.7 Emergency stop


CAUTION

An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! Initiate emergency stop only in emergency situations.

Emergency stop from LOP


Item EMERGENCY STOP but ton Task Press. Engine is stopped by switching off power supply to ECU; Signalization (e.g. by horn, flashing lamp) is released.

After emergency stop from LOP


Item Switching cabinet, control panel etc. (depending on manufacturer) Task Press button for alarm acknowledgement. Audible and visual signalization stops.

TIM-ID: 0000002305 - 002

MS15018/01E 2012-05 | Operation | 33

3.8 After stopping the engine Engine remains ready for operation
After stopping the engine
Item Engine/generator/pump control Action Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.

34 | Operation | MS15018/01E 2012-05

TIM-ID: 0000000983 - 002

3.9 After stopping the engine putting the engine out of service
Preconditions
MTU Fluids and Lubricants Specifications (A001061/..) is available.

After stopping the engine


Item Cooling system Task Drain engine coolant ( Page 118); Drain charge-air coolant ( Page 124) if: freezing temperatures are expected and the engine is to remain out of service for an extended period and coolant has no antifreeze additive; the engine room is not heated; the coolant is not maintained at a suitable temperature; the antifreeze concentration is insufficient for the engine-room tempera ture; antifreeze concentration is 50 % and engine-room temperature is below -40C. Engine/generator/pump controller Switch OFF.

Air intake and exhaust sys If the engine is to remain out of service for more than 1 week, seal the tem engine's air and exhaust sides. If the engine is to remain out of service for more than 1 month, preserve engine ( MTU Fluids and Lubricants Speci fications A001061/.. ).

TIM-ID: 0000002706 - 001

MS15018/01E 2012-05 | Operation | 35

4 Maintenance
4.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule. Task W0500 W0501 W0502 W0503 W0505 W0506 W0507 W0508 W0534 W1001 W1002 W1003 W1005 W1006 W1007 W1008 W1010 W1011 W1056 W1178 Maintenance tasks Check engine oil level. Visually inspect engine for leaks and general condition. Check intercooler drain. Check signal ring position of service indicator on air filter. Check relief bores of water pump(s). Check engine for abnormal running noises, exhaust color and vibrations. Drain water and contaminants from fuel prefilter. Check reading on differential pressure gage of fuel prefilter. Carry out test run, minimum duration: until steady-state tem perature is reached, no less than 1/3 load (monthly). Replace fuel filter or fuel filter element. Check valve clearance. Check belt condition and tension, replace if necessary. Replace air filter. Replace fuel injectors. Replace fuel injection pump(s). Replace engine oil filter when changing engine oil, or when the time limit (years) is reached, at the latest. Coolant cooler: Check exterior of cooler elements for dirt. Perform endoscopic examination. Replace fuel pressure maintaining valve. Replace pressure pipe neck in cylinder head. ( Page 113) ( Page 31) ( Page 31) ( Page 31) ( Page 31) ( Page 31) ( Page 31) ( Page 31) ( Page 67) ( Page 100) ( Page 75) ( Page 129) ( Page 109) ( Page 84) ( Page 79) ( Page 115) ( Page 127) ( Page 68) ( Page 95) ( Page 93)

36 | Maintenance | MS15018/01E 2012-05

TIM-ID: 0000037729 - 001

5 Troubleshooting
5.1 Troubleshooting
Engine does not turn when starter is actuated
Component Battery Probable Cause Low or defective Cable connections defective Starter Engine wiring Engine/generator control system Engine Governor Engine Engine wiring or starter defective Defective Secure seating of assemblies or con nectors not provided Plug-in connections are loose Running gear blocked (engine cannot be barred manually) Task Charge or replace (see manufacturer's documentation). Check if cable connections are proper ly secured (see manufacturer's docu mentation). Check if cable connections are proper ly secured, contact Service. Check (REFDM TARGET NOT FOUND). Perform visual inspection (see manu facturer's documentation). Check plug-in connections ( Page 141). Contact Service.

Engine turns but does not fire


Component Starter Engine wiring Fuel system Engine Governor Probable Cause Poor rotation by starter: Battery low or defective Defective Not vented Defective Task Charge or replace battery (see manu facturer's documentation). Check (REFDM TARGET NOT FOUND). Vent fuel system ( Page 98). Contact Service.

Engine fires unevenly


Component Fuel injection equip ment
TIM-ID: 0000002534 - 002

Probable Cause Injector defective Injection pump defective Defective Not vented Defective

Task Replace ( Page 84). Replace ( Page 79). Check (REFDM TARGET NOT FOUND). Vent fuel system ( Page 98). Contact Service.

Engine wiring Fuel system Engine Governor

Engine does not reach nominal speed


Component Fuel supply Probable Cause Fuel prefilter clogged Easy-change fuel filter clogged Task Replace ( Page 106). Replace ( Page 100). MS15018/01E 2012-05 | Troubleshooting | 37

Component Air supply Fuel injection equip ment Engine wiring Engine

Probable Cause Air filter clogged Injector defective Injection pump defective Defective Overloaded

Task Check signal ring position of service in dicator ( Page 111). Replace ( Page 84). Replace ( Page 79). Check (REFDM TARGET NOT FOUND). Contact Service.

Engine speed not steady


Component Fuel injection equip ment Speed sensor Fuel system Engine Governor Probable Cause Injector defective Injection pump defective Defective Not vented Defective Task Replace ( Page 84). Replace ( Page 79). Contact Service. Vent fuel system ( Page 98). Contact Service.

Charge-air temperature too high


Component Coolant Intercooler Engine room Probable Cause Incorrect coolant concentration Contaminated Air-intake temperature too high Task Check (MTU test kit). Contact Service. Check fans and air supply / ventilation ducts.

Charge-air pressure too low


Component Air supply Intercooler Probable Cause Air filter clogged Contaminated Task Check signal ring position of service in dicator ( Page 111). Contact Service. Contact Service.

Exhaust turbocharger Defective

Coolant leaks on intercooler


Component Intercooler Probable Cause Leaking, major coolant discharge Task Contact Service.

Exhaust gas black


Component Air supply Fuel injection equip ment Engine Probable Cause Air filter clogged Injector defective Injection pump defective Overloaded Task Check signal ring position of service in dicator ( Page 111). Replace ( Page 84). Replace ( Page 79). Contact Service.
TIM-ID: 0000002534 - 002

38 | Troubleshooting | MS15018/01E 2012-05

Exhaust gas blue


Component Engine oil Probable Cause Too much oil in engine Oil separator of crankcase breather contaminated Exhaust turbocharg Defective er, cylinder head, pis ton rings, cylinder lin er Task Drain engine oil ( Page 114). Replace ( Page 72). Contact Service.

Exhaust gas white


Component Engine Fuel system Intercooler Probable Cause Not at operating temperature Water in fuel Leaking Task Run engine to reach operating temper ature. Check fuel system on fuel prefilter. Drain fuel prefilter ( Page 103). Contact Service.

TIM-ID: 0000002534 - 002

MS15018/01E 2012-05 | Troubleshooting | 39

5.2 Fault indication on SAM display Genset applications


SAM fault messages

1 2-line LC display 2 Time indicator for alarms

3 Fault type 4 Node number

The structure of the display is as follows: First line Time indicator for alarms (e.g. #) Type of fault (e.g. SE03) Node number at which the fault occurred (e.g. nd11) Second line (option) Running text, providing more information about the fault currently displayed Time indicator for alarms # A B C D E Meaning Alarm is no longer active, does not appear on next power-up. Alarm is active. Alarm was active during the last hour. Alarm was active during the last four hours. Alarm was active during the last four to twelve hours. Alarm was active more than twelve hours ago.
TIM-ID: 0000008508 - 002

Proceed to the next alarm by pressing key ( ).

40 | Troubleshooting | MS15018/01E 2012-05

Fault type fault message text SE no. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Error message text Sensor Temperatur Defect Temperature failure Sensor Voltage Defect Voltage failure CAN Bus- 1 Error/Bus Defec CAN Bus- 1 Overrun CAN Bus- 2 Error/Bus Defec CAN Bus- 2 Overrun Temperatur Compensation Error I/O-Module Slot2 Defect I/O-Module Slot3 Defect I/O-Module Slot4 Defect Serial Conection Lost CAN Bus- 3 Error/Bus Defec CAN Bus- 3 Overrun S/A Bus Faulty PAN 1 Defect PAN 2 Defect PAN 3 Defect PAN 4 Defect PAN 5 Defect PAN 6 Defect I/O-Module Slot1 Defect I/O-Module Slot5 Defect I/O-Module Slot6 Defect I/O-Module Slot7 Defect I/O-Module Slot8 Defect Download Server Collision not projected node

Engine governor messages


TIM-ID: 0000008508 - 002

Recommended action in case of alarm Yellow alarm: The engine can still be operated providing that automatic engine shutdown to protect the engine has not been configured or is not tripped. Contact Service immediately/start fault rectification. Red alarm: Caution, the engine is running at its limits. Shut down manually without further delay if the engine does not shut itself down immediately after a red alarm is signaled.

MS15018/01E 2012-05 | Troubleshooting | 41

Fault and alarm messages The fault code numbers are generated by the engine governor and transmitted to the display below.

The fault code (1) comprises three digits. Fault messages can also be caused by faulty sensors/actuators. Contact Service to have sensors/actua tors checked and replaced as necessary if the troubleshooting measures listed in the table below prove unsuccessful. IMPORTANT NOTE: The information provided in the columns Meaning and Action applies to the standard default state of the genset on delivery. Differing system responses requiring different action may result when settings are changed by the OEM. The OEM is responsible for documenting any changes and defining appropriate counteraction. The table below lists possible fault codes: Fault code no. 003 Full designation HI T-Fuel Meaning Prewarning: Fuel tempera ture too high (limit value 1, alarm configuration parame ter, see PR 2.8008.100 for explanation). Main warning: Fuel temper ature too high (limit value 2, alarm configuration parame ter, see PR 2.8008.100 for explanation). Action Setting param eter no.

004

SS T-Fuel

Check tank temper 2.0122932 ature, contact Serv ice if no fault de tected.

42 | Troubleshooting | MS15018/01E 2012-05

TIM-ID: 0000008508 - 002

Check tank temper 2.0122931 ature, contact Serv ice if no fault de tected.

Fault code no. 005

Full designation HI T-Charge Air

Meaning Prewarning: Charge-air temperature too high (limit value 1, alarm configuration parameter, see PR 2.8008.100 for explanation). Main warning: Charge-air temperature too high (limit value 2, alarm configuration parameter, see PR 2.8008.100 for explanation). Prewarning: Coolant tem perature in intercooler too high (limit value 1, alarm configuration parameter, see PR 2.8008.100 for ex planation).

Action Check cooler, check intercooler, contact Service if no fault detected. Check cooler, check intercooler, contact Service if no fault detected. Check cooler, con tact Service if no fault detected.

Setting param eter no. 2.0121.931

006

SS T-Charge Air

2.0121.932

009

HI T-Coolant Inter cooler

2.0124.931

010

SS T-Coolant Inter cooler

Main warning: Coolant tem Check cooler, con perature in intercooler too tact Service if no high (limit value 2, alarm fault detected. configuration parameter, see PR 2.8008.100 for ex planation). Prewarning: Lube-oil pres Check oil level, sure too low (limit value 1, contact Service if alarm configuration parame no fault detected. ter, see PR 2.8008.100 for explanation). Main warning: Lube-oil Check oil level, pressure too low (limit value contact Service. 2, alarm configuration pa rameter, see PR 2.8008.100 for explanation). Automatic engine shutdown. Coolant level too low (limit value 2, alarm configuration parameter, see PR 2.8008.100 for explanation). Automatic engine shutdown.

2.0124.932

015

LO P-Lube Oil

2.0100.921

016

SS P-Lube Oil

2.0100.922

024

SS Coolant Level

Check coolant level 2.0152.912 in expansion tank, check for leakage and seal any leaks as necessary. 2.2510.932

030

TIM-ID: 0000008508 - 002

SS Engine Overspeed Engine overspeed (limit val Attempt to restart ue 2, alarm configuration engine. parameter, see PR 2.8008.100 for explanation). Automatic engine shutdown. LO Coolant Level In tercooler Intercooler coolant level too low (limit value 1, alarm configuration parameter, see PR 2.8008.100 for ex planation). Automatic en gine shutdown.

044

Check coolant level 2.0153.921 in expansion tank, check for leakage and seal any leaks as necessary.

MS15018/01E 2012-05 | Troubleshooting | 43

Fault code no. 051

Full designation HI T-Lube Oil

Meaning Lube-oil temperature too high (limit value 1, alarm configuration parameter, see PR 2.8008.100 for ex planation). Warning. Lube-oil temperature too high (limit value 2, alarm configuration parameter, see PR 2.8008.100 for ex planation). Automatic en gine shutdown.

Action Check cooling sys tem.

Setting param eter no. 2.0125.931

052

SS T-Lube Oil

Check cooling sys tem, contact Serv ice if cooling sys tem is in order.

2.0125.932

065

LO P-Fuel

Fuel inlet pressure too low Check filter, check (limit value 1, alarm configu genset fuel supply. ration parameter, see PR 2.8008.100 for explanation). Warning. Fuel inlet pressure too low Check filter, check (limit value 2, alarm configu genset fuel supply. ration parameter, see PR 2.8008.100 for explanation). Warning. Coolant temperature too high (limit value 1, alarm configuration parameter, see PR 2.8008.100 for ex planation). Warning. Coolant temperature too high (limit value 2, alarm configuration parameter, see PR 2.8008.100 for ex planation). Automatic en gine shutdown. Pressure gradient in rail too low on starting or too high on stopping, HP system leaking (alarm configuration parameter, see PR 2.8008.100 for explanation). Check cooling sys tem.

2.0102.921

066

SS P-Fuel

2.0102.922

067

HI T-Coolant

2.0120.931

068

SS T-Coolant

Check cooling sys tem. Contact Serv ice if cooling sys tem is in order.

2.0120.932

081

AL Rail Leakage

On stopping: Seal 1.8004.046 off system, contact Service; On start ing: Check engine for leakage, if none found, attempt re starting as per op erating instructions (air in system).
TIM-ID: 0000008508 - 002

082

HI P-Fuel (Common Rail)

Rail pressure is greater than set value (alarm configura tion parameter, see PR 2.8008.100 for explanation). Warning. Rail pressure is less than set value (alarm configura tion parameter, see PR 2.8008.100 for explanation). Warning.

Check HP fuel con 2.0104.931 trol block wiring, if no fault detected, contact Service. Check HP fuel con 2.0104.921 trol block wiring, check HP system for leakage, if no fault detected, con tact Service.

083

LO P-Fuel (Common Rail)

44 | Troubleshooting | MS15018/01E 2012-05

Fault code no. 089

Full designation SS Engine Speed too Low

Meaning

Action

Setting param eter no. 2.2500.030

Engine speed too low Check for addition (alarm configuration param al messages. eter, see PR 2.8008.100 for explanation). Engine stop. Idling speed not reached Check for addition (alarm configuration param al messages. eter, see PR 2.8008.100 for explanation). Start terminat ed. Runup speed not reached (alarm configuration param eter, see PR 2.8008.100 for explanation). Start terminat ed.

090

SS Idle Speed Not Reached

2.1090.925

091

SS Release Speed Not Reached

Check for addition 2.1090.924 al messages. Re charge battery. En gine under load: Check fuel supply; if no fault detected, contact Service. Check for addition 2.1090.923 al messages. Re charge battery. En gine under load: Check fuel supply; if no fault detected, contact Service. Engine start inter lock is active as coolant tempera ture is too low for engine start, pre heating necessary. Engine start inter lock is active as coolant tempera ture is too low for engine start, pre heating necessary. 2.1090.922

092

SS Starter Speed Not Starter speed not reached Reached (alarm configuration param eter, see PR 2.8008.100 for explanation). Start terminat ed. Starter does not turn or turns slowly. SS T-Preheat Preheating temperature too low (limit value 2, alarm configuration parameter, see PR 2.8008.100 for ex planation). Preheating temperature too low (limit value 1, alarm configuration parameter, see PR 2.8008.100 for ex planation).

093

094

LO T-Preheat

2.1090.921

095

AL Prelubrication Fault

Oil priming pressure not Contact Service. reached (alarm configura tion parameter, see PR 2.8008.100 for explanation). Electronic fault: Consump tion counter faulty (alarm configuration parameter, see PR 2.8008.100 for ex planation). Replace engine governor at next opportunity.

2.1090.920

102
TIM-ID: 0000008508 - 002

AL Fuel Cons. Coun ter Defect

1.8004.624

104

AL Eng Hours Coun ter Defect

Electronic fault: Hour meter Replace engine faulty (alarm configuration governor at next parameter, see PR opportunity. 2.8008.100 for explanation).

1.8004.623

MS15018/01E 2012-05 | Troubleshooting | 45

Fault code no. 118

Full designation LO ECU Power Sup ply Voltage

Meaning Supply voltage too low (limit value 1, alarm configuration parameter, see PR 2.8008.100 for explanation). Warning. Supply voltage too low (limit value 2, alarm configuration parameter, see PR 2.8008.100 for explanation). Warning.

Action

Setting param eter no.

Check batteries 2.0140.921 and charge as nec essary; check gen erator. Check batteries 2.0140.922 and charge as nec essary; check gen erator. 2.0140.931

119

LOLO ECU Power Supply Voltage

120

HI ECU Power Supply Supply voltage too high Check batteries Voltage (limit value 1, alarm configu and generator. ration parameter, see PR 2.8008.100 for explanation). Warning. HIHI ECU Power Sup Supply voltage too high Check batteries ply Voltage (limit value 2, alarm configu and generator. ration parameter, see PR 2.8008.100 for explanation). Warning. HI T-ECU

121

2.0140.932

122

Electronics temperature too Check engine room 2.0132.921 high (limit value 1, alarm ventilation. configuration parameter, see PR 2.8008.100 for ex planation). Warning. No (suitable) LifeData back Contact Service. up system available, backup system has no LifeData function when timeout fol lowing ECU reset expires or CAN bus to backup system is disrupted (alarm configu ration parameter, see PR 2.8008.100 for explanation). 2.4000.004

176

AL LifeData not avail able

177

180

AL CAN1 Node Lost

Connection to a node on Test devices con 2.0500.680 CAN bus 1 has failed (alarm nected to CAN, test configuration parameter, wiring. see PR 2.8008.100 for ex planation).

46 | Troubleshooting | MS15018/01E 2012-05

TIM-ID: 0000008508 - 002

AL LifeData restore in This fault message is gener Contact Service. complete ated when a CRC is faulty (stated for each module) or upload is incomplete during a restore data upload proc ess (into ADEC) (alarm con figuration parameter, see PR 2.8008.100 for explana tion).

2.4000.006

Fault code no. 181

Full designation AL CAN2 Node Lost

Meaning

Action

Setting param eter no.

Connection to a node on Check devices con 2.0500.681 CAN bus 2 has failed (alarm nected to CAN. configuration parameter, see PR 2.8008.100 for ex planation). Incorrect parameter values entered in data record (alarm configuration param eter, see PR 2.8008.100). 2.0500.682

182

AL CAN Wrong Pa rameters

183

AL CAN No PU-Data

The selected CAN mode ini Check devices con 2.0500.683 tializes communication by nected to CAN. means of the PU data mod ule. However, the required PU data module is unavaila ble or invalid (alarm configu ration parameter, see PR 2.8008.100 for explanation). Programming error on at Contact Service. tempting to copy a received PU data module into the Flash module (alarm config uration parameter, see PR 2.8008.100 for explanation). CAN controller 1 is in "Bus Contact Service. Off" state, automatic switch ing to CAN2 results. Causes are e.g. short circuit, mas sive disruptions or baud rate incompatibility (alarm con figuration parameter, see PR 2.8008.100 for explana tion). CAN controller 1 has indi Contact Service. cated a warning. Causes are e.g. missing associate nodes, minor disruptions and temporary bus overload (alarm configuration param eter, see PR 2.8008.100 for explanation). CAN controller 2 is in "Bus Contact Service. Off" state, automatic switch ing to CAN1 results. Causes are e.g. short circuit, mas sive disruptions or baud rate incompatibility (alarm con figuration parameter, see PR 2.8008.100 for explana tion). 2.0500.684

184

AL CAN PU-Data Flash Error

186

AL CAN1 Bus Off

2.0500.686

187

AL CAN1 Error Pas sive

2.0500.687

188
TIM-ID: 0000008508 - 002

AL CAN2 Bus Off

2.0500.688

MS15018/01E 2012-05 | Troubleshooting | 47

Fault code no. 189

Full designation AL CAN2 Error Pas sive

Meaning

Action

Setting param eter no. 2.0500.689

CAN controller 2 has indi Contact Service. cated a warning. Causes are e.g. missing associate nodes, minor disruptions and temporary bus overload (alarm configuration param eter, see PR 2.8008.100 for explanation). SD alarm configuration, coolant temperature sensor faulty, short circuit or wire break.

201

SD T-Coolant

Check sensor and 1.8004.570 wiring (B6), replace as necessary. 1.8004.572

202

SD T-Fuel

SD alarm configuration, fuel Check sensor and temperature sensor faulty, wiring (B33), re short circuit or wire break. place as necessa ry.

203

SD T-Charge Air

SD alarm configuration, Check sensor and 1.8004.571 charge-air temperature sen wiring (B9), replace sor faulty, short circuit or as necessary. wire break. SD alarm configuration, coolant temperature sensor of intercooler faulty, short circuit or wire break. SD alarm configuration, charge-air pressure sensor faulty, short circuit or wire break. SD alarm configuration, lube-oil pressure sensor faulty, short circuit or wire break. SD alarm configuration, rail pressure sensor faulty, HP controller in emergency mode, short circuit or wire break. SD alarm configuration, lube-oil temperature sensor faulty, short circuit or wire break. Check sensor and wiring (B26), re place as necessa ry. Check sensor and wiring (B10), re place as necessa ry. 1.8004.574

205

SD T-Coolant Inter cooler

208

SD P-Charge Air

1.8004.566

211

SD P-Lube Oil

Check sensor and 1.8004.563 wiring (B5), replace as necessary. Check sensor and wiring (B48), re place as necessa ry. 1.8004.567

215

SD P-HD

216

SD T-Lube Oil

Check sensor and 1.8004.575 wiring (B7), replace as necessary.


TIM-ID: 0000008508 - 002

219

SD T-Intake Air

SD alarm configuration, in Check sensor and 1.8004.573 take air temperature sensor wiring (B3), replace faulty, short circuit or wire as necessary. break. Check sensor and wiring (F33), re place as necessa ry.Fault is rectified when electronics are switched back on 1.8004.584

220

SD Level Coolant Wa SD alarm configuration, ter coolant level sensor faulty, short circuit or wire break.

48 | Troubleshooting | MS15018/01E 2012-05

Fault code no. 223

Full designation SD Level Coolant In tercooler

Meaning SD alarm configuration, coolant level sensor faulty, short circuit or wire break.

Action Check sensor and wiring (F57), re place as necessa ry. Fault is rectified when electronics are switched back on.

Setting param eter no. 1.8004.583

229

AL Stop Camshaft Sensor Defect

Engine stop due to cam shaft sensor fault (and a previous crankshaft sensor fault in the same operating cycle).Alarm configuration parameter, see PR 2.8008.100 for explanation.

Check connector 1.8004.562 and wiring to sen sor B1, replace as necessary. Fault is rectified when en gine is restarted. If camshaft and crankshaft sensor are both faulty, check connector and wiring to sen sor B1 and B13. Restart. Fault is rectified when en gine is restarted, contact Service if this is not the case. Check sensor and 1.8004.498 wiring (B13), at tempt restart, fault may be rectified when engine is re started. Contact Service if this is not the case Check sensor and 1.8004.499 wiring (B1), attempt restart, fault may be rectified when engine is restarted. Contact Service if this is not the case. Check sensor and wiring (B34), re place as necessa ry. 1.8004.565

230

SD Crankshaft Speed SD alarm configuration, crankshaft sensor faulty, short circuit or wiring dam age, engine remains opera tional.

231

SD Camshaft Speed

SD alarm configuration, camshaft sensor faulty, short circuit or wiring dam age, engine remains opera tional.

240

SD P-Fuel

TIM-ID: 0000008508 - 002

SD alarm configuration, en gine remains operational, fuel pressure sensor faulty, short circuit or wiring dam age.

245

SD ECU Power Sup ply Voltage

SD alarm configuration, in Execute engine 2.8006.589 ternal engine governor fault. governor self-test, replace engine gov ernor in case of fault.

MS15018/01E 2012-05 | Troubleshooting | 49

Fault code no. 266

Full designation SD Speed Demand

Meaning SD alarm configuration, an alog speed setting faulty, short circuit or wiring dam age.

Action

Setting param eter no.

Check speed set 2.8006.586 ting transmitter and wiring, replace as necessary. Fault is rectified when en gine is restarted. Check wiring, re place as necessa ry.Fault is rectified when engine is re started. 2.8006.588

269

SD Loadp.Analog filt.

SD alarm configuration, fil tered analog signal of load pulse not available, short circuit or wiring damage

270

SD Frequency Input

SD alarm configuration, fre Contact Service. quency input faulty, short circuit or wiring damage.

2.8006.590

301

AL Timing Cylinder A1 Time-of-flight measuring Replace plug-in fault injector cylinder A1: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A2 Time-of-flight measuring Replace plug-in fault injector cylinder A2 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A3 Time-of-flight measuring Replace plug-in fault injector cylinder A3: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A4 Time-of-flight measuring Replace plug-in fault injector cylinder A4 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A5 Time-of-flight measuring Replace plug-in fault injector cylinder A5 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation).

1.8004.500

302

1.8004.501

303

1.8004.502

304

1.8004.503

305

1.8004.504

50 | Troubleshooting | MS15018/01E 2012-05

TIM-ID: 0000008508 - 002

Fault code no. 306

Full designation

Meaning

Action

Setting param eter no. 1.8004.505

AL Timing Cylinder A6 Time-of-flight measuring Replace plug-in fault injector cylinder A6 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A7 Time-of-flight measuring Replace plug-in fault injector cylinder A7 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A8 Time-of-flight measuring Replace plug-in fault injector cylinder A8 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A9 Time-of-flight measuring Replace plug-in fault injector cylinder A9 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A10 Time-of-flight measuring Replace plug-in fault injector cylinder A10: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation).

307

1.8004.506

308

1.8004.507

309

1.8004.508

310

1.8004.509

311

AL Timing Cylinder B1 Time-of-flight measuring Replace plug-in fault injector cylinder B1: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B2 Time-of-flight measuring Replace plug-in fault injector cylinder B2: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation).

1.8004.510

TIM-ID: 0000008508 - 002

312

1.8004.511

MS15018/01E 2012-05 | Troubleshooting | 51

Fault code no. 313

Full designation

Meaning

Action

Setting param eter no. 18004.512

AL Timing Cylinder B3 Time-of-flight measuring Replace plug-in fault injector cylinder B3: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B4 Time-of-flight measuring Replace plug-in fault injector cylinder B4: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B5 Time-of-flight measuring Replace plug-in fault injector cylinder B5: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B6 Time-of-flight measuring Replace plug-in fault injector cylinder B6: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B7 Time-of-flight measuring Replace plug-in fault injector cylinder B7: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B8 Time-of-flight measuring Replace plug-in fault injector cylinder B8: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B9 Time-of-flight measuring Replace plug-in fault injector cylinder B9: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation).

314

1.8004.513

315

1.8004.514

316

1.8004.515

317

1.8004.516

318

1.8004.517

52 | Troubleshooting | MS15018/01E 2012-05

TIM-ID: 0000008508 - 002

319

1.8004.518

Fault code no. 320

Full designation AL Timing Cylinder B10

Meaning

Action

Setting param eter no. 1.8004.519

Time-of-flight measuring Replace plug-in fault injector cylinder B10: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation).

321

AL Wiring Cylinder A1 Wiring fault in injector wiring cylinder A1. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

Check injector wir 1.8004.520 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.521 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.522 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.523 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.524 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted.

322

AL Wiring Cylinder A2 Wiring fault in injector wiring cylinder A2. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

323

AL Wiring Cylinder A3 Wiring fault in injector wiring cylinder A3. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

324

AL Wiring Cylinder A4 Wiring fault in injector wiring cylinder A4. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

TIM-ID: 0000008508 - 002

325

AL Wiring Cylinder A5 Wiring fault in injector wiring cylinder A5. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

MS15018/01E 2012-05 | Troubleshooting | 53

Fault code no. 326

Full designation

Meaning

Action

Setting param eter no.

AL Wiring Cylinder A6 Wiring fault in injector wiring cylinder A6. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

Check injector wir 1.8004.525 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.526 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.527 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.528 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.529 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.530 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted.

327

AL Wiring Cylinder A7 Wiring fault in injector wiring cylinder A7. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

328

AL Wiring Cylinder A8 Wiring fault in injector wiring cylinder A8. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

329

AL Wiring Cylinder A9 Wiring fault in injector wiring cylinder A9. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

330

AL Wiring Cylinder A10

Wiring fault in injector wiring cylinder A10. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

331

AL Wiring Cylinder B1 Wiring fault in injector wiring cylinder B1. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

54 | Troubleshooting | MS15018/01E 2012-05

TIM-ID: 0000008508 - 002

Fault code no. 332

Full designation

Meaning

Action

Setting param eter no.

AL Wiring Cylinder B2 Wiring fault in injector wiring cylinder B2. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

Check injector wir 1.8004.531 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.532 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.533 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.534 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004535 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.536 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted.

333

AL Wiring Cylinder B3 Wiring fault in injector wiring cylinder B3. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

334

AL Wiring Cylinder B4 Wiring fault in injector wiring cylinder B4. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

335

AL Wiring Cylinder B5 Wiring fault in injector wiring cylinder B5. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

336

AL Wiring Cylinder B6 Wiring fault in injector wiring cylinder B6. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

TIM-ID: 0000008508 - 002

337

AL Wiring Cylinder B7 Wiring fault in injector wiring cylinder B7. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

MS15018/01E 2012-05 | Troubleshooting | 55

Fault code no. 338

Full designation

Meaning

Action

Setting param eter no.

AL Wiring Cylinder B8 Wiring fault in injector wiring cylinder B8. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

Check injector wir 1.8004.537 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.538 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004539 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.540 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.541 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.542 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle.

339

AL Wiring Cylinder B9 Wiring fault in injector wiring cylinder B9. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

340

AL Wiring Cylinder B10

Wiring fault in injector wiring cylinder B10. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).

341

AL Open Load Cylin der A1

Disruption fault in injector wiring to cylinder A1. Re sult: Misfiring (alarm config uration parameter, see PR 2.8008.100 for explanation).

342

AL Open Load Cylin der A2

Disruption fault in injector wiring cylinder A2. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

343

AL Open Load Cylin der A3

Disruption fault in injector wiring cylinder A3. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

56 | Troubleshooting | MS15018/01E 2012-05

TIM-ID: 0000008508 - 002

Fault code no. 344

Full designation AL Open Load Cylin der A4

Meaning Disruption fault in injector wiring cylinder A4. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

Action

Setting param eter no.

Check injector wir 1.8004.543 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.544 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.545 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.546 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.547 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.548 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle.

345

AL Open Load Cylin der A5

Disruption fault in injector wiring cylinder A5. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

346

AL Open Load Cylin der A6

Disruption fault in injector wiring cylinder A6. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

347

AL Open Load Cylin der A7

Disruption fault in injector wiring cylinder A7. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

348

AL Open Load Cylin der A8

Disruption fault in injector wiring cylinder A8. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

349
TIM-ID: 0000008508 - 002

AL Open Load Cylin der A9

Disruption fault in injector wiring cylinder A9. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

MS15018/01E 2012-05 | Troubleshooting | 57

Fault code no. 350

Full designation AL Open Load Cylin der A10

Meaning Disruption fault in injector wiring cylinder A10. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

Action

Setting param eter no.

Check injector wir 1.8004.549 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.550 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.551 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.552 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.553 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.554 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle.

351

AL Open Load Cylin der B1

Disruption fault in injector wiring cylinder B1. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

352

AL Open Load Cylin der B2

Disruption fault in injector wiring cylinder B2. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

353

AL Open Load Cylin der B3

Disruption fault in injector wiring cylinder B3. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

354

AL Open Load Cylin der B4

Disruption fault in injector wiring cylinder B4. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

355

AL Open Load Cylin der B5

58 | Troubleshooting | MS15018/01E 2012-05

TIM-ID: 0000008508 - 002

Disruption fault in injector wiring cylinder B5. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

Fault code no. 356

Full designation AL Open Load Cylin der B6

Meaning Disruption fault in injector wiring cylinder B6. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

Action

Setting param eter no.

Check injector wir 1.8004.555 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.556 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.557 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.558 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.559 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Start engine gover 1.8004.496 nor self-test. Re place engine gover nor in case of fault; if self-test diagno ses Electronics OK check for addi tional fault messag es (e.g. wiring fault).

357

AL Open Load Cylin der B7

Disruption fault in injector wiring cylinder B7. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

358

AL Open Load Cylin der B8

Disruption fault in injector wiring cylinder B8. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

359

AL Open Load Cylin der B9

Disruption fault in injector wiring cylinder B9. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

360

AL Open Load Cylin der B10

Disruption fault in injector wiring cylinder B10. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).

361
TIM-ID: 0000008508 - 002

AL Power Stage Low

Internal electronic fault (electronics may be defec tive). If parameter 1.1020.021 (Power Stage Failure: Stop Engine) is set, engine is stopped here ad ditionally (alarm configura tion parameter, see PR 2.8008.100 for explanation).

MS15018/01E 2012-05 | Troubleshooting | 59

Fault code no. 362

Full designation AL Power Stage high

Meaning Internal electronic fault (electronics may be defec tive). If parameter 1.1020.021 (Power Stage Failure: Stop Engine) is set, engine is stopped here ad ditionally (alarm configura tion parameter, see PR 2.8008.100 for explanation). Internal electronic fault (electronics may be defec tive). If parameter 1.1020.021 (Power Stage Failure: Stop Engine) is set, engine is stopped here ad ditionally (alarm configura tion parameter, see PR 2.8008.100 for explanation).

Action

Setting param eter no.

Start engine gover 1.8004.497 nor self-test. Re place engine gover nor in case of fault; if self-test diagno ses Electronics OK check for addi tional fault messag es (e.g. wiring fault). Start engine gover 1.8004.560 nor self-test. Re place engine gover nor in case of fault; if self-test diagno ses Electronics OK check for addi tional fault messag es (e.g. wiring fault).

363

AL Stop Power Stage

365

AL Stop MV-Wiring Ground

Injector wiring fault. Engine Check wiring, re 1.8004.561 stop configurable (alarm place wiring har configuration parameter, ness as necessary. see PR 2.8008.100 for ex planation). Possible causes: 1. Short circuit of injector positive connection to ground of one or more injec tors. 2. Short circuit of injec tor negative connection to ground of one or more injec tors. Short circuit or wire break at Check wiring. transistor output 1 plant side (TOP 1, alarm configuration parameter, see PR 2.8008.100 for explanation). Short circuit or wire break at Check wiring. transistor output 2 plant side (TOP 2, alarm configuration parameter, see PR 2.8008.100 for explanation). Short circuit or wire break at Check wiring. transistor output 3 plant side (TOP 3, alarm configuration parameter, see PR 2.8008.100 for explanation). Short circuit or wire break at Check wiring. transistor output 4 plant side (TOP 4, alarm configuration parameter, see PR 2.8008.100 for explanation). 2.8006.638

381

AL Wiring TOP 1

382

AL Wiring TOP 2

2.8006.639

384

AL Wiring TOP 4

2.8006.641

60 | Troubleshooting | MS15018/01E 2012-05

TIM-ID: 0000008508 - 002

383

AL Wiring TOP 3

2.8006.640

Fault code no. 390

Full designation AL MCR exceeded

Meaning

Action

Setting param eter no. 1.1085.009

DBR/MCR function: MCR None. (maximum continuous rate) exceeded. Engine power is limited to admissible contin uous power (alarm configu ration parameter, see PR 2.8008.100 for explanation). Line disruption at digital in put 1, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 2, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 3, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 4, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 5, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 6, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 7, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Check wiring.

400

AL Open Load Digital Input 1

2.8006.625

401

AL Open Load Digital Input 2

Check wiring.

2.8006.626

402

AL Open Load Digital Input 3

Check wiring.

2.8006627

403

AL Open Load Digital Input 4

Check wiring.

2.8006.628

404

AL Open Load Digital Input 5

Check wiring.

2.8006.629

405

AL Open Load Digital Input 6

Check wiring.

2.8006.630

TIM-ID: 0000008508 - 002

406

AL Open Load Digital Input 7

Check wiring.

2.8006.631

MS15018/01E 2012-05 | Troubleshooting | 61

Fault code no. 407

Full designation AL Open Load Digital Input 8

Meaning Line disruption at digital in put 8, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation).

Action Check wiring.

Setting param eter no. 2.8006.632

408

AL Open Load Emerg. Line disruption at input for Check wiring. Stop Input ESI emergency stop, wiring faul ty or no resistance via switch LO U-PDU Injector voltage too low (lim it value 1, alarm configura tion parameter, see PR 2.8008.100 for explanation). Injector voltage too low (lim it value 2, alarm configura tion parameter, see PR 2.8008.100 for explanation). Injector voltage too high (limit value 1, alarm configu ration parameter, see PR 2.8008.100 for explanation). Injector voltage too high (limit value 2, alarm configu ration parameter, see PR 2.8008.100 for explanation).

2.8006.633

410

Execute engine 2.0141.921 governor self-test, replace engine gov ernor in case of fault. Execute engine 2.0141.922 governor self-test, replace engine gov ernor in case of fault. Execute engine 2.0141.931 governor self-test, replace engine gov ernor in case of fault. Execute engine 2.0141.932 governor self-test, replace engine gov ernor in case of fault. 1.8004.578

411

LOLO U-PDU

412

HI U-PDU

413

HIHI U-PDU

444

SD U-PDU

SD alarm configuration, Replace engine sensor fault at injector out governor. put stage. Engine governor internal fault. Engine gover nor replacement. SD alarm configuration, in put signal for initial/final tor que faulty, short circuit or wiring damage

450

SD Idle/End-Torque Input [%]

Check signal trans 2.8006.592 mitter and wiring, replace as neces sary.Fault is recti fied when engine is restarted.
TIM-ID: 0000008508 - 002

62 | Troubleshooting | MS15018/01E 2012-05

Fault code no. 454

Full designation SS Power Reduction Active

Meaning

Action

Setting param eter no. 2.7000.011

Power reduction activated, None. engine operating outside standard limits. The follow ing variables may also com bine to lead to this mes sage: Intake depression, ex haust back pressure, charge-air coolant tempera ture, intake air temperature. Alarm configuration param eter, see PR 2.8008.100 for explanation. SD alarm configuration, an alog input signal for Aux 2 faulty, short circuit or wiring damage. SD alarm configuration, an alog input signal for pres sure Aux 1 faulty, short cir cuit or wiring damage. Analog input for tempera ture Aux 1 faulty, short cir cuit or wiring damage SD alarm configuration, an alog input signal for Aux 1 faulty, short circuit or wiring damage. Engine governor defective.

463

SD AUX 2

Check signal trans 1.8004.591 mitter and wiring, replace as neces sary. Check pressure 1.8004.589 transmitter and wir ing, replace as nec essary. Check signal trans 1.8004.579 mitter and wiring, replace as neces sary. Check signal trans 1.8004.590 mitter and wiring, replace as neces sary. Replace engine governor at next opportunity. Check sensor and wiring, replace as necessary.Fault is rectified when en gine is restarted. 1.8004.587

464

SD P-AUX 1

468

SD T-AUX 1

469

SD AUX 1

470

SD T-ECU

471

SD Coil Current

SD alarm configuration, HP fuel control block activation, short circuit or wiring dam age.

1.8004.592

472

AL Stop SD

Engine stop as shutdown Contact Service. channels have "sensor fault" (alarm configuration parameter, see PR 2.8008.100 for explanation). Line break or short circuit at Contact Service. channel FO (alarm configu ration parameter, see PR 2.8008.100 for explanation). Replace engine governor at next opportunity. Contact Service.

2.8006.593

TIM-ID: 0000008508 - 002

474

AL Wiring FO

2.8006.655

475

AL CR Trigger Engine Tripped by crash recorder Stop triggering due to engine shutdown. AL Crash Rec. Init. Er Initialization error of crash ror recorder.

1.8010.009

476

1.8010.007

MS15018/01E 2012-05 | Troubleshooting | 63

Fault code no. 478

Full designation AL Comb. Alarm Yel (Plant)

Meaning

Action

Setting param eter no. 2.8006.001

YELLOW combined alarm Contact Service. from plant (alarm configura tion parameter, see PR 2.8008.100 for explanation). RED combined alarm from Contact Service. plant (alarm configuration parameter, see PR 2.8008.100 for explanation). External engine protection Contact Service. function active (alarm con figuration parameter, see PR 2.8008.100 for explana tion). Power reduction caused by Contact Service. maintenance function (maintenance concept, alarm configuration parame ter, see PR 2.8008.100 for explanation).

479

AL Comb. Alarm Red (Plant)

2.8006.002

480

AL Ext. Engine Pro tection

2.0291.921

555

AL Call MTU Field Service

2.0555.001

64 | Troubleshooting | MS15018/01E 2012-05

TIM-ID: 0000008508 - 002

6 Task Description
6.1 Engine
6.1.1 Engine Barring manually
Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Barring device for 12V engines Barring device for 16V, 18V engines
DANGER

Part No. F6558556 F6558557

Qty. 1 1

Unguarded rotating and moving engine components. Risk of serious injury danger to life! before barring or starting the engine, ensure that nobody is in the danger zone. After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.

Barring the engine manually


1. 2. 3. Remove access cover from flywheel hous ing. Install barring device (arrow) on flywheel housing. Rotate crankshaft in engine direction of ro tation. Apart from the normal compression resistance, there should be no abnormal re sistance. If the resistance exceeds the normal com pression resistance, contact Service. For barring device removal, follow reverse sequence of working steps.

Result: 4.

TIM-ID: 0000000012 - 001

MS15018/01E 2012-05 | Task Description | 65

6.1.2

Engine Barring with starting system


Preconditions
External pushbutton Bar engine without starting is provided.

DANGER

Unguarded rotating and moving engine components. Risk of serious injury danger to life! before barring or starting the engine, ensure that nobody is in the danger zone. After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.

Engine Barring with starting system


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

66 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000013 - 001

6.1.3
DANGER

Engine Test run


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.

Engine Test run


1. 2. 3. 4. Start engine ( Page 29). Perform test run not below 1/3 load and at least until steady-state temperature is reached. Carry out operational checks ( Page 31). Stop engine ( Page 32).

TIM-ID: 0000000870 - 007

MS15018/01E 2012-05 | Task Description | 67

6.2 Cylinder Liner


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

Special tools, Material, Spare parts


Designation / Use Rigid endoscope Part No. Y20097353 Qty. 1

Preparatory steps
1. 2. Remove cylinder head cover ( Page 78). Remove injector ( Page 85).

Positioning crankshaft at BDC


1. 2. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC. Insert endoscope into cylinder liner through injector seat.

Endoscopic examination of cylinder liner


Findings Thin carbon coating on circumference of carbon scraper ring Slight localized additive deposits at top edge Localized smooth areas on bottom edge Carbon deposits on circumference in clearance between top piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Consistent honing pattern without objections First signs of marks left by lower cooling bores Running pattern seems darker Action No action required

Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined and do not cover the entire stroke area Dark areas in the upper section of the cooling bore, remaining cir cumference without objections Piston rings without objections

Further endoscopic examina tion required as part of main tenance work

On the entire circumference, apart from light areas of discoloration Cylinder liner must be re (that do not impair operation) clearly darker stripes that start at the placed; Service must be con top piston ring tacted Heat discoloration in the direction of stroke and honing pattern dam age Heat discoloration of piston rings 1. 2. 3. Compile endoscopy report using the table. Use technical terms for description of the liner surface ( Page 70). Depending on findings: do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service; cylinder liner must be replaced.

68 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000015 - 013

Final steps
1. 2. Install injector ( Page 85). Install cylinder head cover ( Page 78).

TIM-ID: 0000000015 - 013

MS15018/01E 2012-05 | Task Description | 69

6.2.2

Cylinder liner Instructions and comments on endoscopic and visual examination


Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami nation report. Findings Minor dirt scores Measure Minor dirt scores can occur during the assembly of a new engine (honing prod ucts, particles, broken-off burrs). Removed cylinders clearly show such scoring on the running surface under endoscope magnification. Cannot be felt with the fingernail. Findings not critical. Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area and cross through the hone pattern in the direction of stroke. Findings not critical. Scored area These areas consist of scores of different length and depth next to one anoth er. In most cases, they are found at the 6-o'clock and 12-o'clock positions (in let/exhaust) along the transverse engine axis. Findings not critical. Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern is still visible. Smoothened areas appear brighter and more brilliant than the surrounding running surface. Findings not critical. Bright area Discoloration Bright areas are on the running surface and show local removal of the honing pattern. Grooves from honing process are not visible any more. This is caused by oxidation (surface discoloration through oil or fuel) and tem perature differences around the liner. It appears rather darker within the honed structure in contrast to the bright metallic running surface. The honing pattern is undisturbed. Discolorations extend in stroke direction and may be interrupt ed. Findings not critical. 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. Cylinder liners with a large number of black lines around the running surface have limited service life and should be replaced.
TIM-ID: 0000000014 - 013

70 | Task Description | MS15018/01E 2012-05

Findings Burn mark

Measure This is caused by a malfunction in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring 2 onwards and less pro nounced from TDC-ring 1. The honing pattern is usually no longer visible and displays a clearly defined (straight) edge to the undisturbed surface. The dam aged surface is usually discolored. The circumferential length varies. Liners with burn marks, or heat discoloration, starting in TDC ring 1 have to be replaced.

Seizure marks, scuff ing

Irregular circumference lengths and depths. Can be caused either by the pis ton skirt or the piston crown. Material deposits on the liner (smear), heavy dis coloration. Severe, visible scoring. Replace liner.

Evaluation of findings and further measures


The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after fur ther operation of the engine.

TIM-ID: 0000000014 - 013

MS15018/01E 2012-05 | Task Description | 71

6.3 Crankcase Breather


6.3.1 Crankcase breather Oil separator element replacement, diaphragm check and replacement
Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Torque wrench, 6-50 Nm Ratchet adapter Engine oil Filter element Diaphragm Gasket
WARNING

Part No. F30027336 F30027340 ( Spare Parts Catalog) ( Spare Parts Catalog) ( Spare Parts Catalog)

Qty. 1 1

Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! Wear protective clothing, gloves, and goggles / safety mask. Avoid contact with skin. Do not inhale oil vapor.

Replacing oil separator element


1. 2. 3. 4. Remove cover (2) with O-ring (3). Remove filter element (1) from housing (4). Insert new filter element in housing (4). Install cover (2) with new O-ring.

5.

Use torque wrench to tighten the screws of cover (2) to the specified torque. Name Screw Size Type Tightening torque Lubricant (Engine oil) Value/Standard 10 Nm 2 Nm

6.

Replace further oil separator elements in the same way.

72 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000017 - 006

Checking diaphragm
1. 2. 3. 4. 5. Remove cover (4). Remove spring (5), gasket (2) and dia phragm (3). Check diaphragm (3) for damage, fit new diaphragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).

6.

Use torque wrench to tighten the screws of cover (4) to the specified torque. Name Screw Size Type Tightening torque Lubricant (Engine oil) Value/Standard 10 Nm 2 Nm

7.

Check diaphragms in further oil separators in the same way.

TIM-ID: 0000000017 - 006

MS15018/01E 2012-05 | Task Description | 73

6.3.2

Crankcase breather Wire mesh cleaning


Special tools, Material, Spare parts
Designation / Use Cleaner Diesel fuel Petroleum jelly Sealing ring Part No. Qty.

( Spare Parts Catalog)

WARNING

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors. Excessive reaction time of cleaning agents on components. Damage to component! Observe manufacturer's instructions. Wear protective clothing, gloves, and goggles / safety mask.

WARNING

CAUTION

Crankcase breather Wire mesh cleaning


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Remove hose. Loosen clamp (5). Remove oil separator cover (7). Remove individual parts from oil separator cover (7). Wash filter element (wire mesh) (3) with diesel fuel. Blow out filter element (wire mesh) (3) with compressed air. Clean residual parts with cleaner. Remove cleaner. Coat sealing ring (6) with petroleum jelly and insert in groove in the oil separator cov er (7). Insert both holders (2, 4) and filter element (wire mesh) (3) into the oil separator cover (7), ensuring correct installation sequence. Install oil separator cover (7) with clamp (5) on cylinder head cover (1). Install hose, ensuring that it is not subjected to tension.

74 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000003469 - 001

6.4 Valve Drive


6.4.1 Valve clearance Check and adjustment
Preconditions
Engine is stopped and starting disabled. Engine coolant temperature is max. 40 C. Valves are closed.

Special tools, Material, Spare parts


Designation / Use Feeler gauge Torque wrench, 20-100 Nm Ratchet Engine oil Part No. Y4342013 F30026582 F30027340 Qty. 1 1 1

Preparatory steps
1. 2. 3. Remove cylinder head cover ( Page 78). Install barring device ( Page 65). Bar engine with barring device in engine di rection of rotation until TDC pointer and TDC mark on the flywheel are aligned.

TIM-ID: 0000000018 - 003

MS15018/01E 2012-05 | Task Description | 75

Checking valve clearance at two crankshaft positions


1. Check TDC position of piston in cylinder A1: If the rocker arms are unloaded on cylin der A1, the piston is in firing TDC. If the rocker arms are under load on cyl inder A1, the piston is in overlap TDC. Check valve clearance with cold engine: Inlet = 0.4 mm; Exhaust = 0.6 mm; Check all valve clearances in two crank shaft positions (firing TDC and overlap TDC of cylinder A1) as per diagram: 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Use feeler gauge to determine the distance between valve bridge and rocker arm. If the deviation from the reference value ex ceeds 0.1 mm, adjust valve clearance.

2. 3.

4. 5.

Adjusting valve clearance


1. 2. 3. Loosen locknut (1) and unscrew adjusting screw (2) by a few threads. Insert feeler gauge between valve bridge and rocker arm. Readjust adjusting screw (2) so that the feeler gauge just passes through the gap.

4.

Tighten locknut (1) with torque wrench to the specified tightening torque while holding adjusting screw (2) firmly with screw driver. Name Locknut Size M12 x 1 Type Tightening torque Lubricant (Engine oil) Value/Standard 50 Nm

76 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000018 - 003

5. Result:

Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap. If not, adjust valve clearance.

Final steps
1. 2. 3. Remove barring device ( Page 65). Install cylinder head cover ( Page 78). Install end cover.

TIM-ID: 0000000018 - 003

MS15018/01E 2012-05 | Task Description | 77

6.4.2

Cylinder head cover Removal and installation


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Torque wrench, 8-40 Nm Ratchet Gasket Part No. F30043446 F30027340 ( Spare Parts Catalog) Qty. 1 1

Preparatory steps
1. 2. On cylinder head covers with crankcase breather: Loosen clamps. Slide rubber sleeves onto the pipe.

Cylinder head cover Removal and installation


1. 2. 3. 4. 5. Remove cylinder head cover with gasket from cylinder head. Clean installation surface. Check condition of gasket in cylinder head cover. Replace damaged gasket(s). Install cylinder head cover with screws.

Final steps
1. 2. Slide rubber sleeves onto the relevant pipe connection. Tighten all clamps.

78 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000019 - 002

6.5 Injection Pump / HP Pump


6.5.1 Injection pump Removal and installation
Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Torque wrench, 20-100 Nm Ratchet adapter Adapter Crowfoot wrench, 19 mm Crowfoot wrench, 22 mm Torque wrench, 0.5-5 Nm Grease (Kluthe Hakuform 30-10/Emulgier) Engine oil Sealing ring Sealing ring Seal
DANGER

Part No. F30026582 F30027340 F30006234 F30027424 F30027425 0015384230 X00058060 ( Spare Parts Catalog) ( Spare Parts Catalog) ( Spare Parts Catalog)

Qty. 1 1 1 1 1 1 1

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

WARNING

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.

Preparatory steps
1. 2. 3. 4.
TIM-ID: 0000000021 - 002

Shut off fuel supply line before fuel filter. Drain fuel ( Page 96). Remove engine governor, if required ( Page 142). Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).

MS15018/01E 2012-05 | Task Description | 79

Removing injection pump


1. 2. 3. 4. Result: Mark installation position of injection pump. Disconnect wiring (1) from injection pump. Disconnect fuel line (2). Unscrew securing screws of injection pump by approx. 6 mm. The pretensioned compression spring presses the injection pump out of the crank case; if not: Turn crankshaft using barring device ( Page 65). The pump cam of the camshaft presses the injection pump out of the crankcase; if not: Carefully press out injection pump at the recess in the injection pump head. Remove injection pump securing screws. Remove injection pump. Remove sealing rings from injection pump. Seal all openings with appropriate covers after removal.

5. 6. 7. 8.

Installing injection pump


1. 2. Note: 3. Note: 4. 5. 6. 7. Remove all blanking plugs and covers. Clean mating face of injection pump and roller. Sealing ring (1) 47 mm Coat sealing ring (1) with grease and fit on to injection pump. Sealing ring (2) 45 mm Coat sealing ring (2) with grease and fit on to injection pump. Coat roller (arrow) with engine oil. Clean sealing face and fuel bores in crank case. Using barring device ( Page 65), set pump cam on camshaft to base circle.

80 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000021 - 002

8.

Install injection pump, observing marked in stallation position.

9.

Install securing screws of injection pump and tighten with torque wrench to the specified torque. Name Screw Size M10 Type Tightening torque Lubricant (Engine oil) Value/Standard 60 Nm +12 Nm

10. 11. Note: 12.

Coat the mating face between union nut and fuel line, ball seal and thread on both ends of the fuel line (3) with engine oil. Install fuel line (3). Observe the inscription on the union nuts (2, 4). Tighten union nuts (2, 4) marked with 35 +3 Nm (see arrow) with torque wrench to the specified tighten ing torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 35 Nm +3 Nm

13.

Tighten union nuts (2, 4) marked with 30 +3 Nm (see arrow) with torque wrench to the specified tighten ing torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 30 Nm +3 Nm

14. 15.

Install injection pump wiring (1). Use torque wrench to tighten screws to the specified tightening torque. Name Screw Size Type Tightening torque Lubricant (Engine oil) Value/Standard 1.5 Nm 0.2 Nm

TIM-ID: 0000000021 - 002

Final steps
1. 2. 3. 4. 5. 6. 7. 8. Remove barring device ( Page 65). Clean mating faces on cylinder head and charge-air manifold. Check gaskets for damage and replace them, if required. Coat gaskets with grease and place onto cylinder head. Install charge-air manifolds. Install engine governor ( Page 142). Open fuel supply line. Vent fuel system ( Page 98)

MS15018/01E 2012-05 | Task Description | 81

6.5.2

Injection pump Removal


Preconditions
Preparatory steps have been carried out.

Special tools, Material, Spare parts


Designation / Use Engine barring device
WARNING

Part No. F6557929

Qty. 1

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Component is hot. Risk of burning! Wear protective gloves.

WARNING

Injection pump Removal


1. 2. Mark installation position of injection pump (2). Unscrew screw (1) approx. 6 mm. Pretensioned compression spring forces the injection pump (2) out of the crank case, if not turn crankshaft using barring device pump cam forces the injection pump (2) through the pump cam out of the crank case, if not carefully press injection pump (2) out at the recess on the injection pump head. Remove screw (1) and injection pump (2). Remove sealing rings (3) and (4). Seal openings with suitable covers.

3. 4. 5.

82 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000004547 - 004

6.5.3

Injection pump Installation


Special tools, Material, Spare parts
Designation / Use Torque wrench, 20-100 Nm Ratchet adapter, " Barring device Grease (Kluthe Hakuform 30-10/Emulgier) Engine oil Sealing ring Sealing ring Part No. F30026582 F30450902 F6557929 X00029933 ( Spare Parts Catalog) ( Spare Parts Catalog) Qty. 1 1 1 1

Injection pump Installation


Note: 1. Note: 2. 3. 4. 5. 6. 7. Sealing ring (4) dia. 47 mm Coat sealing ring (4) with grease and fit on injection pump (2). Sealing ring (3) dia.45 mm Coat sealing ring (3) with grease and fit on injection pump (2). Coat roller on injection pump (2) with en gine oil. Remove plugs and/or covers. Clean sealing face and fuel bores in crank case. Use engine barring device to align camshaft pump cams with base circle. Assign injection pump (2) to installation po sition as marked and press into crankcase by hand against spring force. Insert screw (1) and use torque wrench to tighten evenly to specified tightening torque . Name Screw 9. Size Type Tightening torque Lubricant Value/Standard 60 Nm +12 Nm

8.

Insert screw for cabling in injection pump and use torque wrench to tighten to specified tightening tor que . Name Screw Size Type Tightening torque Lubricant Value/Standard 1 Nm 0.2 Nm

TIM-ID: 0000004566 - 005

MS15018/01E 2012-05 | Task Description | 83

6.6 Injection Valve / Injector


6.6.1 Injector Replacement
Special tools, Material, Spare parts
Designation / Use Injector Part No. ( Spare Parts Catalog) Qty.

Replacing injector
u Remove injector and install new injector ( Page 85).

84 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000022 - 013

6.6.2

Injector Removal and installation


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Impact extractor Fuel suction device Torque wrench, 20-100 Nm Ratchet adapter Adapter Socket wrench, 19 mm Crowfoot wrench, 19 mm Crowfoot wrench, 22 mm Double box wrench Grease (Kluthe Hakuform 30-10/Emulgier) Engine oil Sealing ring Sealing ring Seal
WARNING

Part No. F30377999 F30378207 F30026582 F30027340 F30006234 F30025897 F30027424 F30027425 F30011450 X00029933 ( Spare Parts Catalog) ( Spare Parts Catalog) ( Spare Parts Catalog)

Qty. 1 1 1 1 1 1 1 1 1 1

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors.

WARNING

Preparatory steps
1. 2. 3. 4. 5. Shut off fuel supply line before fuel filter. Drain fuel ( Page 96). Remove engine governor, if required ( Page 142). Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling). Remove cylinder head cover ( Page 78).

TIM-ID: 0000000023 - 001

MS15018/01E 2012-05 | Task Description | 85

Removing injector
1. 2. 3. 4. 5. Disconnect leak-off fuel line from cylinder head. Disconnect fuel line (1). Remove thrust screw (2). Pull off pressure pipe neck (3). Extract fuel from the exposed bores using the suction device.

6. 7. 8. 9. 10. 11.

Remove screw (2). Take off clamp (1). Screw impact extractor into injector. Remove injector using the impact extractor. Remove injector sealing ring using a selfmade hook. Seal all openings with appropriate covers after removal.

86 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000023 - 001

Installing injector
1. 2. 3. 4. 5. Result: Remove all covers before installation. Clean sealing surface on cylinder head and protective sleeve. Coat sealing ring (1) with grease and fit on to injector. Coat sealing ring (2) with grease and fit on to injector. Press injector into cylinder head by hand. The pin is at 11-o'clock position to the transversal axis of the engine. The pin is engaged in the groove of the clamp (4). Install clamp (4) with screw (5), positioning it correctly. The pin is engaged in the groove of the clamp. Forked clamp end is engaged in the cov er recess. Tighten screw (5) of the clamp by hand. Injector can still be rotated. Blow out fuel line (2) and pressure pipe neck (5) with compressed air. Coat sealing ring with grease and fit onto pressure pipe neck (5). Coat the tape of the pressure pipe neck (5) with engine oil. Insert pressure pipe neck (5) into cylinder head until the sealing ring is in contact with the cylinder head. Fully press in pressure pipe neck (5) by hand.

6. Result:

7. Result: 8. 9. 10. 11. 12.

13.

Tighten thrust screw (4) with torque wrench to the specified tightening torque. Name Thrust screw Size Type Lubricant (Engine oil) Value/Standard 40 Nm 5 Nm M22 x 1.5 Tightening torque

14.
TIM-ID: 0000000023 - 001

Use torque wrench to tighten screw for clamp at injector to the specified tightening torque. Name Screw Size M10 Type Tightening torque Lubricant (Engine oil) Value/Standard 50 Nm

15. 16.

Coat the mating face between union nut and fuel line, ball seal and thread on both ends of the fuel line (2) with engine oil. Connect fuel line (2).

MS15018/01E 2012-05 | Task Description | 87

Note: 17.

Observe the inscription on the union nuts (1, 3). Tighten union nuts (1, 3) marked with 35 +3 Nm (see arrows) with torque wrench to the specified tight ening torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 35 Nm +3 Nm

18.

Tighten union nuts (1, 3) marked with 30 +3 Nm (see arrows) with torque wrench to the specified tight ening torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 30 Nm +3 Nm

19.

Connect leak-off fuel line to cylinder head.

Final steps
1. 2. 3. 4. 5. 6. 7. 8. Install cylinder head cover ( Page 78). Clean mating faces on cylinder head and charge-air manifold. Check gaskets for damage and replace them, if required. Coat gaskets with grease and place onto cylinder head. Install charge-air manifolds. Install engine governor ( Page 142). Open fuel supply line. Vent fuel system ( Page 98)

88 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000023 - 001

6.6.3

Injector Removal
Preconditions
Preparatory steps have been carried out.

Special tools, Material, Spare parts


Designation / Use Impact extractor
WARNING

Part No. F30377999

Qty. 1

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.

Injector Removal
1. 2. Remove screw (1). Remove clamp (2).

3. 4. 5.

Screw impact extractor into injector. Remove injector using the impact extractor. Remove sealing rings.

TIM-ID: 0000004614 - 003

MS15018/01E 2012-05 | Task Description | 89

Remove end cover for clamp


1. 2. Remove end cover from cylinder head with screwdriver. Remove sealing ring.

90 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000004614 - 003

6.6.4

Injector Installation
Special tools, Material, Spare parts
Designation / Use Engine barring device Grease (Kluthe Hakuform 30-10/Emulgier) Engine oil Sealing ring Copper sealing ring Part No. F6557929 X00029933 ( Spare Parts Catalog) ( Spare Parts Catalog) Qty. 1 1

WARNING

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Contamination of components. Damage to component! Observe manufacturer's instructions. Check components for special cleanness.

CAUTION

Installing end cover


1. 2. Coat sealing ring with grease and insert in groove of end cover. Insert end cover in bore.

TIM-ID: 0000004633 - 003

MS15018/01E 2012-05 | Task Description | 91

Injector Installation
1. 2. 3. 4. 5. Use engine barring device to turn engine several times to blow out remaining fuel. Coat sealing ring (2) with grease. Wind sealing ring (2) on to injector (3). Fix copper sealing ring (1) with grease on injector (3). Press injector (3) by hand into cylinder head, in doing so make sure that the pin in the injector (3) is at 11 o'clock position to the engine's longitudinal axis.

6. Result: 7. Result:

Attach clamp (2) in correct position. Pin (1) is in recess of clamp (2). Fork of clamp (2) engages in end cover fixation. Insert screw (3) by hand. Injector can still be turned.

92 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000004633 - 003

6.7 Fuel System


6.7.1 Fuel injection line Pressure pipe neck replacement
Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Torque wrench, 20-100 Nm Ratchet adapter Adapter Socket wrench, 19 mm Crowfoot wrench, 19 mm Crowfoot wrench, 22 mm Double box wrench Grease (Kluthe Hakuform 30-10/Emulgier) Engine oil Pressure pipe neck Seal
WARNING

Part No. F30026582 F30027340 F30006234 F30025897 F30027424 F30027425 F30011450 X00029933 ( Spare Parts Catalog) ( Spare Parts Catalog)

Qty. 1 1 1 1 1 1 1 1

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors.

WARNING

Preparatory steps
1. 2. 3. 4.
TIM-ID: 0000000024 - 001

Shut off fuel supply line before fuel filter. Drain fuel ( Page 96). Remove engine governor, if required ( Page 142). Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).

MS15018/01E 2012-05 | Task Description | 93

Replacing pressure pipe neck


1. 2. 3. 4. 5. 6. 7. 8. Disconnect fuel line (2). Blow out fuel line (2) with compressed air. Remove thrust screw (4). Pull off pressure pipe neck (5). Coat sealing ring with grease and fit on new pressure pipe neck (5). Coat the tape of the pressure pipe neck (5) with engine oil. Insert pressure pipe neck (5) into cylinder head until the sealing ring is in contact with the cylinder head. Fully press in pressure pipe neck (5) by hand.

9.

Tighten thrust screw (4) with torque wrench to the specified tightening torque. Name Thrust screw Size Type Lubricant (Engine oil) Value/Standard 40 Nm 5 Nm M22 x 1.5 Tightening torque

10. Note: 11.

Connect fuel line (2). Observe the inscription on the union nuts (1, 3). Tighten union nuts (1, 3) marked with 35 +3 Nm (see arrows) with torque wrench to the specified tight ening torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 35 Nm +3 Nm

12.

Tighten union nuts (1, 3) marked with 30 +3 Nm (see arrows) with torque wrench to the specified tight ening torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 30 Nm +3 Nm

Final steps
1. 2. 3. 4. 5. 6. 7. Clean mating faces on cylinder head and charge-air manifold. Check gaskets for damage and replace them, if required. Coat gaskets with grease and place onto cylinder head. Install charge-air manifolds. Install engine governor ( Page 142). Open fuel supply line. Vent fuel system ( Page 98)
TIM-ID: 0000000024 - 001

94 | Task Description | MS15018/01E 2012-05

6.7.2

Fuel pressure maintaining valve Removal and installation


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Pressure relief valve Sealing ring Sealing ring
WARNING

Part No. ( Spare Parts Catalog) ( Spare Parts Catalog) ( Spare Parts Catalog)

Qty.

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.

Fuel pressure maintaining valve Removal and installation


1. 2. 3. 4. 5. 6. 7. 8. Shut off fuel supply. Remove fuel line (6). Remove banjo screws (1) and (3). Remove sealing rings (2) and (4). Remove screws (9) with washer (8). Remove screws (7) and take off holder. Install new pressure relief valve (5) with new sealing rings (2) and (4), following the reverse sequence of working steps. Open fuel supply.

TIM-ID: 0000000028 - 002

MS15018/01E 2012-05 | Task Description | 95

6.7.3

Fuel Draining
Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Torque wrench, 8-40 Nm Box wrench, 17 mm Engine oil
WARNING

Part No. F30043446 F30028341

Qty. 1 1

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.

Fuel Draining
1. Loosen nut (arrow) on banjo union.

2. 3.

Disconnect fuel line on non-return valve (ar row). Remove non-return valve and collet emerg ing fuel in a suitable container.

96 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000025 - 001

4.

If fuel no longer emerges, install non-return valve and tighten with torque wrench to the specified tighten ing torque. Name Non-return valve Size Type Tightening torque Lubricant (Engine oil) Value/Standard 10 Nm +1 Nm

5. 6.

Connect fuel line. Tighten nut on banjo union.

TIM-ID: 0000000025 - 001

MS15018/01E 2012-05 | Task Description | 97

6.7.4

Fuel system Venting


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Engine oil
WARNING

Part No.

Qty.

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.

Fuel system Venting


1. Unlock fuel priming pump, unscrew handle.

2. 3. 4.

Loosen nut (arrow) on banjo union. Operate the pump with the handle until bub ble-free fuel emerges. Tighten nut on banjo union.

98 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000026 - 001

5. 6. 7.

Loosen banjo screw (arrow). Operate the pump with the handle until bub ble-free fuel emerges. Tighten banjo screw.

8. 9. 10.

Loosen union nut of fuel return line. Loosen non-return valve (arrow). Operate the pump with the handle until bub ble-free fuel emerges.

11.

Use torque wrench to non-return valve to the specified tightening torque. Name Non-return valve Size Type Tightening torque Lubricant (Engine oil) Value/Standard 10 Nm +1 Nm

12. 13.

Tighten union nut of fuel return line. Lock fuel priming pump, screw in handle.

TIM-ID: 0000000026 - 001

MS15018/01E 2012-05 | Task Description | 99

6.8 Fuel Filter


6.8.1 Fuel filter Replacement
Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Filter wrench Diesel fuel Easy-change filter
WARNING

Part No. F30379104 ( Spare Parts Catalog)

Qty. 1

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.

Fuel filter Replacement


1. 2. 3. 4. 5. Remove easy-change filter using the filter wrench. Clean the sealing surface on the bracket. Fill the new easy-change filter with clean fuel. Install and tighten new filter by hand. Vent fuel system ( Page 98)

100 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000027 - 001

6.8.2

Fuel prefilter cleaning


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Diesel fuel Sealing ring
WARNING

Part No. ( Spare Parts Catalog)

Qty.

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.

Fuel prefilter cleaning


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Shut off fuel supply. Remove nuts from filter head. Take off filter housing and drain fuel into appropriate container. Remove filter-element securing nut and re move filter element by pulling it downwards. Wash filter element in clean fuel using a smooth brush. Wash filter housing with clean fuel. Insert filter element into filter housing and secure with nut. Place new sealing ring into groove in filter head. Fit cover with seal and secure it with nuts crosswise. Open fuel supply.

TIM-ID: 0000004936 - 001

MS15018/01E 2012-05 | Task Description | 101

6.8.3
DANGER

Fuel prefilter Differential pressure gauge check and adjustment


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.

Adjusting differential pressure gauge


1. 2. When installing the new filter element: align adjustable pointer (2) with pressure-indicat ing pointer (3) of pressure gauge (1). Check differential pressure.

Checking differential pressure of fuel prefilter


1. 2. With the engine running at full load or rated power, read off pressure at gauge (1). If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating pointer (3) of pressure gauge is 0.3 bar, flush filter element of the cut-in filter ( Page 104).

102 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000004925 - 005

6.8.4

Fuel prefilter Draining


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Diesel fuel Gasket
WARNING

Part No. ( Spare Parts Catalog)

Qty.

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.

Fuel prefilter Draining


1. Cut out filter to be drained. I Left filter cut in II Right filter cut in

2. 3. 4. 5. 6.
TIM-ID: 0000004929 - 003

7. 8. 9. 10. 11.

Open threaded vent plug (5) of filter to be drained. Unlock drain valve (6) by pressing toggle and open it. Drain water and contaminants from filter un til pure fuel emerges. Close drain valve (6). Remove screws for cover and take off cov er (2). Fill filter housing with clean fuel. Place new gasket in cover (2). Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges.

MS15018/01E 2012-05 | Task Description | 103

6.8.5

Fuel prefilter Flushing


Special tools, Material, Spare parts
Designation / Use Fuel Gasket Part No. ( Spare Parts Catalog) Qty.

DANGER

Unguarded rotating and moving engine components. Risk of serious injury danger to life! Take special care when working on a running engine.

WARNING

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.

WARNING

Fuel prefilter Flushing


1. Cut out clogged filter. I Left filter cut in II Right filter cut in

104 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000004937 - 015

2. 3. Result: 4.

Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing valve toggle, open it and drain fuel. Fuel flows from filtered side back to the un filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6).

Fuel prefilter Topping up with fuel


1. 2. 3. 4. 5. 6. Result: Stop engine ( Page 32) and disable engine start. Remove screws for cover and take off cover (2). Fill filter housing with clean fuel. Place new gasket in cover (2). Fit cover with gasket and secure it with screws. Check differential pressure ( Page 102). If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefil ter ( Page 106).

TIM-ID: 0000004937 - 015

MS15018/01E 2012-05 | Task Description | 105

6.8.6

Fuel prefilter Filter element replacement


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Diesel fuel Filter element Gasket
WARNING

Part No. ( Spare Parts Catalog) ( Spare Parts Catalog)

Qty.

Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.

Replacing filter element


1. Cut out filter to be drained. I Left filter cut in II Right filter cut in

106 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000004944 - 004

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

Open threaded vent plug (5) of contaminat ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele ment (3). Insert new filter element (3) and spring housing (4). Fill filter housing with clean fuel. Place new gasket in cover (2). Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges. Adjust the differential pressure gauge ( Page 102).

TIM-ID: 0000004944 - 004

MS15018/01E 2012-05 | Task Description | 107

6.9 Charge-Air Cooling General, Left-Hand Side


6.9.1 Intercooler Checking condensate drains for coolant discharge and obstructions
Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Sealing ring
WARNING

Part No. ( Spare Parts Catalog)

Qty.

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

Intercooler Checking condensate drains for coolant discharge and obstructions


1. 2. 3. 4. 5. Remove plug screw(s) from charge-air manifold. Check drain bore(s) for air discharge. If no air escapes: Clean drain bore(s) and blow out with compressed air. More significant coolant leakage indicates a leaking intercooler. Contact Service. Install plug screw(s) with new sealing ring and tighten.

Emergency measures prior to engine start with a leaking intercooler


1. 2. 3. 4. Remove injectors ( Page 85). Bar the engine manually ( Page 65). Bar the engine with the starting system to blow out cylinder chambers ( Page 66). Install injectors ( Page 85).

108 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000030 - 002

6.10 Air Filter


6.10.1 Air filter Replacement
Special tools, Material, Spare parts
Designation / Use Air filter Filter insert Filter element Part No. ( Spare Parts Catalog) ( Spare Parts Catalog) ( Spare Parts Catalog) Qty.

Air filter Replacement


1. 2. Remove air filter(s) and install new one(s) ( Page 110). Reset signal ring of service indicator ( Page 111).

TIM-ID: 0000013385 - 002

MS15018/01E 2012-05 | Task Description | 109

6.10.2

Air filter Removal and installation


Preconditions
Engine is stopped and starting disabled.

Variant A
1. 2. 3. 4. 5. Release clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it. Place new air filter (3) with clamp (2) onto intake housing (1). Tighten clamp (2).

Variant B
1. 2. 3. 4. 5. 6. Release latches (1). Remove cover (2). Remove filter insert (3) and filter ele ment (4). Wipe out filter housing (5) and cover (2) with moist cloth. Insert new filter element (4) and filter in sert (3). For installation, follow reverse sequence of working steps.

110 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000013395 - 001

6.11 Air Intake


6.11.1 Service indicator Signal ring position check
Preconditions
Engine is stopped and starting disabled.

Checking signal ring position


1. Replace air filter, if the signal ring (2) is completely visible in the red area of the service indicator control window (3) ( Page 109). After installation of new filter, press reset button (1). Signal ring returns to initial position.

2. Result:

TIM-ID: 0000000985 - 003

MS15018/01E 2012-05 | Task Description | 111

6.12 Starting Equipment


6.12.1
DANGER

Air starter Manual operation


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.

Air starter Manual operation


1. 2. 3. Press pushbutton for manual start and hold it. Allow compressed air to enter the air start er, until the engine fires evenly. Release pushbutton.

112 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000006076 - 003

6.13 Lube Oil System, Lube Oil Circuit


6.13.1 Engine oil Level check
Preconditions
Engine is stopped and starting disabled.

Oil level check prior to engine start


1. 2. 3. 4. 5. Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. Oil level must be between "min." and "max." marks. Top up to "max." if required ( Page 114). Insert oil dipstick into guide tube up to the stop.

Oil level check after the engine is stopped


1. 2. 3. 4. 5. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. Oil level must be between min. and "max." marks. Top up to "max." if required ( Page 114). Insert oil dipstick into guide tube up to the stop.

TIM-ID: 0000000032 - 002

MS15018/01E 2012-05 | Task Description | 113

6.13.2

Engine oil Change


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

Special tools, Material, Spare parts


Designation / Use Engine oil Sealing ring
WARNING

Part No. ( Spare Parts Catalog)

Qty.

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.

Oil change without semirotary hand pump: Draining oil at drain plug on oil pan
1. 2. 3. 4. Provide a suitable container to collect the oil. Remove drain plug and drain oil. Install drain plug with new sealing ring. Replace engine oil filter ( Page 115).

Oil change with semirotary hand pump: Oil extraction


1. 2. 3. Provide a suitable container to collect the oil. Extract all oil from oil pan using the semirotary hand pump. Replace engine oil filter ( Page 115).

Filling with new oil


1. 2. 3. 4. 5. Open cover on filler neck. Pour oil in at filler neck up to "max." mark at oil dipstick. Close cover on filler neck. Check engine oil level ( Page 113). After oil change and filter replacement, bar engine with starting system ( Page 66).
TIM-ID: 0000000031 - 005

114 | Task Description | MS15018/01E 2012-05

6.14 Oil Filtration / Cooling


6.14.1 Engine oil filter Replacement
Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Filter wrench Engine oil Oil filter
WARNING

Part No. F30379104 ( Spare Parts Catalog)

Qty. 1

Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! Wear protective clothing, gloves, and goggles / safety mask. Avoid contact with skin. Do not inhale oil vapor.

Engine oil filter Replacement


1. 2. 3. 4. 5. 6. 7. Remove oil filter using the filter wrench. Clean the sealing face of the filter head. Check condition of the new oil filter sealing ring and coat it with oil. Install and tighten new oil filter by hand. Replace further oil filters in the same way. After each oil change and filter replace ment, bar engine with starting system ( Page 66). Check oil level ( Page 113).

TIM-ID: 0000000033 - 001

MS15018/01E 2012-05 | Task Description | 115

6.15 Coolant Circuit, General, High-Temperature Circuit


6.15.1 Engine coolant Filling
Preconditions
Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts


Designation / Use Engine coolant
WARNING

Part No.

Qty.

Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask. Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.

WARNING

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. 2. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove.

116 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000034 - 003

Engine coolant Filling


1. 2. 3. Fill coolant through filler neck on expansion tank or through filling line until coolant level reaches lower edge of cast-in eye or marking plate. Check proper condition of breather valve, clean sealing faces if required. Fit breather valve and close it.

Final steps
1. 2. Start the engine and operate it at idle speed for some minutes. Check coolant level ( Page 120), top up with coolant if required.

TIM-ID: 0000000034 - 003

MS15018/01E 2012-05 | Task Description | 117

6.15.2

Engine coolant Draining


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Sealing ring Sealing ring
WARNING

Part No. ( Spare Parts Catalog) ( Spare Parts Catalog)

Qty.

Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask.

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

Draining engine coolant


1. 2. 3. 4. Turn breather valve of filler neck on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove. Draw off segregated corrosion inhibitor oil in expansion tank through the filler neck. Open drain valves and drain plugs and drain coolant at the following points: At the preheating unit; At the engine coolant pump; At the crankcase, left and right sides; At oil heat exchanger. Close all open drain points. Place breather valve on filler neck and close.

5. 6.

118 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000035 - 002

6.15.3

Engine coolant Change


Special tools, Material, Spare parts
Designation / Use Engine coolant Part No. Qty.

Engine coolant Change


1. 2. Drain engine coolant ( Page 118). Fill with engine coolant ( Page 116).

TIM-ID: 0000035998 - 001

MS15018/01E 2012-05 | Task Description | 119

6.15.4

Engine coolant Level check


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.

Checking coolant level at filler neck:


1. 2. 3. 4. 5. 6. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove. Check coolant level (coolant must be visible at the lower edge of the cast-in eye or at the marking plate). Top up with treated coolant as necessary ( Page 116). Check and clean breather valve. Place breather valve on filler neck and close.

Coolant-level check by means of level sensor:


1. 2. Switch on engine control system and check readings on the display. Top up with treated coolant as necessary ( Page 116).

120 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000037 - 003

6.15.5
DANGER

Coolant pump Relief bore check


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.

Coolant pump Relief bore check


1. 2. 3. 4. Check relief bore for oil and water dis charge. Permissible discharge: Up to 10 drops of coolant per hour Up to 5 drops of oil per hour If discharge exceeds the specified limits, contact Service. If relief bore is dirty: a) Stop engine ( Page 32) and disable engine start. b) Clean relief bore with a wire. c) Start the engine ( Page 29) and oper ate it at idle speed for some minutes. d) Check relief bore again for oil and cool ant discharge.

TIM-ID: 0000000038 - 001

MS15018/01E 2012-05 | Task Description | 121

6.16 Low-Temperature Circuit


6.16.1 Charge-air coolant Filling
Preconditions
Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts


Designation / Use Charge-air coolant Sealing ring
WARNING

Part No. ( Spare Parts Catalog)

Qty.

Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask. Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.

WARNING

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. 2. 3. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove. Remove plug screw from filling point on coolant line to intercooler.

122 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000039 - 002

Charge-air coolant Filling


1. 2. 3. 4. Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level reaches marking plate. Install plug screws of filling points with new sealing rings. Check proper condition of breather valve, clean sealing faces if required. Fit breather valve and close it.

Final steps
1. 2. Start the engine and operate it at idle speed for some minutes. Check coolant level ( Page 126).

TIM-ID: 0000000039 - 002

MS15018/01E 2012-05 | Task Description | 123

6.16.2

Charge-air coolant Draining


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Sealing ring Sealing ring
WARNING

Part No. ( Spare Parts Catalog) ( Spare Parts Catalog)

Qty.

Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask.

Charge-air coolant Draining


1. 2. 3. 4. 5. Provide an appropriate container to drain the coolant into. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck. Open drain plugs and drain coolant at the following points: At the charge-air coolant pump; At the intercooler, engine driving end and free end sides. Screw in drain plugs with new sealing rings. Place breather valve on filler neck and close.

6. 7.

124 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000040 - 002

6.16.3

Charge-air coolant Change


Special tools, Material, Spare parts
Designation / Use Coolant Part No. Qty.

Charge-air coolant Change


1. 2. Drain charge-air coolant ( Page 124). Fill with charge-air coolant ( Page 122).

TIM-ID: 0000000041 - 011

MS15018/01E 2012-05 | Task Description | 125

6.16.4

Charge-air coolant Level check


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.

Checking charge-air coolant level at filler neck:


1. 2. 3. 4. 5. 6. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove. Check coolant level (coolant must be visible at marking plate). Top up coolant if necessary ( Page 122). Check proper condition of breather valve, clean sealing faces if required. Fit breather valve and close it.

Checking charge-air coolant level by means of level sensor:


1. 2. Switch on engine control system and check display (coolant level is automatically monitored by engine control system). Top up coolant if necessary ( Page 122).

126 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000042 - 006

6.17 Coolant System


6.17.1 Cooler Checking cooler elements externally for dirt
Preconditions
Engine is stopped and starting disabled.

Check cooler elements externally for dirt


1. 2. Inspect cooler elements visually for dirt. Clean badly soiled cooler elements ( Page 128).

TIM-ID: 0000015785 - 001

MS15018/01E 2012-05 | Task Description | 127

6.17.2

Cooler Cleaning cooler elements


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. Chemical substances in cleaners. Risk of irritation and chemical burns! Always obey manufacturer's instructions before use!

WARNING

CAUTION

Excessive reaction time of cleaning agents on components. Damage to component! Observe manufacturer's instructions. Wear protective clothing, gloves, and goggles / safety mask. Unsuitable cleaning tool. Damage to component! Observe manufacturer's instructions. Use appropriate cleaning tool.

CAUTION

Cleaning cooler elements


1. 2. Blow out the cooler elements with a jet of compressed air working against the direction of the cooling air parallel to the cooling fins. If cooler elements are badly soiled, treat cooling fins with a hot, grease-dissolving alkaline cleaning agent before cleaning.

128 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000015784 - 001

6.18 Battery-Charging Generator


6.18.1 Drive belt Condition check
Preconditions
Engine is stopped and starting disabled. Guard is removed.

Drive belt Condition check

Item Drive belt A Drive belt Drive belt B Drive belt C

Findings Singular cracks Belt is oily, shows signs of over heating Cracks on entire circumference Chunking

Action None Replace ( Page 132)

TIM-ID: 0000000920 - 009

MS15018/01E 2012-05 | Task Description | 129

6.18.2

Battery-charging generator drive Drive-belt check and adjustment


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Belt-tension tester Torque wrench, 20-100 Nm Ratchet adapter Engine oil Part No. Y20097429 F30026582 F30027340 Qty. 1 1 1

Drive belt Condition check


1. 2. 3. Remove protective cover. Check condition of drive belt visually. Replace drive belt ( Page 132): If belt is oily; If belt shows signs of overheating; If ribs are broken around the entire cir cumference (A); If rib material is broken off in some pla ces (B). Install protective cover.

4.

Drive belt Tension check


1. 2. 3. 4. 5. 6. 7. Remove protective cover. Place belt-tension tester onto drive belt midway between the belt pulleys. Press button uniformly down on drive-belt surface until spring disengagement can be heard and felt. Do not press any further, otherwise the reading is not exact. Take off belt-tension tester without chang ing the position of the indication arm. Read off measuring value at the intersec tion of indication arm and "KG" scale. If the measured value deviates from the specified setting, readjust belt tension.

8.

Install protective cover. Setting (new drive belt) Setting (used drive belt) 450 N - 50 N 350 N - 50 N

130 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000043 - 001

Drive belt Tension adjustment


1. 2. Release screws (2 and 3). Tension drive belt with tensioning nut (1) and check belt tension.

3.

Tighten screw (2) with torque wrench to the specified tightening torque. Name Screw Size M12 Type Tightening torque Lubricant (Engine oil) Value/Standard 40 Nm +4 Nm

4. 5. 6.

Tighten screw (3). Check drive belt tension. Install protective cover.

TIM-ID: 0000000043 - 001

MS15018/01E 2012-05 | Task Description | 131

6.18.3

Battery-charging generator drive Drive belt replacement


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Torque wrench, 20-100 Nm Ratchet adapter Engine oil Drive belt Part No. F30026582 F30027340 ( Spare Parts Catalog) Qty. 1 1

Battery-charging generator drive Drive belt replacement


1. 2. 3. 4. 5. 6. 7. Remove protective cover. Remove drive belt for fan drive ( Page 136). Release securing screws (2 and 3). Release tensioning screw (1) until the drive belt can be removed. Check belt pulleys for cleanliness, remove dirt, if any. Fit new drive belt. Tension drive belt with tensioning nut (1) and check belt tension ( Page 130).

8.

Tighten securing screw (2) with torque wrench to the specified tightening torque. Name Screw Size M12 Type Tightening torque Lubricant (Engine oil) Value/Standard 40 Nm + 4 Nm

9. 10. 11.

Tighten securing screw (3). Install drive belt for fan drive ( Page 136). Install protective cover.

132 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000044 - 001

6.19 Fan Drive


6.19.1 Fan drive Drive-belt check and adjustment
Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Belt tension tester Torque wrench, 20-100 Nm Ratchet adapter Engine oil Part No. 5505890119/00 F30026582 F30027340 Qty. 1 1 1

Preparatory steps
1. 2. Remove screws from protective cover. Remove protective cover.

Drive belt Condition check


1. 2. Check condition of drive belt visually. Replace drive belt ( Page 136): If belt is oily; If belt shows signs of overheating; If belt is cracked; If belt is worn; If cracks are found: .

Drive belt Tension check, variant A


1. 2. 3. 4. 5.
TIM-ID: 0000000045 - 001

Place belt-tension tester onto drive midway between the belt pulleys (arrow). Press button uniformly against drive belt surface until spring disengagement can be heard and felt. Do not press any further, otherwise the reading is not exact. Take off belt-tension tester without chang ing the position of the indication arm. Read off measured value at the intersection of indication arm and KG scale.

6.

If the measured value deviates from the specified setting, readjust belt tension. Setting (new drive belt) Setting (used drive belt) 660 N 510 N

MS15018/01E 2012-05 | Task Description | 133

Drive belt Tension check, variant B


1. 2. 3. 4. 5. Place belt-tension tester onto drive midway between the belt pulleys (arrow). Press button uniformly against drive belt surface until spring disengagement can be heard and felt. Do not press any further, otherwise the reading is not exact. Take off belt-tension tester without chang ing the position of the indication arm. Read off measured value at the intersection of indication arm and KG scale.

6.

If the measured value deviates from the specified setting, readjust belt tension. Setting (new drive belt) Setting (used drive belt) 670 N - 50 N 570 N - 50 N

Drive belt Tension adjustment, variant A


1. 2. 3. 4. 5. Loosen screws (3). Release locknut (2). Screw in screw (1) to tension drive belt. Tighten locknut (2). Check drive belt tension.

6.

Tighten screw (3) with torque wrench to the specified tightening torque. Name Screw Size M12 Type Tightening torque Lubricant (Engine oil) Value/Standard 100 Nm
TIM-ID: 0000000045 - 001

134 | Task Description | MS15018/01E 2012-05

Drive belt Tension adjustment, variant B


1. Note: 2. 3. Release screws (1, 4). Bolt (3) is in position A for variant 50 Hz, and in position B for variant 60 Hz. Screw in screw (2) to tension drive belt. Check drive belt tension.

4.

Tighten screws (1, 4) with torque wrench to the specified tightening torque. Name Screw Size M12 Type Tightening torque Lubricant (Engine oil) Value/Standard 69 Nm

5.

Check drive belt tension.

Final steps
1. 2. Install protective cover. Fit screws and tighten.

TIM-ID: 0000000045 - 001

MS15018/01E 2012-05 | Task Description | 135

6.19.2

Fan drive Drive belt replacement


Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Drive belt Part No. ( Spare Parts Catalog) Qty.

Preparatory steps
1. 2. Remove protective cover from radiator. Remove fan.

Drive belt replacement, variant A


1. 2. 3. 4. Loosen securing screws (3). Release locknut (2). Screw out tensioning screw (1) until drive belts can be removed. Check belt pulley on fan bearing pedestal and crankshaft for contamination, clean if necessary. Drive belts must only be fitted in the grooves as a set and without applying any force. Fit new set of drive belts. To check drive tension, the fan bearing pedestal must rest against the gearcase. Adjust and check drive belt tension ( Page 133).

Note: 5. 6. 7.

Drive belt replacement, variant B


1. 2. 3. Release securing screws (1 and 4). Unscrew tensioning screw (2) with bolt (3) until the drive belts can be removed. Check belt pulley on fan bearing pedestal and crankshaft for contamination, clean if necessary. Drive belts must only be fitted in the grooves as a set and without applying any force. Fit new set of drive belts. To check drive tension, the fan bearing pedestal must rest against the gearcase. Adjust and check drive belt tension ( Page 133).

Note: 4. 5. 6.

136 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000046 - 002

Final steps
1. 2. Install fan. Install protective cover.

TIM-ID: 0000000046 - 002

MS15018/01E 2012-05 | Task Description | 137

6.20 Cabling
6.20.1 Engine wiring Check
Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Isopropyl alcohol Part No. X00058037 Qty. 1

Engine wiring Check


1. 2. 3. 4. 5. Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely. Check that cable ties are firm, tighten loose cable ties. Replace faulty cable ties. Visually inspect the following electrical line components for damage: connector housings; contacts; sockets; cables and terminals; plug-in contacts. ( Contact Service) if cable conductors are damaged. Close male connectors that are not plugged in with the protective cap supplied. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. Ensure that all sensor connectors are securely engaged.

6. Note: 7. 8.

138 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000029 - 018

6.20.2

Sensors and actuators


Illustration is also valid for 16 V and 18 V engines

No. 1 2 3 4 5 6 7 8

Designation B10 B9 B1 B13 B6 B33 B5 B7

Monitoring of Charge-air pressure Charge-air temperature Camshaft speed Crankshaft speed Coolant temperature Fuel temperature Lube oil pressure Lube oil temperature

TIM-ID: 0000012889 - 002

MS15018/01E 2012-05 | Task Description | 139

6.21 Accessories for (Electronic) Engine Governor / Control System


6.21.1 Engine governor and connectors Cleaning
Preconditions
Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Isopropyl alcohol Note: Part No. X00058037 Qty. 1

Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent.

Engine governor and connectors Cleaning


1. 2. 3. Remove coarse dirt from housing surface with isopropyl alcohol. Remove dirt from connector and cable surfaces with isopropyl alcohol. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning severely contaminated connectors on the engine governor


Note: 1. 2. 3. Seal unused connectors with the supplied protective cap. Release the latch and pull off connectors. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol. When connectors, sockets and all contacts are dry: Fit connectors and lock them.

140 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000047 - 009

6.21.2

Engine governor Checking plug-in connections


Preconditions
Engine is stopped and starting disabled.

Note:

Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent.

Checking plug-in connections on engine governor


1. 2. Check all plug-in connections for secure seating. Latch connectors if loose.

TIM-ID: 0000000048 - 005

MS15018/01E 2012-05 | Task Description | 141

6.21.3

ECU 7 engine governor Removal and installation


Preconditions
Engine is stopped and starting disabled.

CAUTION

Wrong engine governor installed. Engine damage! When reassembling an engine, make sure that the governor with the data record for the given engine is installed.

Removing engine governor from engine


1. 2. 3. 4. 5. 6. Note or mark assignment of cables and connectors. Remove all screws (2). Undo latches (3) of the connectors. Remove all connectors. Remove screws (1). Take off engine governor.

Installing engine governor on engine


1. 2. Result: Install in reverse order. In doing so, ensure correct assignment of connectors and sockets. Check rubber mount before installation. If the rubber mount is porous or defective, replace it.

142 | Task Description | MS15018/01E 2012-05

TIM-ID: 0000000049 - 005

7 Appendix A
7.1 Abbreviations
Abbreviation A/D ADEC AFRS ANSI ATL ATS BR BV CAN CDC CEL Meaning Analog/Digital Advanced Diesel Engine Controller Air Filter Restriction Sensor American National Standards Institute Abgasturbolader Air Temperature Sensor Baureihe Betriebsstoffvorschrift Controller Area Network Calibration Drift Compensation Stop Engine Light Series MTU Fluids and Lubricants Specifications, Publication No. A01061/.. Data bus system, bus standard Setting of drift compensation in engine gov ernor with DiaSys 1st function: Warning lamp (rectify fault as soon as possible) 2nd function: Read out fault codes CKT CLS CPS CTS DDEC DDL DDR DIN DL DOC
TIM-ID: 0000000858 - 009

Explanation Transformer: transforms sensor voltages into numeric values Engine management system Association of American standardization or ganizations Exhaust turbocharger (ETC)

Circuit Coolant Level Sensor Coolant Pressure Sensor Coolant Temperature Sensor Detroit Diesel Electronic Controls Diagnostic Data Link Diagnostic Data Reader Deutsches Institut fr Normung e. V. Default Lost Diesel Oxidation Catalyst Diesel Particulate Filter Diagnostic Tool Electronic Control Module Engine Control Unit Engine Data Module Electrically Erasable Programmable Read Only Memory Electronic Foot Pedal Assembly MS15018/01E 2012-05 | Appendix A | 143 Diagnostic unit Electronic control unit of the DDEC system Engine governor Memory module for engine data Monitors coolant level Monitors coolant pressure Monitors coolant temperature Engine control system made by Detroit Die sel Diagnostic lines Diagnostic unit At the same time identifier of German stand ards (DIN = Deutsche Industrie-Norm) Alarm: Default CAN bus failure Oxidation catalyst upstream of the diesel particulate filter

DPF DT ECM ECU EDM EEPROM EFPA

Abbreviation EGR EMU ETK EUI FPS FRS FTS FWCP GND HD HI HIHI HT IDM INJ ISO KGS KS LED LO LOLO LSG N/A LP OEM OI OLS OPS OTS OT PAN PIM PWM P-xyz RL

Meaning Exhaust Gas Recirculation Engine Monitoring Unit Ersatzteilkatalog Electronic Unit Injector Fuel Pressure Sensor Fuel - Differential Pressure Sensor Fuel Temperature Sensor Fire Water Control Panel Ground Hochdruck High High High High Temperature Interface Data Module Injector International Organization for Stand ardization Kraftgegenseite Kraftseite Light Emitting Diode Low Low Low Limiting Speed Governor Not Applicable Low Pressure Original Equipment Manufacturer Optimized Idle Oil Level Sensor Oil Pressure Sensor Oil Temperature Sensor Oberer Totpunkt Panel Peripheral Interface Module Modulated signal Pressure-xyz Redundancy Lost

Explanation

Spare Parts Catalog (SPC) Monitors fuel pressure Monitors fuel temperature Control cabinet High Pressure (HP) Alarm: Measured value exceeds 1st maxi mum limit Alarm: Measured value exceeds 2nd maxi mum limit value Memory module for interface data International umbrella organization for all na tional standardization institutes Engine free end in accordance with DIN ISO 1204 Engine driving end in accordance with DIN ISO 1204 Alarm: Measured value lower than 1st mini mum limit value Alarm: Measured value lower than 2nd mini mum limit value

Monitors oil level Monitors oil temperature Top Dead Center (TDC) Control panel
TIM-ID: 0000000858 - 009

Monitors oil pressure

Pressure measuring point, xyz specifies the measuring point designation Alarm: Redundant CAN bus failure

144 | Appendix A | MS15018/01E 2012-05

Abbreviation SAE SD SEL

Meaning Society of Automotive Engineers Sensor Defect Stop Engine Light

Explanation U.S. standardization organization Alarm: Sensor failure 1st function: Warning lamp (stop engine and rectify fault) 2nd function: Read out fault codes

SID SRS SS TBS TCI TCO TD TPS TRS T-xyz UT VNT VSG VSS WZK

System Identifier Synchronous Reference Sensor Safety System Turbocharger Boost Sensor Turbo Compressor Inlet Turbo Compressor Outlet Transmitter Deviation Throttle Position Sensor Timing Reference Sensor Temperature-xyz Unterer Totpunkt Variable Nozzle Turbine Variable-Speed Governor Vehicle Speed Sensor Werkzeugkatalog Tool Catalog (TC) Temperature measuring point, xyz specifies the measuring point designation Bottom Dead Center (BDC) Alarm: Deviation in transmitter values TDC cylinder 1 Safety system alarm Monitors charge-air pressure

TIM-ID: 0000000858 - 009

MS15018/01E 2012-05 | Appendix A | 145

7.2 MTU contacts/service partners


Service
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service centers ensures fast and direct support on site and the high availability of our products.

Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com

24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you - either during operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply. Your contact at Headquarters: Service-support@mtu-online.com

Spare parts service


Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare part at the right time at the right place. With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse at headquarters and on-site stores at our subsidiary companies, agencies and service workshops. Your contact at Headquarters: E-mail: spare.parts@mtu-online.com Tel.: +49 7541 908555 Fax.: +49 7541 908121

146 | Appendix A | MS15018/01E 2012-05

TIM-ID: 0000000873 - 013

8 Appendix B
8.1 Special Tools
Adapter Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: F30006234 1 6.5.1 Injection pump Removal and installation ( Page 79) 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93)

Barring device Part No.: Qty.: Used in: Barring device for 12V engines Part No.: Qty.: Used in: F6558556 1 6.1.1 Engine Barring manually ( Page 65) F6557929 1 6.5.3 Injection pump Installation ( Page 83)

Barring device for 16V, 18V engines Part No.: Qty.: Used in:
DCL-ID: 0000019467 - 003

F6558557 1 6.1.1 Engine Barring manually ( Page 65)

MS15018/01E 2012-05 | Appendix B | 147

Belt tension tester Part No.: Qty.: Used in: 5505890119/00 1 6.19.1 Fan drive Drive-belt check and adjustment ( Page 133)

Belt-tension tester Part No.: Qty.: Used in: Y20097429 1 6.18.2 Battery-charging generator drive Drive-belt check and adjustment ( Page 130)

Box wrench, 17 mm Part No.: Qty.: Used in: F30028341 1 6.7.3 Fuel Draining ( Page 96)

Crowfoot wrench, 19 mm Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: F30027424 1 6.5.1 Injection pump Removal and installation ( Page 79)
DCL-ID: 0000019467 - 003

1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93)

148 | Appendix B | MS15018/01E 2012-05

Crowfoot wrench, 22 mm Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: F30027425 1 6.5.1 Injection pump Removal and installation ( Page 79) 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93)

Double box wrench Part No.: Qty.: Used in: Qty.: Used in: F30011450 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93)

Engine barring device Part No.: Qty.: Used in: Qty.: Used in: Feeler gauge Part No.: Qty.: Used in: Y4342013 1 6.4.1 Valve clearance Check and adjustment ( Page 75) F6557929 1 6.5.2 Injection pump Removal ( Page 82) 1 6.6.4 Injector Installation ( Page 91)

DCL-ID: 0000019467 - 003

MS15018/01E 2012-05 | Appendix B | 149

Filter wrench Part No.: Qty.: Used in: Qty.: Used in: F30379104 1 6.8.1 Fuel filter Replacement ( Page 100) 1 6.14.1 Engine oil filter Replacement ( Page 115)

Fuel suction device Part No.: Qty.: Used in: F30378207 1 6.6.2 Injector Removal and installation ( Page 85)

Impact extractor Part No.: Qty.: Used in: Qty.: Used in: F30377999 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.6.3 Injector Removal ( Page 89)

Ratchet Part No.: Qty.: Used in: Qty.: Used in: F30027340 1 6.4.1 Valve clearance Check and adjustment ( Page 75)
DCL-ID: 0000019467 - 003

1 6.4.2 Cylinder head cover Removal and installation ( Page 78)

150 | Appendix B | MS15018/01E 2012-05

Ratchet adapter Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: F30027340 1 6.3.1 Crankcase breather Oil separator element re placement, diaphragm check and replacement ( Page 72) 1 6.5.1 Injection pump Removal and installation ( Page 79) 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93) 1 6.18.2 Battery-charging generator drive Drive-belt check and adjustment ( Page 130) 1 6.18.3 Battery-charging generator drive Drive belt re placement ( Page 132) 1 6.19.1 Fan drive Drive-belt check and adjustment ( Page 133)

Ratchet adapter, " Part No.: Qty.: Used in: F30450902 1 6.5.3 Injection pump Installation ( Page 83)

Rigid endoscope Part No.: Qty.: Used in:


DCL-ID: 0000019467 - 003

Y20097353 1 6.2.1 Cylinder liner Endoscopic examination ( Page 68)

MS15018/01E 2012-05 | Appendix B | 151

Socket wrench, 19 mm Part No.: Qty.: Used in: Qty.: Used in: F30025897 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93)

Torque wrench, 0.5-5 Nm Part No.: Qty.: Used in: 0015384230 1 6.5.1 Injection pump Removal and installation ( Page 79)

Torque wrench, 20-100 Nm Part No.: Qty.: Used in: Qty.: Used in: F30026582 1 6.4.1 Valve clearance Check and adjustment ( Page 75) 1 6.5.3 Injection pump Installation ( Page 83)

152 | Appendix B | MS15018/01E 2012-05

DCL-ID: 0000019467 - 003

Torque wrench, 20-100 Nm Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: F30026582 1 6.5.1 Injection pump Removal and installation ( Page 79) 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93) 1 6.18.2 Battery-charging generator drive Drive-belt check and adjustment ( Page 130) 1 6.18.3 Battery-charging generator drive Drive belt re placement ( Page 132) 1 6.19.1 Fan drive Drive-belt check and adjustment ( Page 133)

Torque wrench, 6-50 Nm Part No.: Qty.: Used in: F30027336 1 6.3.1 Crankcase breather Oil separator element re placement, diaphragm check and replacement ( Page 72)

Torque wrench, 8-40 Nm Part No.: Qty.: Used in: F30043446 1 6.4.2 Cylinder head cover Removal and installation ( Page 78)

DCL-ID: 0000019467 - 003

MS15018/01E 2012-05 | Appendix B | 153

Torque wrench, 8-40 Nm Part No.: Qty.: Used in: F30043446 1 6.7.3 Fuel Draining ( Page 96)

154 | Appendix B | MS15018/01E 2012-05

DCL-ID: 0000019467 - 003

8.2 Consumables
Charge-air coolant Part No.: Qty.: Used in: Cleaner Part No.: Qty.: Used in: Coolant Part No.: Qty.: Used in: Diesel fuel Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Engine coolant Part No.: Qty.: Used in: Qty.: Used in: 6.15.1 Engine coolant Filling ( Page 116) 6.15.3 Engine coolant Change ( Page 119) 6.3.2 Crankcase breather Wire mesh cleaning ( Page 74) 6.8.1 Fuel filter Replacement ( Page 100) 6.8.2 Fuel prefilter cleaning ( Page 101) 6.8.4 Fuel prefilter Draining ( Page 103) 6.8.6 Fuel prefilter Filter element replacement ( Page 106) 6.16.3 Charge-air coolant Change ( Page 125) 6.3.2 Crankcase breather Wire mesh cleaning ( Page 74) 6.16.1 Charge-air coolant Filling ( Page 122)

DCL-ID: 0000019467 - 003

MS15018/01E 2012-05 | Appendix B | 155

Engine oil Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Engine oil Part No.: Qty.: Used in: Fuel Part No.:
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6.3.1 Crankcase breather Oil separator element replacement, diaphragm check and replacement ( Page 72) 6.4.1 Valve clearance Check and adjustment ( Page 75) 6.5.1 Injection pump Removal and installation ( Page 79) 6.6.2 Injector Removal and installation ( Page 85) 6.6.4 Injector Installation ( Page 91) 6.7.1 Fuel injection line Pressure pipe neck replacement ( Page 93) 6.7.3 Fuel Draining ( Page 96) 6.7.4 Fuel system Venting ( Page 98) 6.13.2 Engine oil Change ( Page 114) 6.14.1 Engine oil filter Replacement ( Page 115) 6.18.2 Battery-charging generator drive Drive-belt check and adjustment ( Page 130) 6.18.3 Battery-charging generator drive Drive belt replacement ( Page 132) 6.19.1 Fan drive Drive-belt check and adjustment ( Page 133)

6.5.3 Injection pump Installation ( Page 83)

Qty.: Used in:

6.8.5 Fuel prefilter Flushing ( Page 104)

Grease (Kluthe Hakuform 30-10/Emulgier) Part No.: Qty.: Used in: X00058060 1 6.5.1 Injection pump Removal and installation ( Page 79)

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Grease (Kluthe Hakuform 30-10/Emulgier) Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Isopropyl alcohol Part No.: Qty.: Used in: Qty.: Used in: Petroleum jelly Part No.: Qty.: Used in: 6.3.2 Crankcase breather Wire mesh cleaning ( Page 74) X00058037 1 6.20.1 Engine wiring Check ( Page 138) 1 6.21.1 Engine governor and connectors Cleaning ( Page 140) X00029933 1 6.5.3 Injection pump Installation ( Page 83) 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.6.4 Injector Installation ( Page 91) 1 6.7.1 Fuel injection line Pressure pipe neck replacement ( Page 93)

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8.3 Spare Parts


Air filter Part No.: Qty.: Used in: 6.10.1 Air filter Replacement ( Page 109)

Copper sealing ring Part No.: Qty.: Used in: Diaphragm Part No.: Qty.: Used in: 6.3.1 Crankcase breather Oil separator element replacement, diaphragm check and replacement ( Page 72) 6.6.4 Injector Installation ( Page 91)

Drive belt Part No.: Qty.: Used in: Qty.: Used in: 6.18.3 Battery-charging generator drive Drive belt replacement ( Page 132) 6.19.2 Fan drive Drive belt replacement ( Page 136)

Easy-change filter Part No.: Qty.: Used in: Filter element Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Filter insert Part No.: Qty.: Used in: 6.10.1 Air filter Replacement ( Page 109) 6.3.1 Crankcase breather Oil separator element replacement, diaphragm check and replacement ( Page 72) 6.8.6 Fuel prefilter Filter element replacement ( Page 106)
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6.8.1 Fuel filter Replacement ( Page 100)

6.10.1 Air filter Replacement ( Page 109)

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Gasket Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Injector Part No.: Qty.: Used in: Oil filter Part No.: Qty.: Used in: 6.14.1 Engine oil filter Replacement ( Page 115) 6.6.1 Injector Replacement ( Page 84) 6.3.1 Crankcase breather Oil separator element replacement, diaphragm check and replacement ( Page 72) 6.4.2 Cylinder head cover Removal and installation ( Page 78) 6.8.4 Fuel prefilter Draining ( Page 103) 6.8.5 Fuel prefilter Flushing ( Page 104) 6.8.6 Fuel prefilter Filter element replacement ( Page 106)

Pressure pipe neck Part No.: Qty.: Used in: 6.7.1 Fuel injection line Pressure pipe neck replacement ( Page 93)

Pressure relief valve Part No.: Qty.: Used in: Seal Part No.: Qty.: Used in:
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6.7.2 Fuel pressure maintaining valve Removal and installation ( Page 95)

6.5.1 Injection pump Removal and installation ( Page 79) 6.6.2 Injector Removal and installation ( Page 85) 6.7.1 Fuel injection line Pressure pipe neck replacement ( Page 93)

Qty.: Used in: Qty.: Used in:

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Sealing ring Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: 6.3.2 Crankcase breather Wire mesh cleaning ( Page 74) 6.5.1 Injection pump Removal and installation ( Page 79) 6.5.1 Injection pump Removal and installation ( Page 79) 6.5.3 Injection pump Installation ( Page 83) 6.5.3 Injection pump Installation ( Page 83) 6.6.2 Injector Removal and installation ( Page 85) 6.6.2 Injector Removal and installation ( Page 85) 6.6.4 Injector Installation ( Page 91) 6.7.2 Fuel pressure maintaining valve Removal and installation ( Page 95) 6.7.2 Fuel pressure maintaining valve Removal and installation ( Page 95) 6.8.2 Fuel prefilter cleaning ( Page 101) 6.9.1 Intercooler Checking condensate drains for coolant discharge and obstructions ( Page 108) 6.13.2 Engine oil Change ( Page 114) 6.15.2 Engine coolant Draining ( Page 118) 6.15.2 Engine coolant Draining ( Page 118) 6.16.1 Charge-air coolant Filling ( Page 122) 6.16.2 Charge-air coolant Draining ( Page 124) 6.16.2 Charge-air coolant Draining ( Page 124)
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8.4 Index
12/16/18 V 2000 Gx5 engine data, optimized fuel con sumption18 12/16/18 V 2000 Gx5-TB engine data, optimized fuel consumption22 A Abbreviations143 Actuators139 After stopping the engine Engine remains ready for op eration34 After stopping the engine putting the engine out of service35 Air filter Replacement 109 Air filter Removal and installation110 Air starter Manual operation 112 Auxiliary materials11 C Charge-air coolant Change 125 Level check 126 Charge-air coolant Draining 124 Filling 122 Charge-air coolant level Check 126 Connectors Cleaning 140 Contact persons146 Coolant Change 125 Charge-air Draining 124 Filling 122 Filling 116 Coolant - charge air Level check 126 Coolant level Check 120 Cooler Checking cooler elements externally for dirt127 Cooler Cleaning cooler elements128 Crankcase breather Diaphragm check 72 Oil separator element replacement 72 Crankcase breather Wire mesh cleaning74 Cylinder Designation 17 Cylinder head cover Removal and installation 78 Cylinder liner Endoscopic examination 68 Instructions and comments on endoscopic and visual examination 70 D Drive belt Condition check 129 E ECU 7 engine governor Removal and installation 142 Emergency stop33 Engine Main dimensions 16 Overview 14 Test run 67 Wiring check 138 Engine coolant Change 119 Draining 118 Filling 116 Engine coolant level Check 120 Engine governor Checking plug-in connections 141 Cleaning 140 Engine oil Change 114 Engine oil level Check 113 Engine sides Designation 17 Engine wiring Check 138 Environmental protection11 F Fan drive Drive belt replacement 136 Fault indication on SAM display Genset applications 40 Fire prevention11 Firing order26 Fluids and lubricants11 Fuel prefilter Flushing 104 Fuel prefilter Differential pressure gauge Check and adjustment 102 Draining 103 Filter element Replacement 106 Flushing 104 Fuel prefilter cleaning101 Fuel pressure maintaining valve Removal and installation 95 G General conditions5

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H Hotline146 I Injection pump Installation 83 Removal 82 Removal and installation 79 Injector Installation 91 Removal 89 Replacement 84 Intercooler Condensate drains for coolant discharge Check 108 Condensate drains for obstructions Check 108 M Maintenance work Safety regulations 8 MTU contact persons146 O Operational checks31 P Personnel and organizational requirements6 Putting the engine into operation after extended out-ofservice periods (>3 months)27 Putting the engine into operation after scheduled out-ofservice-period 28 R Repair work Safety regulations 8 S Safety instructions13 Safety regulations8 Safety system Override 30 SAM Genset applications 40 Sensors139 Service partners146 Spare parts service146 Start engine in manual mode (testing mode)29 Stop engine in manual mode (testing mode)32 T Transport7 Troubleshooting37 V Valve clearance Adjustment 75 Check 75

W Wiring - engine Check 138

162 | Appendix B | MS15018/01E 2012-05

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