MTU 12V4000Gx5S Series User manual

Operating Instructions
Diesel Engine with Exhaust Gas Aftertreatment
12V4000Gx5S
MS15065/01E

Engine model kW/cyl. Application group
12V4000G15S 124 kW/cyl. 3F, mains backup mode, unlimited, ICXN
12V4000G25S 145 kW/cyl. 3F, mains backup mode, unlimited, ICXN
12V4000G75S 137 kW/cyl. 3D, standby power, fuel stop power, IFN
12V4000G85S 160 kW/cyl. 3D, standby power, fuel stop power, IFN
Table 1: Applicability
© 2019 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 writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.

For more information, go to www.P65warnings.ca.gov/diesel
WARNING
WARNING: Breathing diesel engine exhaust exposesyou to chemicals
known to the State of California to cause cancer and birth defectsorother
reproductive harm.
x Always start and operate the engine in a well-ventilated area.
x If in an enclosed area, vent the exhaust to the outside.
x Do not modify or tamper with the exhaust system.
x Do not idle the engine except as necessary.
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Table of Contents
1 Safety
1.1 Important provisions for all products 6
1.2 Important requirements for Power
Generation application products 8
1.3 Gendrive engines – Intended use 10
1.4 Personnel and organizational requirements 11
1.5 Safety regulations for initial start-up and
operation 12
1.6 Safety regulations for assembly,
maintenance, and repair work 14
1.7 Fire and environmental protection, fluids
and lubricants 18
1.8 Standards for warning notices in the text
and highlighted information 20
1.9 Guards on the engine – Overview 21
2 Transport
2.1 Transport 23
2.2 Lifting specifications 24
2.3 RA tank (optional) – Transport 28
2.4 Crankshaft transport locking device 29
2.5 Engine mount shipping lock 32
3 General Information
3.1 Engine side and cylinder designations 33
3.2 Product summary 34
3.3 High-pressure points on exhaust gas
aftertreatment system – Overview 35
4 Functional Description
4.1 Diesel Engine with Exhaust Gas
Aftertreatment 36
4.1.1 Diesel engine with EGAT – Overview 36
4.1.2 Diesel engine with EGAT – Standard scope of
supply 38
4.1.3 Diesel engine with EGAT – Nameplate and
designation 39
4.2 Series 4000 Engines 41
4.2.1 Engine layout 41
4.2.2 Crankcase with oil pan 44
4.2.3 Gear train 46
4.2.4 Running gear 47
4.2.5 Cylinder head with injector 49
4.2.6 Valve gear 51
4.2.7 Fuel system with Common Rail injection 53
4.2.8 Charge-air and exhaust system 55
4.2.9 Lube oil system 57
4.2.10 Fuel cooler 59
4.2.11 Cooling system 61
4.2.12 Engine management and monitoring 64
4.2.13 Sensors and actuators – Overview 67
4.3 Exhaust Gas Aftertreatment 71
4.3.1 Exhaust gas aftertreatment system – Overview 71
4.3.2 DPF System 72
4.3.2.1 Diesel particulate filter (DPF) – Operating
principle 72
4.3.2.2 Diesel particulate filter (DPF) – Overview 74
4.3.3 SCR System 76
4.3.3.1 SCR catalyst – Operating principle 76
4.3.3.2 SCR catalytic converter – Overview 77
4.3.4 RA Dosing System 79
4.3.4.1 RA dosing system – Overview 79
4.3.4.2 Reducing agent – Handling 81
4.3.4.3 Pre-feed module (PFM) 82
4.3.4.4 Supply unit (SU) 84
4.3.4.5 Dosing unit (DU) 85
4.3.4.6 RA lines 86
4.3.4.7 RA tank (optional) 87
4.3.4.8 RA heating system 88
4.3.5 Monitoring, Control and Regulation Equipment 90
4.3.5.1 EGAT sensors – Overview 90
4.3.5.2 Exhaust gas aftertreatment management
and monitoring 92
4.3.5.3 DCM CAN connections 94
5 Technical Data
5.1 Product data 12V4000G75S 12V4000G85S 95
5.2 Product data 12V4000G15S 12V4000G25S 99
5.3 Product – Main dimensions 103
5.4 Exhaust gas aftertreatment system – Main
dimensions 107
5.5 Firing order 110
6 Operation
6.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 111
6.2 Putting into operation after scheduled out-
of-service-period 112
6.3 Emission label – Check 113
6.4 Engine – Starting in manual mode (test run) 114
6.5 Re-starting the engine following an
automatic safety shutdown 116
6.6 Safety system – Override 117
6.7 Operational monitoring 118
6.8 Emergency engine start (Override mode) 119
6.9 Engine shutdown in manual mode (test run) 120
6.10 Emergency engine stop 121
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6.11 After stopping the engine – Engine remains
ready for operation 122
6.12 After stopping the engine – Putting the
engine out of operation 123
6.13 Plant – Cleaning 124
6.14 Exhaust gas aftertreatment system –
Regeneration procedure 125
7 Troubleshooting
7.1 Fault messages 126
7.2 Troubleshooting 184
8 Maintenance
8.1 Maintenance task reference table [QL1] 187
9 Task Description
9.1 Engine 189
9.1.1 Engine – Barring manually 189
9.1.2 Engine – Cranking on starting system 191
9.1.3 Engine – Test run 192
9.2 Cylinder Liner 193
9.2.1 Cylinder liner – Endoscopic examination 193
9.2.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 195
9.3 Crankcase Breather 197
9.3.1 Crankcase breather – Filter element
replacement 197
9.4 Valve Drive 199
9.4.1 Valve protrusion – Measurement 199
9.4.2 Valve gear – Lubrication 203
9.4.3 Valve clearance – Check and adjustment 204
9.4.4 Cylinder head cover – Removal and
installation 208
9.5 Injection Pump / HP Pump 209
9.5.1 HP fuel pump – Filling with engine oil 209
9.6 Injector 212
9.6.1 Injector – Replacement 212
9.6.2 Injector – Removal and installation 213
9.6.3 Injector rings – Replacement 219
9.7 Fuel System 225
9.7.1 Fuel system – Venting 225
9.7.2 Fuel cooler – External contamination and leak-
tightness check 227
9.7.3 Fuel cooler – Cleaning 228
9.8 Fuel Filter 230
9.8.1 Fuel filter – Replacement 230
9.8.2 Additional fuel filter – Replacement 231
9.8.3 Fuel prefilter – Pressure ratios 232
9.8.4 Fuel prefilter (non-switchable) – Draining 233
9.8.5 Fuel prefilter (switchable) – Draining 235
9.8.6 Fuel prefilter (switchable) – Low pressure
indicator check 238
9.8.7 Fuel prefilter (non-switchable) – Filter element
replacement 239
9.8.8 Fuel prefilter (switchable) – Filter element
replacement 241
9.8.9 Fuel prefilter – Venting 244
9.9 Charge-Air Cooling 246
9.9.1 Charge-air cooler – Leak check 246
9.9.2 Throttle flap after intercooler – Lever position
check 247
9.9.3 Throttle flap after intercooler – Teach-in
routine initiation 248
9.10 Air Filter 249
9.10.1 Air filter ‒ Replacement 249
9.10.2 Air filter – Check 250
9.10.3 Air filter – Removal and installation 251
9.10.4 Heavy duty air filter – Filter insert and filter
element removal and installation 252
9.11 Air Intake 254
9.11.1 Service indicator – Signal ring position check 254
9.12 Exhaust Gas Aftertreatment 255
9.12.1 Reducing agent lines – Replacement 255
9.12.2 Supply unit – Filter element replacement 258
9.12.3 Dosing unit – Replacement 261
9.12.4 Pre-feed module – Filter element replacement 263
9.12.5 NOx sensor – Replacement 265
9.13 Lube Oil System, Lube Oil Circuit 268
9.13.1 Engine oil – Change 268
9.13.2 Engine oil level – Check 271
9.13.3 Engine oil – Sample extraction and analysis 272
9.13.4 Oil priming pump – Visual inspection 274
9.14 Oil Filtration / Cooling 275
9.14.1 Engine oil filter – Replacement 275
9.14.2 Centrifugal oil filter – Cleaning and filter
sleeve replacement 277
9.15 Coolant System, General, High-Temperature
Circuit 280
9.15.1 Engine coolant level – Check 280
9.15.2 Engine coolant – Change 282
9.15.3 Engine coolant – Draining 283
9.15.4 Engine coolant – Filling 285
9.15.5 Engine coolant pump – Relief bore check 289
9.15.6 Engine coolant – Sample extraction and
analysis 290
9.15.7 Preheater – Overview 292
9.15.8 Preheater – Function and leak check 293
9.15.9 Preheater – Overhaul 294
9.15.10 Preheater – Solenoid switch replacement 295
9.15.11 Preheater – Heating element and housing
check 297
9.15.12 Preheater thermostats – Replacement 300
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9.15.13 Coolant expansion tank valve cover –
Replacement 303
9.16 Low-Temperature Circuit 304
9.16.1 Charge-air coolant level – Check 304
9.16.2 Charge-air coolant – Change 306
9.16.3 Charge-air coolant – Draining 307
9.16.4 Charge-air coolant – Filling 309
9.16.5 Charge-air coolant pump – Relief bore check 312
9.17 Belt Drive 313
9.17.1 Drive belt – Condition check 313
9.18 Battery-Charging Generator 314
9.18.1 Battery-charging generator – Drive belt
tension adjustment 314
9.18.2 Battery-charging generator drive – Drive belt
replacement 315
9.19 Engine Mounting / Support 316
9.19.1 Engine mounting – Checking resilient element 316
9.19.2 Engine mounting – Checking securing screws
for firm seating 317
9.19.3 Generator mounting – Check 319
9.19.4 Generator mounting – Securing screw firm
seating check 320
9.20 Wiring (General) for Engine/Gearbox/Unit 321
9.20.1 Engine cabling – Check 321
9.21 Accessories for (Electronic) Engine
Governor / Control System 322
9.21.1 Engine governor and connector – Cleaning 322
9.21.2 Engine Control Unit plug connections – Check 323
9.21.3 Engine governor ECU 9 – Removal and
installation 324
10 Appendix A
10.1 Abbreviations 325
10.2 Conversion tables 330
10.3 MTU Contact/Service Partners 334
11 Appendix B
11.1 Special Tools 335
11.2 Index 345
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1 Safety
1.1 Important provisions for all products
General
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications which are neither made nor authorized by the manufacturer
• Noncompliance with the safety instructions and warning notices
Nameplates
The product is identified by nameplate, model designation or serial number. This data must match the speci-
fications in these instructions.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv-
ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system
is not visible without the removal of components, the system integrator must install the second nameplate in
a clearly visible area on the vehicle/system.
Emission specifications and emission label
Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission-related components must only be serviced, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these specifications will invalidate the design type approval or certification issued by
the emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations.
The product must be operated over its entire life cycle according to the conditions defined as "Intended use"
(→ Page 10).
Emission certification applicable to engines with EPA Nonroad Tier 4 emission
certification in accordance with 40 CFR 1039 and with EPA Locomotive emission
certification in accordance with 40 CFR 1033
Extract from the standard:
Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates
federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
Extract from the standard:
If you install the engine in a way that makes the engine's emission control information label hard to read
during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40
CFR 1068.105.
When fitting the second label, the requirements of 40 CFR 1068.105(c) must be followed and observed. This
paragraph describes the process for requesting and fitting the label, the documentation obligations and stor-
age obligations for the required documents.
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Replacing components with emission labels
On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Exception: Engines used exclusively in land-based, military applications other than by US government agen-
cies.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Emission labels shall not be transferred from the replaced part to the spare part.
• The emission labels must be removed from the replaced part and destroyed.
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1.2 Important requirements for Power Generation application
products
Project-specific operational environment
During integration and use of the diesel engine, all currently valid and relevant standards and guidelines on
safety and specified operation must be implemented and observed. This applies to persons responsible for:
• The installation of the engine
• The design of the engine-generator set
• The installation of the engine-generator set
The relevant standards are, in particular:
• DIN EN 1679-1
• EN ISO 8528-13
The provisions in the application engineering manual must be observed for planning and design of the plant.
Further publications, e.g. Operating Instructions or Assembly Instructions must be observed.
Residual hazards
In the event of a defect, the diesel engine can unexpectedly have insufficient or no drive power at all. We
therefore recommend a redundant design of the engine-generator set system in safety-critical applications.
For safety-critical applications in nuclear power plants, we recommend the installation of an additional re-
dundant system which comprises a product of a different manufacturer.
Protection against hot surfaces
Combustion engines and their auxiliary components have hot surfaces (e.g. exhaust system, exhaust turbo-
chargers, exhaust aftertreatment system, engine oil system, cooling system), which can cause injury to per-
sons who approach or touch them (danger of burns).
• In operation
• During the cooling-down phase after operation
The plant integrator and operator must assess, based on spatial or other plant conditions, whether the dan-
ger potential usually associated with the state of technology is exceeded, e.g.:
• Particularly narrow maintenance spaces
• Particularly exposed position of hot surfaces
In such cases, the plant integrator or operator must equip the plant with the necessary and suitable safety
devices to reliably exclude the possibility of personal injury, e.g.:
• Heat shields
• Insulation
The operator must ensure that the plant is not operated without these protective devices. Operating and
maintenance personnel must be informed about the danger of hot surfaces and the prohibition of operation
without the protective devices.
Noise
Noise protection measures that comply with statutory requirements must be implemented by the plant inte-
grator and operator.
Assembly and maintenance tasks
Prior to assembly and maintenance tasks, the relevant media must be drained.
Secure the product and all connected accessory devices against unwanted starting, e.g. disconnect the elec-
trical power supply.
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Chemical resistance
Only use hoses, pipes, fittings, etc. that can tolerate the fluids and lubricants in accordance with the Fluids
and Lubricants Specifications. Only use options that are resistant to the fluids and lubricants in accordance
with the Fluids and Lubricants Specifications.
Electrical devices
The IP protection class of the electrical devices required by the manufacturer must be observed.
Hoses
For vibration decoupling, where possible only use hoses or rubber sleeves. Install devices in low-vibration
areas and not on the engine. Hoses must be installed such that they do not chafe and are not under tension.
Incorrect synchronization
Load application with incorrect synchronization (generator connection with phase offset) can cause consider-
ably high torque pulses. The plant integrator must design the control system such that the possibility of a
load application with incorrect synchronization is excluded.
Emergency stop
The diesel engine has inputs for Stop and Emergency stop. The emergency-stop function must be executable
in the whole plant independently of the operation stop. This is the only way to ensure that a safe shutdown of
fuel injection takes place on a diverse redundant path and thus results in engine standstill. Through an ap-
propriate design of the engine-generator set or whole plant, the operator of the engine must guarantee that
safe, non-reversible stopping of the engine is as fast as possible, including all of its dangerous system com-
ponents, when the emergency-stop actuating element is activated. In particular, it must always be guaran-
teed that machine shutdown can not be prevented or delayed once the command for shutdown has been
issued. The engine shutdown command must always have priority over the start command.
If machines or machine components are designed to interact, they must be designed and built such that all
devices can shut down. This relates to:
• Emergency-stop command devices for the machine itself (engine, engine-generator set)
• All connected devices insofar as their continued operation could result in a hazard
Important
Engines with exhaust aftertreatment: When the emergency stop is actuated on engine with an exhaust af-
tertreatment system, note that the emergency-stop function also interrupts the reducing agent supply. This
can result in overheating of the reducing agent dosing units. For details and further information, see Oper-
ating Instructions.
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1.3 Gendrive engines – Intended use
Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the admissible operating parameters in accordance with the (→ technical sales documents – prod-
uct data – TVU data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-
so applies to engine control/parameters)
• In compliance with all safety regulations and observance of all safety and warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
The product shall not be operated in explosive atmospheres unless it fulfills the conditions for such use and
approval has been granted.
The section below applies to applications deployed in regions under the jurisdiction of the EPA.
• Use of EPA Tier 2 and Tier 3 certified genset engines.
• EPA Tier 2 and Tier 3 certified genset engines may only be used in generator sets for stationary emergen-
cy applications. Non-emergency operation is limited to 100 hrs per year.
The engines may be used in fixed speed gensets only. Permanent limitation to a max. engine power of less
than 560 kW (e.g. by means of correspondingly low generator power) is not admissible.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to use, ensure
that the most recent version is available. The latest version can be found at:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
Modifications or conversions
Unauthorized changes to the product breach the conditions concerning its intended use and compromise
safety.
Only modifications or conversions expressly authorized by the manufacturer are regarded as compliant in
this sense. The manufacturer shall not be held liable for any damage resulting from unauthorized modifica-
tions or conversions.
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1.4 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and repair based on this manual. In particular, per-
sonnel must have read and understood the safety requirements and warnings before starting work.
This is important in the case of personnel who only occasionally perform work on or around the product.
Such personnel must be instructed repeatedly.
Personnel requirements
All work on the product must be carried out by trained, instructed and qualified personnel only:
• Training at the Training Center of the manufacturer
• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering
and also for work with live parts
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective equipment
Always wear appropriate personal protective equipment, e.g. safety shoes, hearing protection, protective
gloves, goggles, breathing mask. Follow the instructions concerning personal protective equipment in the de-
scriptions of the individual activities.
Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-
tion, Authorization and restriction of Chemicals): We recommend wearing protective gloves at all times in
order to reduce risk when working.
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1.5 Safety regulations for initial start-up and operation
Safety regulations for initial start-up
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safeguards are in place.
• All components must be properly grounded. Ground separately by means of a grounding stake as neces-
sary.
• No persons wearing pacemakers or any other technical body aids are present.
• Adequate ventilation of the operating room must be ensured for any operating status.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• The product must be free of any damage, this applies in particular to lines and cabling.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated e.g. +/- polarity, fuel line/reduction agent line,
supply/return.
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the monitoring, signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation
The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop
Practice emergency procedures, especially emergency stopping, at regular intervals.
Take the following steps if any system malfunctions are detected or signaled by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.
After a safety shutdown, the engine must only be started after the cause of the shutdown has been eliminat-
ed.
Contact Service if the root cause of the malfunction cannot be clearly identified.
Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
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Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent.
Operation of electrical equipment
When electrical equipment is in operation, certain components of these appliances are electrically live.
Follow the applicable operating and safety instructions when operating the devices and heed warnings at all
times.
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1.6 Safety regulations for assembly, maintenance, and repair
work
Safety regulations for work prior to assembly, maintenance, and repair
Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble containers of adequate capacity to catch fluids and lubricants.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
Work must only be carried out on lines when they are free of fluids and lubricants.
Ensure adequate ventilation of the operating room when conducting an oil change, working on the gaseous/
liquid fuel system or working with consumables (e.g. adhesive, cleaner).
Never carry out assembly, maintenance, or repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• Close supply line for hydraulic starting.
• Close the main valve on the compressed-air system and vent the compressed-air line when air starters are
fitted.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.
Before starting work on CaPoS, if used:
• Switch off the charging system (DC/DC converter).
• Discharge the UltraCap modules using the appropriate discharger.
• Short-circuit the UltraCap modules with a suitable wire jumper.
Before working on the exhaust gas aftertreatment system, close the shutoff valve on the reducing agent
tank. Note that the reducing agent pumps continue to run for a certain period when the engine is stopped.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Safety regulations when performing assembly, maintenance, and repair work
Special tools and lifting equipment
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Setting down, lifting and climbing
Carry out work only on assemblies or plants which are properly secured.
Use appropriate lifting equipment for all components. Use all specified attachment points and observe the
center of gravity.
Never stand beneath a suspended load.
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces and secured against tilting over or roll-
ing away. Adopt suitable measures to prevent components/tools from falling down.
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Assume a safe standing position when performing assembly work.
Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Special instructions
for outdoor areas: There must be no risk of slipping e.g. due to icing.
Removing, installing and cleanliness
Pay particular attention to cleanliness at all times.
Completely wipe up escaped fluids and lubricants due to the risk of slipping.
Take special care when removing ventilation or plug screws from the product.
Ensure that O-rings are not installed in a slanted/twisted condition.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Note cooling time for components which are heated for installation or removal (risk of burning).
Ensure that all mounts and dampers are installed correctly.
Remove any accumulation of condensate after assembling chilled components. Coat the components with a
suitable corrosion inhibitor as necessary.
Lines
Ensure that lines for all fluids and lubricants and their connections are clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.
Miscellaneous
Sufficient ventilation must be guaranteed during the work.
Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) when work-
ing on exhaust components. Clean the work area with a dust extraction machine of class H. Wear protective
gloves and goggles for protection against acidic condensate.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
Only install them after painting the engine or mask them prior to painting.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). 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 device.
• Observe the safety data sheet.
Safety regulations after performing assembly, maintenance, and repair work
Before barring the engine, make sure no one is in the danger zone of the engine.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
All safety devices must be installed and all tools and loose parts must be removed (especially the barring
tool).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.
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Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld-
ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-
cants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The
welding current can induce interfering voltages in the wiring harnesses which may damage the electrical sys-
tem.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.
Hydraulic installation and removal
Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-
ces 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 which are under pressure.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft end
until correct sealing is established.
During hydraulic installation and removal of components, ensure that nobody is standing in the immediate
vicinity of the component to be installed/removed.
Working with batteries
Observe the safety instructions of the manufacturer when working on batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. The battery may explode and spray
acid if the battery terminals are connected incorrectly.
Working on electrical and electronic assemblies
Always obtain the permission of the person in charge before commencing assembly, maintenance, and repair
work or switching off any part of the electronic system required to do so.
De-energize the relevant areas prior to working on assemblies.
ESD (Electrostatic Discharge): Work on components which could be damaged by electrostatic discharge
must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically conductive
work surfaces or antistatic wristbands.
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Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-
ing operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable ties to secure lines.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to functional testing on completion of all repair work. The emergen-
cy stop function must be tested in particular. The functional check of the emergency stop, during which the
voltage supply of the engine governor is switched off, must only be carried out when the product is cold.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil (as necessary)
Working with laser equipment
Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to type
and application.
Measuring component dimensions
Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
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1.7 Fire and environmental protection, fluids and lubricants
Fire prevention and fire
Fire, exposed light bulbs and smoking are prohibited.
In case of a fire, stop the fuel supply if this is possible without endangering personnel.
The product has hot surfaces that can ignite combustible gases and other substances in the immediate area.
The operating company must install and operate the product a safe distance away from danger sources and
observe any relevant safety regulations or recommendations. Products that comply with the SOLAS Conven-
tion do not constitute such as danger.
After working with combustible fluids and lubricants (e.g. cleaning agents), ensure the area is well ventilated.
The resultant vapor/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Eliminate leaks of fluids and lubricants immediately. Fluids and lubricants on hot components can cause
fires, so keep the product clean at all times. Do not leave rags saturated with fluids and lubricants on the
product. Do not store combustible materials near the product.
Incorrect refueling of the reducing agent system with fuel can result in fire.
Before welding, clean the area to be welded with a nonflammable fluid. Do not carry out welding work on
pipes and components carrying oil or fuel.
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 cable from the external power source to the
ground cable of the engine or to the ground terminal of the starter.
Ensure that suitable extinguishing agents (fire extinguishers) are always available and that staff are familiar
with their correct handling.
A fire can result in the creation of toxic substances. Always wear protective gloves when handling compo-
nents and wear additional personal protective equipment is necessary.
Noise
Wear hearing protection in workplaces with a sound pressure level in excess of 85 dB (A).
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are compromised.
Environmental protection and disposal
Dispose of used fluids, lubricants and components in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
cled.
Fluids and lubricants/auxiliary materials (process materials)
Process materials can also be or contain hazardous or toxic substances. When using process materials and
other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained
from the relevant manufacturer or from MTU.
Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi-
cations must be used. The most recent respective version must be requested from the manufacturer.
Contamination of process materials with reducing agent (e.g. AdBlue®, DEF): Store process materials in sep-
arate containers and their own drip trays. Even extremely small amounts of reducing agent contamination
can result in malfunctions in sensors and other components.
Used oil contains combustion residues that are harmful to health.
When handling used oil, protective gloves must be used.
Wash relevant areas after contact with used oil.
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