operating instructions diesel engine · 2018-02-01 · written permission of mtu friedrichshafen...

Operating InstructionsDiesel engine12 V 4000 G7316 V 4000 G73Application group 3B

MS150054/02E

Printed in Germany© 2012 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole or in part without the priorwritten 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 damageduring operation.Subject to alterations and amendments.

Table of Contents1 Safety

1.1 General conditions 51.2 Personnel and organizational requirements 61.3 Transport 71.4 Crankshaft transport locking device 81.5 Safety regulations for startup and operation 111.6 Explosion hazard when removing

inspection port cover on engine 121.7 Safety regulations for maintenance and

repair work 131.8 Fluids and lubricants, fire prevention and

environmental protection 161.9 Conventions for safety instructions in the

text 18

2 General Information

2.1 Engine side and cylinder designations 192.2 Engine layout 202.3 Sensors, actuators and injectors –

Overview 21

3 Technical Data

3.1 12, 16V 4000 G73 engine data, emissions-optimized (EPA - Tier 2) 25

3.2 Firing order 283.3 Engine – Main dimensions 29

4 Operation

4.1 Putting the engine into operation afterextended out-of-service periods (>3months) 30

4.2 Putting the engine into operation afterscheduled out-of-service-period 31

4.3 Start engine in manual mode (testingmode) 32

4.4 Starting the engine in emergency situations(override mode) 33

4.5 Operational checks 344.6 Stop engine in manual mode (testing

mode) 354.7 Emergency stop 364.8 After stopping the engine – Engine remains

ready for operation 37

4.9 After stopping the engine – putting theengine out of service 38

5 Maintenance

5.1 Maintenance task reference table [QL1] 39

6 Troubleshooting

6.1 Troubleshooting 406.2 Engine governor ADEC (ECU 7) for Series

4000 Oil &Gas engines – Fault messages 43

7 Task Description

7.1 Engine 637.1.1 Engine – Barring manually 637.1.2 Engine – Barring with starting system 647.1.3 Engine – Test run 65

7.2 Cylinder Liner 667.2.1 Cylinder liner – Endoscopic examination 667.2.2 Cylinder liner - Instructions and comments on

endoscopic and visual examination 68

7.3 Crankcase Breather 707.3.1 Crankcase breather – Oil separator element

replacement, diaphragm check andreplacement 70

7.4 Valve Drive 727.4.1 Valve gear – Lubrication 727.4.2 Valve clearance – Check and adjustment 737.4.3 Cylinder head cover – Removal and

installation 76

7.5 Injection Pump / HP Pump 777.5.1 HP pump – Filling with engine oil 77

7.6 Injection Valve / Injector 787.6.1 Injector – Replacement 787.6.2 Injector – Removal and installation 79

7.7 Fuel System 847.7.1 Fuel system – Venting 84

7.8 Fuel Filter 857.8.1 Fuel filter – Replacement 857.8.2 Fuel prefilter cleaning 867.8.3 Fuel prefilter – Differential pressure gauge

check and adjustment 877.8.4 Fuel prefilter – Draining 88

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7.8.5 Fuel prefilter ‒ Flushing 897.8.6 Fuel prefilter – Filter element replacement 91

7.9 Charge-Air Cooling 937.9.1 Intercooler – Check drain for coolant leakage

and obstruction 93

7.10 Air Filter 947.10.1 Air filter – Replacement 947.10.2 Air filter – Removal and installation 957.10.3 Rubber sleeves between air intake elbow and

turbocharger – Replacement 96

7.11 Air Intake 977.11.1 Contamination indicator – Signal ring position

check 977.11.2 Emergency air-shutoff flaps – Functional

check with electric actuation 987.11.3 Rubber sleeves in air pipework before

intercooler – Replacement 99

7.12 Starting Equipment 1017.12.1 Air starter – Manual operation 101

7.13 Lube Oil System, Lube Oil Circuit 1027.13.1 Engine oil level – Check 1027.13.2 Engine oil – Change 1037.13.3 Engine-oil – Sample extraction and analysis 105

7.14 Oil Filtration / Cooling 1077.14.1 Engine oil filter – Replacement 1077.14.2 Automatic oil filter – Oil filter candles

replacement 1087.14.3 Oil indicator filter – Check 1117.14.4 Centrifugal oil filter – Cleaning and filter-

sleeve replacement 113

7.15 Coolant Circuit, General, High-Temperature Circuit 116

7.15.1 Engine coolant – Level check 1167.15.2 Engine coolant – Change 1177.15.3 Engine coolant – Draining 1187.15.4 Engine coolant – Filling 1207.15.5 Engine coolant pump – Relief bore check 1237.15.6 Engine coolant – Sample extraction and

analysis 1247.15.7 Coolant filter – Replacement 125

7.16 Low-Temperature Circuit 126

7.16.1 Charge-air coolant – Level check 1267.16.2 Charge-air coolant – Change 1277.16.3 Charge-air coolant – Draining 1287.16.4 Charge-air coolant – Filling 1297.16.5 Charge-air coolant pump – Relief bore check 132

7.17 Belt Drive 1337.17.1 Drive belt – Condition check 133

7.18 Battery-Charging Generator 1347.18.1 Battery-charging generator – Check 1347.18.2 Battery-charging generator drive – Drive belt

tension adjustment 1357.18.3 Battery-charging generator drive – Drive belt

and belt tensioner replacement 136

7.19 Fan Drive 1377.19.1 Fan drive – Drive belt check / adjustment 1377.19.2 Fan drive – Drive belt replacement 139

7.20 Wiring (General) for Engine/Gearbox/Unit 1407.20.1 Engine wiring – Check 140

7.21 Accessories for (Electronic) EngineGovernor / Control System 141

7.21.1 Engine governor and connectors – Cleaning 1417.21.2 EMU and connectors – Cleaning 1427.21.3 Engine governor – Checking plug-in

connections 1437.21.4 EMU – Checking plug-in connections 1447.21.5 ECU 7 engine governor – Removal and

installation 1457.21.6 EMU 7 – Removal and installation 146

8 Appendix A

8.1 Abbreviations 1478.2 MTU contacts/service partners 150

9 Appendix B

9.1 Special Tools 1519.2 Index 154

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1 Safety1.1 General conditions

GeneralIn 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. Thisstate-of-the-art engine has been designed to meet all applicable laws and regulations. The engine maynevertheless 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 useThe 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 noliability whatsoever for resultant damage or injury in such case. The responsibility is borne by the useralone.Correct use also includes observation of and compliance with the operating instructions and mainte‐nance and repair specifications.

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

Spare partsOnly genuine MTU spare parts must be used to replace components or assemblies. MTU accepts noliability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shallbe voided in such case.

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

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1.2 Personnel and organizational requirements

Personnel requirementsWork on the engine must only be carried out by appropriately qualified and instructed personnel.Observe the minimum legal age.Responsibilities of the operating, maintenance and repair personnel must be specified by the operatingcompany.

Organizational measuresThis publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐tion.Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair andtransport personnel at all times.Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐nel must have read and understood the safety-relevant instructions.This is especially important for personnel who work on the engine only on an occasional basis. Thesepersons shall receive repeated instruction.Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.

Working clothes and protective equipmentWear proper protective clothing for all work.Depending on the kind of work, use the necessary personal protective equipment.

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1.3 Transport

Transport

Lift the engine only with the lifting eyes provided.The lifting eyes are designed for engine transport only.Use only the transport and lifting equipment approved by MTU.The engine must only be transported in installation position, max. permissible diagonal pull 10°.Take note of the engine center of gravity.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 andengine mounts.Secure the engine against tilting during transportation. The engine must be especially secured againstslipping or tilting when going up or down inclines and ramps.

Setting the engine down after transportPlace 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 todo so.

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1.4 Crankshaft transport locking device

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 10-60 Nm F30510423 1Torque wrench, 60-320 Nm F30047446 1Engine oil

Transport locking device

Note: The locking device protects the crankshaft bearings from shocks and vibration damage during enginetransport.

For installation and removal of the transport locking device, follow the instructionsbelow:

1. The transport locking device must remain installed as long as possible during engine installation in orderto avoid damage.

2. Starting or barring the engine is allowed only with the transport locking device removed. If the generatoris already mounted on the engine, ensure that the transport locking device of the generator is also re‐moved.

3. Prior to every engine transport, the transport locking device must be reinstalled on both sides accordingto the instructions.

4. If the engine is to be moved together with the generator, the transport locking device for the generatormust also be installed.

Removing guard plates and enginemounting brackets (if applicable)on driving end (KS)

1. Remove screws (4) om both sides and takeoff with washers (3), guard plates (1) andengine mounting brackets (2).

2. Store the removed parts of the transportlocking device carefully for possible reuse.

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Fitting the transport locking deviceon driving end (KS)

Note: Always use the screws supplied with or installed in the transport locking device to secure it on the en‐gine.

1. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheelhousing and tighten to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm

2. Screw nut (3) onto screws (4) up to the end of the thread.3. Fit the locks (1) through the openings of plates (2) and fasten with the screws (4).4. Tighten screws (4) alternately with torque wrench to the specified tightening torque.


Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm

5. Screw on nuts (3) of both screws (4) at plates (2) and secure.6. Fit label (7) to mark the engine as "Fitted with transport locking device".

Removing the transport lockingdevice from driving end (KS)

1. Release the locknuts (3) on both sides ofthe flywheel housing, remove screws (4)and take off the two locks (1).

2. Remove screws (6) with washers (5), label(7) and plates (2)..

3. Store the removed parts of the transportlocking device carefully for possible reuse.

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Installing guard plates and enginemounting brackets (if applicable)on driving end (KS)

Note: Always use the screws supplied with the orremoved from the guard plates and enginemounting brackets to secure them on theengine.

1. Install engine mounting brackets (2) on bothsides with guard plates (1) washers (3), andscrews (4).

2. Tighten screws (4).

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1.5 Safety regulations for startup and operation

Safety requirements for initial operationPrior to initial operation of the unit, install the assembly or unit according to the specifications and checkthe installation according to the MTU specifications.Before putting the device or plant into operation, always ensure:• that all maintenance and repair work is completed,• that all loose parts have been removed from rotating machine components,• that nobody is in the danger area of moving machine parts.Immediately after putting the device or plant into operation, make sure that all control and display instru‐ments as well as the signaling and alarm systems work properly.

Safety requirements for operatorsThe procedures for cases of emergency must be practiced regularly.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 re‐gard to present operating status, violation of limit values and warning or alarm messages.The following steps must be taken if a malfunction of the system is recognized or reported by the system:• inform supervisor(s) in charge,• analyze the message,• if required, carry out emergency operations e.g. emergency engine stop.

Engine operationThe following conditions must be fulfilled before starting the engine:• Wear ear protection.• Ensure that the engine room is well ventilated.• Do not inhale engine exhaust gases.• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.• Protect battery terminals, battery-charger terminals and cables against accidental contact.• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.

Operation of electrical equipmentWhen electrical equipment is in operation, certain components of these appliances are electrically live.Observe the safety instructions for these devices.

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1.6 Explosion hazard when removing inspection port cover onengine

DANGER Explosion hazard due to oil vapors.Risk of serious injury – danger to life!• Allow the engine to cool down before opening the crankcase!• Avoid open flames, electrical sparks and ignition sources.

Safety instructionsu Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion

due to oil vapors).

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1.7 Safety regulations for maintenance and repair work

Safety regulations for maintenance and repair workHave 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 plugwith 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 adequatelyventilated.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 doso.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 pneumaticstarters 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 guardshave 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 orthe starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐vice as an additional measure.

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Welding workNever carry out welding work on the assembly, system, or engine-mounted units. Cover the engine whenwelding 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 currentmay otherwise induce an interference voltage in the wiring harnesses which could conceivably damagethe electrical system.Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.

Hydraulic installation and removalCheck the function and safe operating condition of tools and fixtures to be used. Use only the specifieddevices 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 shaftend until correct sealing is established.During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of thecomponent to be installed/removed.

Working on electrical/electronic assembliesAlways obtain the permission of the person in charge before commencing maintenance and repair workor 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 duringoperation 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.

Working with laser equipmentWhen 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 totype and application.

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For conducting light-beam procedures and measurement work, only the following laser devices must beused:• 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 preventany risk to the eyes.

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1.8 Fluids and lubricants, fire prevention and environmentalprotection

Fire preventionRectify 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 tothe 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 theiruse.

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

Environmental protection and disposalModification 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 ofthe 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 Actand involves the termination of the operating license by the emission authorities. MTU does not acceptany liability for violations of the emission regulations. MTU will provide assistance and advice if emission-relevant 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 aresubjected to proper recycling procedures.

Fluids and lubricantsUse only fluids and lubricants that have been tested and approved by MTU.Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants andother chemical substances, follow the safety instructions that apply to the product. Take special carewhen using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and donot smoke.

Used oilUsed oil contains harmful combustion residues.Rub barrier cream into hands.Wash hands after contact with used oil.

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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 airObserve 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 reducingvalve 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.

Painting• 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 alkalis, 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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1.9 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

Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard whichbegin with one of the signal words listed above depending on the severity of the hazard.

Safety instructions1. Read and familiarize yourself with all safety notices before starting up or repairing the product.2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.

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2 General Information2.1 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 "A" and those of the right side "B" (as per DIN ISO1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end ofthe engine.Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

1 KGS = Free end2 Right engine side

3 KS = Driving end4 Left engine side

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2.2 Engine layout

Illustration also applicable to 16 V

1 Oil cooler2 Crankcase breather3 Exhaust pipe4 Combustion-air inlet con‐

nection (elbows are op‐tional)

5 Exhaust turbocharger6 Exhaust gas outlet con‐

nection7 Engine governor

8 Intercooler9 Flywheel

10 Lifting eye11 Starter12 Charge-air pipe13 Engine mounting14 Oil filler neck15 Cylinder head16 Fuel priming pump17 Oil pan

18 Fuel filter19 HP fuel pump20 Engine oil filter, (automat‐

ic oil filter is optional)21 Coolant filter22 Centrifugal oil filter, (2

centrifugal oil filters areinstalled if automatic oilfilter is fitted)

Engine model designationKey to the engine model designations 12/16 V 4000 Gxy12/16 Number of cylindersV Cylinder arrangement: V engine4000 SeriesG Applicationx Application segment (7)y Design index (3)

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2.3 Sensors, actuators and injectors – Overview

Illustration also applicable to 16 V

a Version with easy-changefilter

b Version with automatic fil‐ter

1 Injectors Y39.1 to Y39.n(A-side)

2 B34 Fuel pressure afterfilter

3 F46 Leak fuel level moni‐toring

4 M8 Suction restrictor (HPpump)

5 F25 Differential engine oilpressure after filter

6 B05 Engine oil pressure

7 B07 Engine oil tempera‐ture

8 XY44 Solenoid valve offan clutch

The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and necessa‐ry activities (→ Page 78).


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1 B50 Crankcase pressure2 B05 Engine oil pressure3 B33 Fuel temperature in

Common Rail4 B48 Fuel pressure in

Common Rail

5 B01 Camshaft speed6 B43 Charge-air coolant

pressure7 B26 Charge-air coolant

temperature

8 B06 Engine coolant tem‐perature


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1 Injectors Y39.11 to Y39.n(B-side)

2 B16 Engine coolant pres‐sure

3 B10 Charge-air pressure4 XM2 Oil priming pump5 B09 Charge-air tempera‐

ture

6 Engine governor

The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and necessa‐ry activities (→ Page 78).


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1 B13 Crankshaft speed


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3 Technical Data3.1 12, 16V 4000 G73 engine data, emissions-optimized (EPA -

Tier 2)

ExplanationAbbr. MeaningDL Ref. value: Continuous powerBL Ref. value: Fuel stop powerA Design valueG Guaranteed valueR Guideline valueL Limit value, up to which the engine can be operated without changes (e.g. of power set‐

ting)N Not yet defined value- Not applicableX Applicable* Data not yet available when at time of publication

REFERENCE CONDITIONSEngine model 12V 4000

G7316 V4000

G73Application group 3B 3BIntake air temperature °C 25 25Charge-air coolant temperature °C 45 45Barometric pressure mbar 1000 1000Site altitude above sea level m 100 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)Number of cylinders 12 16Engine rated speed A rpm 1200 1200Continuous power as per ISO 3046 (10% overload capability)(rated power DIN 6280, ISO 8528)

A kW 1105 1390

GENERAL CONDITIONS (for maximum power)Number of cylinders 12 16Intake air depression (new filter) A mbar 15 15Intake air depression, max. L mbar 50 50Exhaust backpressure A mbar 30 30Exhaust back pressure, max. L mbar 50 50

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MODEL-RELATED DATA (basic design)Number of cylinders 12 16Engine with turbochargers (ETC) and charge-air cooling (CAC) X XUncooled exhaust lines X XWorking method: four-stroke diesel engine, single-acting X XCombustion method: direct injection X XCooling method: treated water X XDirection of rotation: c.c.w. (viewed on driving end) X XNumber of cylinders 12 16Cylinder configuration: V angle Degrees

(°)90 90

Bore mm 170 170Stroke mm 210 210Cylinder displacement liter 4.77 4.77Total displacement liter 57.2 76.3Compression ratio 16.4 16.4Cylinder heads: Single cylinder heads X XCylinder liners: wet, replaceable X XNumber of inlet valves, per cylinder 2 2Number of exhaust valves, per cylinder 2 2Standard flywheel housing flange (engine main PTO) SAE 00 00

AIR / EXHAUSTNumber of cylinders 12 16Charge-air pressure before cylinder - DL R bar abs 3.3 3.0

COOLANT SYSTEM (HT circuit)Number of cylinders 12 16Coolant temperature (at engine connection: outlet to coolingequipment)

A °C 100 94

Coolant temperature after engine, warning R °C 102 102Coolant temperature after engine, shutdown L °C 104 105Antifreeze percentage in coolant, max. L % 50 50Pressure-loss in off-engine cooling system, max. L bar 0.7 0,7

COOLANT SYSTEM (LT circuit)Number of cylinders 12 16Coolant temperature before intercooler (at engine connection:inlet from cooling equipment)

A °C 45 45

Antifreeze percentage in coolant, max. L % 50 50Pressure-loss in off-engine cooling system, max. L bar 0.7 0.7

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LUBE OIL SYSTEMNumber of cylinders 12 16Lube oil operating temperature before engine, from R °C 88 84Lube-oil operating temperature before engine, to R °C 98 94Lube-oil temperature before engine, warning R °C 99 99Lube-oil temperature before engine, shutdown L °C 101 101Lube oil operating pressure before engine, from R bar 4 4.5Lube oil operating pressure before engine, to R bar 6 6

FUEL SYSTEMNumber of cylinders 12 16Fuel pressure at supply connection on engine, min. (when en‐gine is starting)

L bar -0.1 -0.1

Fuel pressure at supply connection to engine (when engine isstarting), max.

L bar 1.5 1.5

GENERAL OPERATING DATANumber of cylinders 12 16Coolant preheating: preheating temperature (min.) R °C 40 40Firing speed, from R rpm 80 80Firing speed, to R rpm 120 120

CAPACITIESNumber of cylinders 12 16Engine coolant, engine side (without cooling system) R liter 137 175Charge-air coolant, engine side R liter 44 42Engine oil capacity, initial filling (standard oil system) (Option:max. operating inclinations)

R liter 221 295

Oil pan capacity, dipstick mark min. (standard oil system) (Op‐tion: max. operating inclinations)

L liter 160 *

Oil pan capacity, dipstick mark max. (standard oil system) (Op‐tion: max. operating inclinations)

L liter 210 260

WEIGHTS / MAIN DIMENSIONSNumber of cylinders 12 16Engine dry weight (basic engine configuration acc. to specifiedscope of supply)

R kg 6300 7400

ACOUSTICSNumber of cylinders 12 16Exhaust noise, unsilenced - DL (sound power level LW, ISO6798)

R db(A) 125 124

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

R db(A) 120 *


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3.2 Firing order

Number of cyl‐inders

Firing order

12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B116 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7

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3.3 Engine – Main dimensions

Engine – Main dimensions

Length(A)

12V16V

approx. 2550 mmapprox. 3020 mm

Width (B) 12V16V


Height (C) 12V16V



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4 Operation4.1 Putting the engine into operation after extended out-of-

service periods (>3 months)

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

Putting into operation after long out-of-service periods (>3 months)Item ActionEngine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).Valve drive Lubricate valve drive every ≥ 6 months (→ Page 72).Lube oil system Check engine oil level (→ Page 102).

Bar engine with starting equipment (→ Page 64).Fuel prefilter Fill with fuel (if fitted).Coolant circuit If engine is out of service for more than one year, change engine coolant

(→ Page 117).Change charge-air coolant (→ Page 127).

Coolant circuit Check engine coolant level (→ Page 116);Check charge-air coolant level (→ Page 126).

Coolant circuit Preheat coolant with coolant preheating unit (if applicable).Engine governor Check plug connections (→ Page 143).HP fuel pump Only for engines without oil priming pump

Fill HP fuel pump with new engine oil (→ Page 77).

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4.2 Putting the engine into operation after scheduled out-of-service-period

Preconditions☑ Engine is stopped and starting disabled.

Putting into operationItem ActionLube oil system Check engine oil level (→ Page 102).Coolant circuit Check engine coolant level (→ Page 116), check charge-air coolant level

(→ Page 126).Coolant circuit Preheat engine coolant with coolant preheating unit, if fitted.Fuel prefilter (if fitted) Drain water and contaminants, see manufacturer's documentation.Engine control system Switch on.

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4.3 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.

PreparationItem TaskOperating mode selectorswitch (if provided)

Change to manual mode.

Preheating pump (if provid‐ed)

Switch ON.

Starting the engineItem TaskSwitchgear cabinet, controlpanel etc. (depending onmanufacturer)

If coolant temperature is• > 40 °C (with preheating equipment), or• > 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 operatingtemperature )Item TaskSwitchgear cabinet, controlpanel etc. (depending onmanufacturer)

Close the generator circuit breaker.

Engine Apply full load only after engine has reached operating temperature (cool‐ant temperature approx. 75 °C).

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4.4 Starting the engine in emergency situations (override mode)

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

PreparationItem TaskOperating mode switch Set to emergency mode.

Starting the engine in emergency situationsItem TaskControl cabinet Actuate switch/button for ECU override input.Control cabinet • Automatic starting procedure is performed; any safety functions and

alarms leading to engine shutdown are disregarded;• Tachometer indicates increasing crankshaft speed;• Engine is running at rated speed when the starting sequence is com‐

pleted.

Connecting the generator (if fitted) to mainsItem TaskControl cabinet If generator is not connected to mains: Close generator circuit breaker.Engine Operate engine at rated power.

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4.5 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.


Operational checksItem TaskControl and display panels Check readings of operational data (speed, temperature, pressures).Engine oil Check engine oil level (→ Page 102).Engine operation Check engine visually for leaks and general condition;

Check for abnormal running noise, exhaust discoloration and vibrations(→ Page 40).

Battery-charging generator Check battery-charging generator for contamination, clean as necessa‐ry (→ Page 134).

Air filter Check differential pressure indication at gauge (if fitted).Exhaust system Check exhaust color (→ Page 40).Fuel prefilter Drain water and contaminants at the drain cock of fuel prefilter (if fitted)

(→ Page 88)Check reading on vacuum gauge of fuel prefilter (if fitted).

Intercooler Check condensate drain(s) for water discharge and obstruction(→ Page 93).

Engine coolant pump Check relief bore (→ Page 123).Charge-air coolant pump Check relief bore (→ Page 132).

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4.6 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 TaskEngine After opening the generator breaker (if provided), allow to cool down off-

load for approx. 5 minutes.

Preparing the pump drive (diesel-mechanical/diesel-electric)Item TaskEngine Allow to cool down for approx. 5 minutes at reduced engine speed. Ob‐

serve natural resonance of engine (installation-dependent)!

Stopping the engineItem TaskSwitchgear cabinet, controlpanel etc. (depending onmanufacturer)

Press stop button.• Automatic stopping sequence is performed;• Engine is stopped.

After stopping the engineItem TaskCoolant pump Allow to run on for sufficient time after stopping.

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4.7 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 stopItem ActionEmergency stop pushbut‐ton

Press EMERGENCY STOP button.• Engine is stopped by disconnecting the power supply to the ECU;• Emergency air shutoff flaps close (if provided);• signalization (e.g. by horn, beacon) is activated.

After emergency stopItem ActionSwitchgear cabinet, controlpanel etc. (depending onmanufacturer)

Press pushbutton for alarm acknowledgment.• Audible and visual signalization stops.

Engine Manually open emergency air shutoff flaps (if provided).• Engine is ready for starting.

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4.8 After stopping the engine – Engine remains ready foroperation

After stopping the engineItem ActionEngine/generator/pumpcontrol

Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.

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4.9 After stopping the engine – putting the engine out of service

Preconditions☑ MTU Fluids and Lubricants Specifications (A001061/..) is available.

After stopping the engineItem TaskCooling system Drain engine coolant (→ Page 118);

Drain charge-air coolant (→ Page 128) 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

-40°C.Engine/generator/pumpcontroller

Switch OFF.

Air intake and exhaust sys‐tem

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

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5 Maintenance5.1 Maintenance task reference table [QL1]

The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. TheMaintenance Schedule is a stand-alone publication.The task numbers in this table provide reference to the maintenance tasks specified in the MaintenanceSchedule.

Task Maintenance tasksW0500 Check engine oil level (→ Page 102)W0501 Visually inspect engine for leaks and general condition (→ Page 34)W0502 Check intercooler drain (if fitted) (→ Page 93)W0503 Check air filter service indicator (→ Page 97)W0505 Check relief bores of coolant pump(s) (→ Page 123)W0506 Check engine for abnormal running noises, exhaust color

and vibrations(→ Page 34)

W0507 Drain water and contaminants from fuel prefilter (if fitted) (→ Page 34)W0508 Check vacuum gauge reading on fuel prefilter (if fitted) (→ Page 34)W0525 Check battery-charging generator for contamination, clean if

necessary(→ Page 134)

W1001 Replace fuel filter or fuel filter element (→ Page 85)W1005 Replace air filter (→ Page 94)W1006 Replace fuel injectors (→ Page 78)W1008 Replace engine oil filter at each oil change or when the time

limit (years) is reached, at the latest(→ Page 107)

W1009 Check layer thickness of oil residue, clean and replace filtersleeve (if fitted)

(→ Page 113)

W1011 Perform endoscopic inspection of combustion chambers (→ Page 66)W1024 Check (electric) operation of emergency air-shutoff flaps (→ Page 98)W1036 Replace coolant filter (→ Page 125)W1046 Crankcase breather: Replace filter or filter element (→ Page 70)W1241 Check condition of belt drive and replace if necessary; adjust

belt tension(→ Page 133)

W1247 Lubricate emergency air-shutoff flap lubrication pointsW1250 Replace all rubber sleeves (→ Page 96)

(→ Page 99)W1251 Replace all hose linesW1294 Check valve clearance, ATTENTION! Initial adjustment after

500 operating hours!(→ Page 73)

Table 1: Maintenance task reference table [QL1]

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6 Troubleshooting6.1 Troubleshooting

Engine does not turn when starter is actuatedComponent Cause ActionBattery Low or faulty Charge or replace (see manufacturer's

documentation).Cable connections defective Check if cable connections are proper‐

ly secured (see manufacturer's docu‐mentation).

Starter Engine wiring or starter defective Check if cable connections are proper‐ly secured, contact Service.

Engine cabling Faulty Check (→ Page 140).Engine/generatorcontrol

Secure seating of assemblies or con‐nectors not provided

Perform visual inspection (see manu‐facturer's documentation).

Engine governor Plug-in connections are loose Check plug-in connections(→ Page 143).

Engine Running gear blocked (engine cannotbe barred manually).

Contact Service.

Engine turns but does not fireComponent Cause ActionStarter Poor rotation by starter: Battery low or

defective.Charge or replace battery (see manu‐facturer's documentation).

Engine cabling Faulty Check (→ Page 140).Fuel system Air in fuel system. Vent fuel system (→ Page 84).Engine governor Faulty Contact Service.

Engine fires unevenlyComponent Cause ActionFuel injection equip‐ment

Injector faulty. Replace (→ Page 78).

Engine cabling Faulty Check (→ Page 140).Fuel system Air in fuel system. Vent fuel system (→ Page 84).Engine governor Faulty Contact Service.

Engine does not reach rated speedComponent Cause ActionFuel supply Fuel prefilter clogged. Replace

Easy-change fuel filter clogged Replace (→ Page 85).Air supply Air filter clogged. Check signal ring position of service in‐

dicator (if fitted) .

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Component Cause ActionFuel injection equip‐ment


Engine cabling Faulty Check (→ Page 140).Engine Overload Contact Service.

Engine speed not steadyComponent Cause ActionFuel injection equip‐ment


Speed sensor Faulty Contact Service.Fuel system Air in fuel system. Vent fuel system (→ Page 84).Engine governor Faulty Contact Service.

Charge air temperature too highComponent Cause ActionEngine coolant Incorrect engine coolant concentration. Check (MTU test kit).Intercooler Contaminated Contact Service.Engine room Air inlet temperature too high. Check fans and intake/exhaust lines.

Charge-air pressure too lowComponent Cause ActionAir supply Air filter clogged. Check signal ring position of service in‐

dicator (if fitted) .Intercooler Contaminated Contact Service.Exhaust turbocharger Faulty Contact Service.

Coolant leaks at intercoolerComponent Cause ActionIntercooler Leaking, major coolant discharge. Contact Service.

Black exhaust gasComponent Cause ActionAir supply Air filter clogged. Check signal ring position of service in‐

dicator (if fitted) .Fuel injection equip‐ment


Engine Overload Contact Service.

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Blue exhaust gasComponent Cause ActionEngine oil Too much oil in engine. Drain engine oil (→ Page 103).

Oil separator of crankcase breathercontaminated

Replace (→ Page 70).

Exhaust turbocharg‐er, cylinder head, pis‐ton rings, cylinder lin‐er

Faulty Contact Service.

White exhaust gasComponent Cause ActionEngine Not at operating temperature. Run up to operating temperature.Fuel system Water in fuel. Check fuel system on fuel prefilter;

Drain fuel prefilterIntercooler Leaking Contact Service.


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6.2 Engine governor ADEC (ECU 7) for Series 4000 Oil &Gasengines – Fault 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 may also be caused by faulty sensors/actuators. Contact Service to have sensors/actua‐tors tested and replaced as necessary if troubleshooting as described in the table below proves unsuc‐cessful.The table below lists possible fault codes:

Fault codeNo. Designation Meaning Task

RelatedparameterNo.

003 HI T-FuelPreliminary warning: Fueltemperature too high. Contact Service.

2.0122.931

004 SS T-Fuel

Main warning: Fuel temper‐ature too high; engine shut‐down. Contact Service.

2.0122.932

005 HI T-Charge Air

Preliminary warning:Charge-air temperature toohigh

1. Reduce power.2. Check intercool‐er.

2.0121.931

006 SS T-Charge Air

Main warning: Charge-airtemperature too high; en‐gine shutdown.

1. Reduce power.2. Check intercool‐er.

2.0121.932

009HI T-Coolant Intercool‐er

Charge-air coolant tempera‐ture too high (1st limit val‐ue). Reduce power.

2.0124.931

010SS T-Coolant Intercool‐er

Main warning: Intercoolercoolant temperature toohigh; engine shutdown. Reduce power.

2.0124.932


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RelatedparameterNo.

015 LO P-Lube OilOil pressure too low(1st limit value).

Check oil level, topup as necessary(→ Page 102).

2.0100.921

016 SS P-Lube Oil

Oil pressure too low(2nd limit value), automaticengine shutdown.

1. Check oil level,top up as necessa‐ry (→ Page 102).2. Attempt to re‐start engine(→ Page 32).

2.0100.922

019 HI T-Exhaust A

Exhaust temperature of cyl‐inder bank A too high(1st limit value).

1. Check cabling(→ Page 140).2. Contact Service.

2.0126.931

020 SS T-Exhaust A

Exhaust temperature of cyl‐inder bank A too high(2nd limit value).


2.0126.932

021 HI T-Exhaust B

Exhaust temperature of cyl‐inder bank B too high(1st limit value).


2.0127.931

022 SS T-Exhaust B

Exhaust temperature of cyl‐inder bank B too high(2nd limit value).


2.0127.932

023 LO Coolant LevelCoolant level too low(1st limit value).

Check coolant lev‐el in expansiontank (→ Page 116).

2.0152.921

024 SS Coolant LevelCoolant level too low(2nd limit value).

Check coolant lev‐el in expansiontank (→ Page 116).

2.0152.912

025 HI P-Diff-Lube OilOil filter differential pressuretoo high (1st limit value).

Replace oil filtercandles(→ Page 108).

2.0154.931

026 SS P-Diff-Lube Oil

Alarm configuration limitvalue 1; Preliminary warn‐ing: Oil filter differentialpressure too high.

Replace oil filtercandles(→ Page 108).

2.0154.932

027 HI Level Leakage FuelLeak fuel level too high (1stlimit value).

1. Check fuel sys‐tem.2. Contact Service.

2.0151.931

029HI ETC Idle Speed tooHigh

Idle speed of ETC 2 toohigh. Contact Service.

1.8004.206

030 SS Engine OverspeedEngine overspeed; auto‐matic engine shutdown.

1. Acknowledgealarm.2. Attempt to re‐start engine.

2.2510.932


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RelatedparameterNo.

031 HI ETC1 Overspeed

Alarm configuration limitvalue 1; preliminary warn‐ing: speed of primary turbo‐charger too high. Contact Service.

2.3011.931

032 SS ETC1 OverspeedETC 1 – overspeed (2ndlimit value)

Automatic powerreduction by en‐gine control sys‐tem. Check air fil‐ters.

2.3012.932

036 HI ETC2 Overspeed

Alarm configuration limitvalue 1; preliminary warn‐ing: speed of secondary tur‐bocharger too high.

1. Reduce power.2. Contact Service.

2.3013.931

037 SS ETC2 Overspeed

Alarm configuration limitvalue 2; main warning:speed of secondary turbo‐charger too high. Fuel limi‐tation to a fixed value.


2.3013.912

038AL ETC Speed Devia‐tion

Synchronization error be‐tween ETCs 1 and 2.


1.8004.205

039 AL ETC2 Cutin Failure ETC2 failed to cut in.1. Reduce power.2. Contact Service.

1.8004.204

044L1 Coolant Level Inter‐cooler

Charge-air coolant level toohigh/low (1st limit).

Check coolant lev‐el (→ Page 126).

2.0153.921

051 HI T-Lube OilLube oil temperature toohigh (1st limit). Reduce power.

2.0125.931

052 SS T-Lube OilLube oil temperature toohigh (2nd limit).

1. Reduce power.2. Check engine oillevel(→ Page 102).

2.0125.932

057 LO P-CoolantCoolant pressure too low(1st limit).

Check coolant cir‐cuit.

2.0101.921

058 SS P-CoolantCoolant pressure too low(2nd limit).

Automatic engineshutdown. Checkcoolant level(→ Page 116).

2.0101.922

063 HI P-Crank CasePreliminary warning: Crank‐case pressure too high.

1. Reduce power.2. Replace filter el‐ement of oil sepa‐rator (→ Page 70).

2.0106.931

064 SS P-Crank Case

Main warning: Crankcasepressure too high; engineshutdown.

1. Contact Service.2. Replace filter el‐ement of oil sepa‐rator (→ Page 70).

2.0106.932


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RelatedparameterNo.

065 LO P-FuelFuel supply pressure toolow (1st limit).

Check fuel lines forleaks.Clean fuel prefilter.Flush fuel prefilter.Replace filter ele‐ment of fuel prefil‐ter.Replace fuel filter(→ Page 85).

2.0102.921

066 SS P-FuelFuel supply pressure toolow (2nd limit).

Check fuel lines forleaks.Clean fuel prefilter.Flush fuel prefilter.Replace filter ele‐ment of fuel prefil‐ter.Replace fuel filter(→ Page 85).

2.0102.922

067 HI T-CoolantCoolant temperature toohigh (1st limit). Reduce power.

2.0120.931

068 SS T-CoolantCoolant temperature toohigh (2nd limit).

1. Allow the engineto cool down;2. Contact Service.3.Check coolantcooler, clean ifnecessary.4. Restart engine(→ Page 32).

2.0120.932

081 AL Rail Leakage

Pressure gradient in rail istoo low during starting ortoo high during stopping;HP system leaky, air in sys‐tem). Contact Service.

1.8004.046

082HI P-Fuel (CommonRail)

Rail pressure > set value;DBR fuel limitation, start ofinjection readjusted towardslate; (suction restrictor ofHP fuel block jamming orHP fuel control block wiringfaulty) Contact Service.

2.0104.931

083LO P-Fuel (CommonRail)

Rail pressure <set value;DBR fuel limitation; (suctionrestrictor of HP fuel controlblock defective or leakagein HP fuel system) Contact Service.

2.0104.921


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RelatedparameterNo.

085 HI T-Recirculation

Preliminary warning: Recir‐culation temperature toohigh. Reduce power.

2.0128.931

086 SS T-RecirculationMain warning: Recirculationtemperature too high. Reduce power.

2.0128.932

089SS Engine Speed tooLow

Engine speed did not attain200 rpm. A stop is activat‐ed.

Check for addition‐al messages.

2.2500.030

090SS Idle Speed NotReached

Alarm configuration limitvalue; Idling speed was notattained. Contact Service.

2.1090.925

091SS Release Speed NotReached

Alarm configuration limitvalue; Runup speed wasnot attained. Contact Service.

2.1090.924

092SS Starter Speed NotReached

Alarm configuration limitvalue; Starter speed wasnot attained; Termination ofstarting sequence; Starterrotates too slowly or doesnot rotate at all. Contact Service.

2.1090.923

093 SS T-Preheat

Alarm configuration limitvalue 2; Main warning: pre‐heating temperature toolow; coolant temperaturetoo low for engine start; en‐gine start interlock active. Check preheater.

2.1090.922

094 LO T-Preheat

Alarm configuration limitvalue 1; Preheating temper‐ature too low; coolant tem‐perature too low for enginestart. Check preheater.

2.1090.921

095 AL Prelubrication FaultAlarm configuration; Oil pri‐ming fault.

Check oil primingsystem.

2.1090.920

102AL Cons. Counter De‐fect

Invalid fuel consumptiondisplay, checksum error inEDM/EEPROM 1 (redun‐dant data record 1). Contact Service.

1.8004.624

104AL Eng Hours CounterDefect

Checksum error of hour me‐ter in EDM/EEPROM 1 . Contact Service. 18004.623

118LO ECU Power SupplyVoltage

Supply voltage too low (1stlimit value).

Check ECU supplyvoltage.Contact Service.

2.0140.921

119LOLO Power ECUSupply Voltage

Supply voltage too low (2ndlimit value).


2.0140.922

120HI ECU Power SupplyVoltage

Supply voltage too high (1stlimit value).


2.0140.931


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RelatedparameterNo.

121HIHI ECU Power Sup‐ply Voltage

Supply voltage too high(2nd limit value); automaticengine shutdown (configu‐rable).


2.0140.932

122 HI T-ECUTemperature in ECU hous‐ing too high (1st limit value).

1. Improve engineroom ventilation.2. Reduce power.

2.0132.921

13415V POS ECU DE‐FECT

Internal voltage (-15 VDC)faulty; automatic engineshutdown.

Replace enginegovernor.

13615V NEG ECU DE‐FECT

Internal voltage (-15 VDC)missing; automatic engineshutdown. Contact Service.

139 L1 TE BUFFER TESTSupply voltage of tempera‐ture sensors faulty.

Contact Service.Check sensors;Replace enginegovernor.

140 TE BUF. ECU DEFECTSupply voltage of tempera‐ture sensors faulty.

Contact Service.Check sensors;Replace enginegovernor.

142 BANK1 ECU DEFECT

Power output stage for con‐trol of the solenoid valveson bank 1 is faulty; Enginedoes not start.


144 BANK2 ECU DEFECT

Power output stage for con‐trol of the solenoid valveson bank 2 is faulty; Enginedoes not start.


14515V_GOOD ECU DE‐FECT

Power supply faulty; auto‐matic engine shutdown.


146 L1 AD-TEST1 SUPPLYSupply voltage A/D convert‐er too low.


147AD-TEST1 ECU DE‐FECT

Electronic fault; automaticengine shutdown.


148 L1 AD-TEST2 SUPPLYSupply voltage A/D convert‐er too low.



Internal electronic fault; au‐tomatic engine shutdown.


150 L1 AD-TEST3 SUPPLYInternal electronic fault; au‐tomatic engine shutdown.



Internal electronic fault; au‐tomatic engine shutdown.


176AL LifeData not availa‐ble

Alarm configuration; No (ap‐propriate) LifeData backupsystem available, ECU re‐set after expiration of time-out period. Contact Service.

2.4000.004


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RelatedparameterNo.

177AL LifeData restore in‐complete

Alarm configuration; Thiserror message is generatedif a CRC is faulty during adata upload to ADEC (indi‐cated for each indiv. mod‐ule). Contact Service.

2.4000.006

180 AL CAN1 Node Lost

Alarm configuration; Con‐nection to a node on CANbus 1 failed. Contact Service.

2.0500.680

181 AL CAN2 Node Lost

Alarm configuration; Con‐nection to a node on CANbus 2 failed. Contact Service.

2.0500.681

182AL CAN Wrong Param‐eters

Alarm configuration; Incor‐rect parameter values en‐tered in data record. Contact Service.

2.0500.682

183 AL CAN No PU-Data

Alarm configuration; A CANmode has been selected inwhich communication withthe PU data module is ini‐tialized. However, the re‐quired PU data module isnot available or not valid. Contact Service.

2.0500.683

184AL CAN PU-Data FlashError

Alarm configuration; A pro‐gramming error occurredwhen attempting to copy areceived PU data moduleinto the Flash module. Contact Service.

2.0500.684

186 AL CAN1 Bus Off

CAN 1 in Bus-Off state: Ei‐ther short circuit on bus. Ormassive magnetic fields dis‐rupting the bus.

Contact Service.Inspect CAN busfor short circuit andrectify short circuitas necessary.Check shielding,improve as neces‐sary.

2.0500.686

187 AL CAN1 Error Passive

CAN 1 in Error-Passivestate, minor bus disruptionor CAN station missing.

Contact Service.Check that at leastone CAN station isavailable. Checkcabling as re‐quired. Checkshielding, improveas necessary.

2.0500.687

188 AL CAN2 Bus Off

CAN 2 in Bus-Off state: Ei‐ther short circuit on bus. Ormassive magnetic fields dis‐rupting the bus.

Contact Service.Inspect CAN busfor short circuit andrectify short circuitas necessary.Check shielding,improve as neces‐sary.

2.0500.688


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RelatedparameterNo.

189 AL CAN2 Error Passive

CAN 2 in Error-Passivestate, minor bus disruptionor CAN station missing.

Contact Service.Check that at leastone CAN station isavailable. Checkcabling as re‐quired. Checkshielding, improveas necessary.

2.0500.689

190AL EMU Parameter NotSupported

Alarm configuration; EMUparameters are not support‐ed. Contact Service.

2.0500.690

201 SD T-CoolantSensor B06 faulty (coolanttemperature).

1. Check cabling.2. Replace if nec‐essary.

1.8004.570

202 SD T-FuelSensor B33 faulty (fuel tem‐perature).


1.8004.572

203 SD T-Charge AirSensor B09 faulty (charge-air temperature) A side.


1.8004.571

204SD T-Coolant Intercool‐er

Sensor B26 faulty (charge-air coolant temperature).


1.8004.574

205 SD T-Exhaust A

Sensor B4.21 faulty (ex‐haust temperature) engineA side.

1. Check cabling2. Replace if nec‐essary.

1.8004.576

206 SD T-Exhaust B

Sensor B4.22 faulty (ex‐haust temperature) engineB side.


1.8004.577

208 SD P-Charge Air

Sensor B10 faulty (charge-air pressure), short circuit orwire break

Check sensor andcabling, replace asnecessary. Errorcleared after re‐starting the engine.

1.8004.566

211 SD P-Lube OilSensor B05 faulty (lube oilpressure).


1.8004.563

212 SD P-CoolantSensor B16 faulty (coolantpressure).


1.8004.564

213SD P-Coolant Inter‐cooler

Sensor B43 faulty (inter‐cooler coolant pressure).


1.8004.569


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214 SD P-CrankCaseSensor B50 faulty (crank‐case pressure).


1.8004.568

215 SD P-HD

Sensor B48 faulty (rail pres‐sure, HP regulator); emer‐gency mode active.


1.8004.567

216 SD T-Lube OilSensor B07 faulty (lube oiltemperature).


1.8004.575

219 SD T-Intake AirSensor B03 faulty (intakeair temperature).


1.8004.573

220SD Level Coolant Wa‐ter

Sensor F33 faulty (coolantlevel 1).

1. Switch systemOFF and ONagain;2. Check errormessage;3. Check cabling;4. Contact Service;5. Check sensor.

1.8004.584

221 SD Diff-Lube OilSensor F25 faulty (lube oildifferential pressure).

1. Check sensorand wiring.2. Replace if nec‐essary.Error cleared afterrestarting the en‐gine.

1.8004.585

222 SD Level Leakage FuelSensor F46 faulty (leakfuel).

1. Check sensorand wiring.2. Replace if nec‐essary.3. Contact Service.

1.8004.582

223SD Level Coolant Inter‐cooler

Sensor F57 faulty (charge-air coolant level).

1. Check sensorand wiring.2. Contact Service.

1.8004.583

227 SD P-Oil before Filter

SD alarm configuration;Sensor B5.3 (lube oil pres‐sure before filter) faulty;short circuit or wire break.


1.8004.620

229AL Stop Camshaft Sen‐sor Defect

Crankshaft and camshaftspeed sensor faulty.

1. Check cabling.2. Contact Serv‐ice.; Check sensor.

1.8004.562


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230 SD crankshaft SpeedSensor B13 faulty (crank‐shaft speed).


1.8004.498

231 SD Camshaft SpeedSensor B1 faulty (camshaftspeed).


1.8004.499

232 SD Charger 1 SpeedSensor B44 faulty (turbo‐charger speed 1).


1.3011.128

233 SD Charger 2 SpeedSensor B44.2 faulty (turbo‐charger speed 2).


1.3011.129

240 SD P-FuelSensor B34 faulty (fuelpressure).


1.8004.565

241 SD T-UmblasenSensor B49 faulty (recircu‐lation temperature).


1.8004.581

242 SD T-Coolant (R)Redundant coolant temper‐ature sensor faulty.


1.8004.622

244 SD P-Lube Oil (R)

SD alarm configuration; Re‐dundant lube oil pressuresensor faulty; Short circuitor wire break.


1.8004.621

245SD ECU Power SupplyVoltage

Sensor fault (ECU operatingvoltage).

Replace enginegovernor. 2.8006589

266 SD Speed DemandExternal speed demandfaulty.

1. Check cabling.2. Check speeddemand.

2.8006.586

269 SD Loadp.Analog filt

SD alarm configuration; Fil‐tered analog signal of loadpulse missing; short circuitor wire break.

Check cabling, re‐place as necessa‐ry.Error cleared afterrestarting the en‐gine.

2.8006.588

270 SD Frequency InputFrequency setting sensorfaulty.

1. Check cabling.2. Contact Serv‐ice.; Check set‐point speed trans‐mitter.

2.8006.590


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RelatedparameterNo.

301AL Timing Cylinder(A1-A10)

Timing Bank 1 (solenoidvalve 1) ... Timing Bank 1(solenoid valve 10)

Replace injectorconcerned if thefault message ap‐pears frequently(→ Page 78).

1.8004.500

3021.8004.501

3031.8004.502

3041.8004.503

3051.8004.504

3061.8004.505

3071.8004.506

3081.8004.507

3091.8004.508

3101.8004.509

311AL Timing Cylinder(B1- B10)

Timing Bank 2 (solenoidvalve 1) ... Timing Bank 2(solenoid valve 10)

Replace injectorconcerned if thefault message ap‐pears frequently(→ Page 78).

1.8004.510

3121.8004.511

3131.8004.512

3141.8004.513

3151.8004.514

3161.8004.515

3171.8004.516

3181.8004.517

3191.8004.518

3201.8004.519


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RelatedparameterNo.

321AL Wiring Cylinder (A1-A10)

Wiring Bank 1 (solenoidvalve 1) ... Wiring Bank 1(solenoid valve 10)

1. Check solenoidvalve.2. Contact Service.

1.8004.520

3221.8004.521

3231.8004.522

3241.8004.523

3251.8004.524

3261.8004.525

3271.8004.526

3281.8004.527

3291.8004.528

3301.8004.529

331AL Wiring Cylinder (B1-B10)

Wiring Bank 2 (solenoidvalve 1) ... Wiring Bank 2(solenoid valve 10)


1.8004.530

3321.8004.531

3331.8004.532

3341.8004.533

3351.8004.534

3361.8004.535

3371.8004.536

3381.8004.537

3391.8004.538

3401.8004.539

341AL Open Load Cylinder(A1- A10)

Open Load Bank 1 (sole‐noid valve 1) ... Open LoadBank 1 (solenoid valve 10)


1.8004.540


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RelatedparameterNo.

3421.8004.541

3431.8004.542

3441.8004.543

3451.8004.544

3461.8004.545

3471.8004.546

3481.8004.547

3491.8004.548

3501.8004.549

351AL Open Load Cylinder(B1- B10)

Open Load Bank 2 (sole‐noid valve 1) ... Open LoadBank 2 (solenoid valve 10)


1.8004.550

3521.8004.551

3531.8004.552

3541.8004.553

3551.8004.554

3561.8004.555

3571.8004.556

3581.8004.557

3591.8004.558

3601.8004.559

361 AL Power Stage Low

Alarm configuration; Internalelectronic fault (electronicspossibly faulty: Start ITS). Ifthe ITS diagnosis result is"electronics OK", note fur‐ther fault messages (e.g.cabling faults).

1. Check solenoidvalve cabling.2. Replace enginegovernor.

1.8004.496


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RelatedparameterNo.

362 AL Power Stage High

Alarm configuration; Internalelectronic fault (electronicspossibly faulty: Start ITS). Ifthe ITS diagnosis result is"electronics OK", note fur‐ther fault messages (e.g.cabling faults).

1. Check solenoidvalve cabling.2. Replace enginegovernor.

1.8004.497

363 AL Stop Power Stage

Alarm configuration; Internalelectronic fault (electronicspossibly faulty: Start ITS).

1. Check cabling.2. Attempt to re‐start engine.

1.8004.560

365AL Stop MV-WiringGround

Alarm configuration; Injectorcabling fault. If bit"1.1020.021" (Power StageFailure: Stop Engine) is set,engine will be shut down asadditional measure. 1. Shortcircuit of positive connectionof one or more injectors toground 2. Short circuit ofnegative connection of oneor more injectors to ground .

1. Check cabling.2. Attempt to re‐start engine.

1.8004.561

371 AL Wiring TO 1

Alarm configuration; Shortcircuit or wire break on tran‐sistor output 1 (TO 1).

1. Check turbo‐charger valve/ca‐bling, repair asnecessary2. Replace enginegovernor.

1.8004.634

372 AL Wiring TO 2

Alarm configuration; Shortcircuit or wire break on tran‐sistor output 2 (TO 2).

1. Check recircula‐tion valve/cabling,repair as necessa‐ry2. Replace enginegovernor.

1.8004.635

373 AL Wiring TO 3

Alarm configuration; Shortcircuit or wire break on tran‐sistor output 3 (TO 3). -

1.8004.636

374 AL Wiring TO 4

Alarm configuration; Shortcircuit or wire break on tran‐sistor output 4 (TO 4). -

1.8004.637

381 AL Wiring TOP 1

Alarm configuration; Shortcircuit or wire break on tran‐sistor output, plant-side 1(TOP 1).

Check cabling toplant.

2.8006.638

382 AL Wiring TOP 2



2.8006.639


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RelatedparameterNo.

383 AL Wiring TOP 3



2.8006.640

384 AL Wiring TOP 4



2.8006.641

390 AL MCR exceeded

Alarm configuration; DBR/MCR function: MCR hasbeen exceeded.

1. If alarm is onlytemporary, no ac‐tion required;2. <if alarm is con‐tinuously active,contact Service.

1.1085.009

392 HI T-Coolant Red

Alarm configuration limitvalue 1; Preliminary warn‐ing: Redundant coolanttemperature reading toohigh.

1. Check cabling.2. Contact Service.

2.0129.931

393 SS T-Coolant Red

Alarm configuration limitvalue 1; Main warning: Re‐dundant coolant tempera‐ture reading too high; en‐gine shutdown.


2.0129.932

394 LO P-Lube Oil Red

Alarm configuration limitvalue 1; Preliminary warn‐ing: Redundant lube oilpressure reading too low.


2.0112.921

395 SS P-Lube Oil Red

Alarm configuration limitvalue 2; Main warning: Re‐dundant lube oil pressurereading too low.


2.0112.922

396AL T-Coolant Max De‐viation

Alarm configuration; Maxi‐mum coolant temperaturedeviation.


1.8004.626

397 AL P-Oil Max Deviation

Alarm configuration; Maxi‐mum lube oil pressure devi‐ation.


1.8004.625

400AL Open Load DigitalInput 1

Alarm configuration; Linedisruption on digital input 1;Cabling faulty or no resist‐ance over switch.

1. Check cabling.2. Contact Serv‐ice.;3. Check input oftarget device.

2.8006.625



1. Check cabling.2. Contact Serv‐ice.; Check input oftarget device.

2.8006.626


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RelatedparameterNo.




2.8006.627




2.8006.628




2.8006.629




2.8006.630




2.8006.631




2.8006.632

408AL Open Load Emerg.Stop Input ESI

Alarm configuration; Linedisruption on the input foremergency stop; Cablingfaulty or no resistance overswitch.


2.8006.633

410 LO U-PDU

Alarm configuration limitvalue 1; Preliminary warn‐ing: Injector voltage too low.

1. Check cabling.2. Check powersupply.3. Contact Service.

2.0141.921

411 LOLO U-PDU

Alarm configuration limitvalue 2; Main warning: In‐jector voltage too low.


2.0141.922

412 HI U-PDU

Alarm configuration limitvalue 1; Preliminary warn‐ing: Injector voltage toohigh.


2.0141.931


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RelatedparameterNo.

413 HIHI U-PDU

Alarm configuration limitvalue; Main warning: Injec‐tor voltage too high.


2.0141.932

414HI Level Water FuelPrefilter

Alarm configuration limitvalue 1; Warning: water lev‐el in fuel prefilter too high. Drain water.

2.0156.931

415LO P-Coolant Intercool‐er

Alarm configuration limitvalue 1; Preliminary warn‐ing: Coolant pressure in in‐tercooler too low.

Top up coolant(→ Page 129).

2.0107.921

416SS P-Coolant Intercool‐er

Alarm configuration limitvalue 2; Main warning:Coolant pressure in inter‐cooler too low. engine shut‐down.

Top up coolant(→ Page 129).

2.0107.922

417SD Level Water FuelPrefilter

SD alarm configuration;Sensor for water level infuel prefilter faulty; short cir‐cuit or wire break.


1.8004.594

420 L1 Aux 1

Alarm configuration limitvalue 1; Input signal of Aux1 has exceeded/not at‐tained limit value 1, depend‐ing on configuration.

Determine andrectify reason forlimit value viola‐tion.

2.0160.921

421 L2 Aux 1

Alarm configuration limitvalue 1; Input signal of Aux1 has exceeded/not at‐tained limit value 2, depend‐ing on configuration.


2.0160.922

428 L1 T-Aux 1

Alarm configuration limitvalue 1; Preliminary warn‐ing: Temperature signal ofAux 1 has exceeded / notattained limit value 1, de‐pending on configuration.


2.0130.921

440 L1 P-Aux 1

Alarm configuration limitvalue 1; Preliminary warn‐ing: Pressure signal of Aux1 has exceeded / not at‐tained limit value 1, depend‐ing on configuration.


2.0110.921

442 L2 P-Aux 1

Alarm configuration limitvalue 2; Preliminary warn‐ing: Pressure signal of Aux1 has exceeded / not at‐tained limit value 2, depend‐ing on configuration.


2.0110.931


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RelatedparameterNo.

444 SD U-PDU

SD alarm configuration; In‐jector power stage sensordefect; Internal fault inECU7.

Replace ADEC(ECU 7).

1.8004.578

445 SD P-Ambient Air

SD alarm configuration;Ambient air pressure sensorfaulty.


1.8004.580

448 HI P-Charge Air

Alarm configuration limitvalue 1; Preliminary warn‐ing: Charge-air pressure toohigh. Contact Service.

2.0103.931

449 SS P-Charge Air

Alarm configuration limitvalue 2; Main warning:Charge-air pressure toohigh. Contact Service.

2.0103.932

450SD Idle/end Torque In‐put [%]

SD alarm configuration; In‐put signal for initial/final tor‐que faulty; Short circuit orwire break.

Check signal sen‐sor and cabling,replace as neces‐sary.Error cleared afterrestarting the en‐gine.

2.8006.592

454SS Power ReductionActive

Alarm configuration; powerreduction is active.

1. Note furtherfault messages.2. Determine andrectify reason forpower reduction.

2.7000.011

455 AL L1 Aux 1 Plant

Alarm configuration limitvalue 1; Input signal of Aux1 (plant side) has exceed‐ed/not attained limit value 1,depending on configuration.


2.8006.650

456 AL L2 Aux 1 Plant

Alarm configuration limitvalue 2; Input signal of Aux1 (plant side) has exceed‐ed/not attained limit value 2,depending on configuration.


2.8006.651

460 HI T-Exhaust EMU

Alarm configuration limitvalue; EMU exhaust tem‐perature value too high.


2.8006.652

461 LO T-Exhaust EMU

Alarm configuration limitvalue; EMU exhaust tem‐perature value too low.


2.8006.653

462 AL L1 T-Coolant EMU

Alarm configuration limitvalue; EMU coolant temper‐ature value too high/low.

Check configura‐tion with DiaSys.

2.8006.654


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RelatedparameterNo.

463 SD AUX 2

SD alarm configuration; An‐alog input signal for Aux 2faulty; Short circuit or wirebreak.

Check signal sen‐sor and cabling,replace as neces‐sary.Error cleared afterrestarting the en‐gine.

1.8004.591

464 SD P-AUX 1

SD alarm configuration; An‐alog input signal for Aux 1pressure faulty; Short circuitor wire break.

Check pressuresensor and ca‐bling.Error cleared afterrestarting the en‐gine.

1.8004.589

465 SD P-AUX 2

SD alarm configuration; An‐alog input signal for Aux 2pressure faulty; Short circuitor wire break.

Check pressuretransmitter and ca‐bling, replace asnecessary. Errorcleared after re‐starting the engine.

1.8004.588

466 SD T-AUX 2

SD alarm configuration; An‐alog input signal for Aux 2temperature faulty; Shortcircuit or wire break.

Check temperaturesensor and ca‐bling, replace asnecessary. Errorcleared after re‐starting the engine.

1.8004.586

467 AL L2 T-Aux 1

Alarm configuration limitvalue 2; Preliminary warn‐ing: Temperature signal ofAux 1 has exceeded / notattained limit value 2, de‐pending on configuration.


2.0130.922

468 SD T-AUX 1

SD alarm configuration; An‐alog input for Aux 1 temper‐ature faulty.

Replace enginegovernor. 1.8004579

469 SD AUX 1

SD alarm configuration; An‐alog input signal for Aux 1faulty; Short circuit or wirebreak.

Check signal sen‐sor and cabling,replace as neces‐sary. Error clearedafter restarting theengine.

1.8004.590

470 SD T-ECU

SD alarm configuration;Temperature sensor forECU faulty; Short circuit orwire break.


1.8004.587

471 SD Coil Current

SD alarm configuration;Control of HP fuel controlblock faulty; Short circuit orwire break.


1.8004.592


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RelatedparameterNo.

472 AL Stop SD

Alarm configuration; Enginestop, since all shutdownchannels have "sensor faul‐ty".


2.8006.593

473 AL Wiring PWM_CM2

Alarm configuration; Cablebreak or short circuit onchannel PWM_CM2.


1.8004.593

474 AL Wiring FO

Alarm configuration; Cablebreak or short circuit onchannel FO.


2.8006.655

475AL CR Trigger EngineStop

Alarm configuration; initiat‐ed when crash recorder istriggered due to engineshutdown.

Determine andrectify cause oftriggering / engineshutdown.

1.8010.009

476AL Crash Rec. Init. Er‐ror

Alarm configuration; Crashrecorder initialization error.

Check setting withDiaSys.

1.8010.007

478AL Comb. Alarm Yel(Plant)

Alarm configuration; YEL‐LOW summary alarm fromplant.

Note further faultmessages.

2.8006.001

479AL Comb. Alarm Red(Plant)

Alarm configuration; REDsummary alarm from plant.

Note further faultmessages.

2.8006.002

480AL Ext. Engine Protec‐tion

Alarm configuration limitvalue; Input signal has ex‐ceeded/not attained limitvalue, depending on config‐uration.


2.0291.921


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7 Task Description7.1 Engine

7.1.1 Engine – Barring manually


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Barring device F6555766 1Ratchet with extension F30006212 1

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

Engine – Barring manually1. Remove guard plate.2. Engage barring device (2) with ring gear (3)

and install on flywheel housing.3. Place ratchet (1) onto barring device (2).4. Rotate crankshaft in engine direction of ro‐

tation. Apart from the normal compressionresistance, there should be no further re‐sistance.

5. For barring device removal, follow reversesequence of working steps.

MS150054/02E 2012-02 | Task Description | 63

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7.1.2 Engine – Barring with starting system

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 system1. Release latch of connector X4.2. Remove connector from engine governor.3. Bar engine in unloaded condition: Press START button.4. Let the crankshaft rotate until oil pressure is indicated.5. Engine start is automatically interrupted when specified starting period has passed. If necessary, re-start

the engine after approx. 20 seconds.6. Connect connector X4 to engine governor and latch in position.

64 | Task Description | MS150054/02E 2012-02

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7.1.3 Engine – Test run



Engine – Test run1. Start engine (→ Page 32).2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.3. Carry out operational checks (→ Page 34).4. Stop engine (→ Page 35).


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7.2 Cylinder Liner7.2.1 Cylinder liner – Endoscopic examination


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Rigid endoscope Y20097353 1

Preparatory steps1. Remove cylinder head cover (→ Page 76).2. Remove injector (→ Page 79).

Positioning crankshaft at BDC1. Using barring device, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached

BDC.2. Insert endoscope into cylinder liner through injector seat.

Endoscopic examination of cylinder linerFindings Action• Thin carbon coating on circumference of carbon scraper ring• Slight localized additive deposits at top edge• Localized smooth areas at 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

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(that do not impair operation) clearly darker stripes that start at thetop piston ring

• Heat discoloration in the direction of stroke and honing pattern dam‐age

• Heat discoloration of piston rings

Cylinder liner must be re‐placed; Service must be con‐tacted

1. Compile endoscopy report using the table.2. Use technical terms for description of the liner surface (→ Page 68).3. 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.


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Final steps1. Install injector (→ Page 79).2. Install cylinder head cover (→ Page 76).


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7.2.2 Cylinder liner - Instructions and comments on endoscopic and visualexamination

Terms used for endoscopic examinationUse the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐nation report.

Findings MeasureMinor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐

ucts, particles, broken-off burrs). Removed cylinders clearly show such scoringon the running surface under endoscope magnification. Cannot be felt with thefingernail.Findings not critical.

Single scores Clearly visible scores caused by hard particles. They usually start in the TDCarea 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 honingpattern is still visible. Smoothened areas appear brighter and more brilliantthan the surrounding running surface.Findings not critical.

Bright area Bright areas are on the running surface and show local removal of the honingpattern. Grooves from honing process are not visible any more.

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐perature differences around the liner. It appears rather darker within the honedstructure in contrast to the bright metallic running surface. The honing patternis 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 inthe overlap (open) position. They are clearly visible due to the dark color of thehoning 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 cleardiscoloration from TDC to BDC in the running surface and the start of localizeddamage to the honing pattern.Cylinder liners with a large number of black lines around the running surfacehave limited service life and should be replaced.


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Findings MeasureBurn mark 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 andbecoming 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 anddisplays 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 bereplaced.

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


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7.3 Crankcase Breather7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check

and replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 6-50 Nm F30027336 1Ratchet adapter F30027340 1Engine oilFilter element (→ Spare Parts Catalog)Diaphragm (→ Spare Parts Catalog)Gasket (→ Spare Parts Catalog)

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

Replacing oil separator element1. Remove cover (2) with O-ring (3).2. Remove filter element (1) from housing (4).3. Insert new filter element in housing (4).4. Install cover (2) with new O-ring.

5. Use torque wrench to tighten the screws of cover (2) to the specified torque.


Screw Tightening torque (Engine oil) 10 Nm − 2 Nm

6. Replace further oil separator elements in the same way.


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Checking diaphragm1. Remove cover (4).2. Remove spring (5), gasket (2) and dia‐

phragm (3).3. Check diaphragm (3) for damage, fit new

diaphragm if used one is damaged.4. Install diaphragm (3) on housing (1).5. 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.


Screw Tightening torque (Engine oil) 10 Nm − 2 Nm

7. Check diaphragms in further oil separators in the same way.


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7.4 Valve Drive7.4.1 Valve gear – Lubrication


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Engine oil

Valve gear – Lubrication1. Remove cylinder head covers (→ Page 76).2. Fill oil chambers of valve bridges with oil.3. Fill oil chambers of rocker arms and adjust‐

ing screws with oil.4. Install cylinder head covers (→ Page 76).


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7.4.2 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 partsDesignation / Use Part No. Qty.Feeler gauge Y20010128 1Torque wrench, 60-320 Nm F30047446 1Ring socket, 24 mm F30039526 1

Preparatory steps1. Remove cylinder head cover (→ Page 76).2. Install barring device (→ Page 63).3. Rotate crankshaft with barring device in en‐

gine direction of rotation until "OT-A1" markand pointer are aligned.


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Diagram for 12V engines (twocrankshaft positions)

Diagram for 16V engines (twocrankshaft positions)

Checking valve clearance at two crankshaft positions1. Check TDC position of piston in cylinder A1:

• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.

2. Check valve clearance with cold engine:• Inlet valves (long rocker arm) = 0.2 mm• Exhaust valves (short rocker arm) = 0.5 mm

3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) asper diagram.

1 Cylinder A1 is in firing TDC2 Cylinder A1 is in overlap TDCI Inlet valve

X Exhaust valve4. Use feeler gauge to determine the distance between valve bridge and rocker arm.5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.


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Adjusting valve clearance1. Release locknut (1).2. Insert feeler gauge between valve bridge

and rocker arm.3. Using Allen key, set adjusting screw (2) so

that the specified valve clearance is provid‐ed.

4. Feeler gauge must just pass through thegap.

5. Tighten locknut (1) to 90 +9 Nm, holdingadjusting screw (2) firmly.

6. Replace or rectify adjusting screws and/orlocknuts which do not move freely.

7. Check valve clearance.

Final steps1. Remove barring device (→ Page 63).2. Install cylinder head cover (→ Page 76).


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7.4.3 Cylinder head cover – Removal and installation


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Grease (Kluthe Hakuform 30-10/Emulgier) X00058061O-ring (→ Spare Parts Catalog)

Removing cylinder head cover1. Clean very dirty cylinder head covers (3)

prior to removal.2. Remove screws (1) and washers (2).3. Take off cylinder head cover (3) with O-

ring (4) from cylinder head (5).

Installing cylinder head cover1. Clean mounting surface.2. Check O-ring (4) for damage, replace if necessary.3. Coat O-ring (4) with grease.4. Position O-ring (4) in groove of cylinder head cover (3).5. Fit cylinder head cover (3) on cylinder head (5).6. Install cylinder head cover (3) with screws (1) and washers (2).


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7.5 Injection Pump / HP Pump7.5.1 HP pump – Filling with engine oil


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Engine oil

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

WARNING Oils/oil vapors are combustible.Risk of fire!• No open flames, no electric sparks. Do not smoke. Avoid ignition sources.

CAUTION Fuel system high-pressure pump not filled with engine oil.Damage to components, major material damage!• Make sure that the high-pressure fuel pump is filled with engine oil before installation or initial

operation.

Filling HP pump1. Fill fresh engine oil into a clean receptacle.2. Fill HP pump (1) at connection (2).


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7.6 Injection Valve / Injector7.6.1 Injector – Replacement

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Injector (→ Spare Parts Catalog)

Replacing injectoru Remove injector and install new injector (→ Page 79).


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7.6.2 Injector – Removal and installation


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Installation/removal tool F6789889 1Milling cutter F30452739 1Torque wrench, 0.5-5 Nm 0015384230 1Torque wrench, 10-60 Nm F30452769 1Torque wrench, 60-320 Nm F30452768 1Assembly paste (Optimoly Paste White T) 40477 1Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1Engine oilO-ring (→ Spare Parts Catalog)


Preparatory steps1. Shut off fuel supply to engine.2. Remove cylinder head cover (→ Page 76).

Removing injector1. Disconnect cable connector on injector.


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2. Remove HP fuel line (4).3. Remove return line (5).

Note: The injector accumulator will be emptiedwhen removing the adapter.

4. Remove adapter (3).5. Remove screw (2) and take off hold-down

clamp (1).

6. Install installation/removal tool on cylinderhead.

7. Remove injector with installation/removaltool.

8. Remove installation/removal tool.

9. Remove sealing ring (4) from injector or usea self-made hook to take it out of the cylin‐der head.

10. Remove O-rings (3), O-ring (2) and damperring (1) from injector.

11. Clean all mating and sealing surfaces.12. Cover all connections and bores, or seal

with suitable plugs.


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Installing injector1. Remove plug before installing the injec‐

tor. (Do not remove the plug from the HPline before installing the adapter.)

2. Coat injector with assembly paste at theseat of the nozzle clamping nut.

3. Fit new sealing ring (4) (included in thescope of supply of the injector) with greaseon injector, observe installation position ofsealing ring (4).

4. Fit new O-rings (3) (included in the scope ofsupply of the injector), O-ring (2) and damp‐ing ring (1) onto the injector and coat withgrease.

5. Clean sealing face on cylinder head andprotective sleeve with milling cutter.

6. Insert injector into cylinder head, ensuringthat the HP line adapter is correctly aligned.

7. Use installation/removal tool to press in in‐jector.

8. Remove installation/removal tool.


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9. Coat screw head mating face (2) andthread with engine oil.

10. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the specifiedinitial tightening torque.


Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm

Note: Ensure special cleanness.11. Coat thread and sealing cone of adapter (3) with engine oil.12. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.


Adapter Preload torque (Engine oil) 5 Nm to 10 Nm

13. Tighten screw (2) with torque wrench to the specified tightening torque.


Screw M12 Tightening torque 100 Nm + 10 Nm

14. Tighten adapter (3) with torque wrench to the specified tightening torque.


Adapter Tightening torque 100 Nm + 10 Nm

15. Install return line (7).Note: Ensure special cleanness.

16. Coat thread and sealing cone of HP line (5) with engine oil.Note: Two HP line versions (single- and double-walled) with different torques as described below.

17. Mount single-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening se‐quence:

1 Rail (6)2 Adapter (4)


Union nut / thrustscrew

Tightening torque 30 Nm + 5 Nm


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18. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tighteningsequence:

1 Adapter (4)2 Rail (6)


Union nut / thrustscrew

Tightening torque 40 Nm + 5 Nm

19. Fit cable connector onto injector.

Final steps1. Install cylinder head cover (→ Page 76).2. Open fuel supply to engine.


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7.7 Fuel System7.7.1 Fuel system – Venting


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuel


Venting LP fuel system1. Open threaded vent plug (1).2. Unlock fuel priming pump (2), screw out

handle by turning it counterclockwise.3. Operate the pump with the handle (2) until

bubble-free fuel emerges at the threadedvent plug (1).

4. Close threaded vent plug (1).5. Screw in handle by turning it clockwise.6. Verify that fuel priming pump (2) is locked:

Handle must be tightened.


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7.8 Fuel Filter7.8.1 Fuel filter – Replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Filter wrench F30379104 1Engine oilEasy-change filter (→ Spare Parts Catalog)


Replacing fuel filter1. Remove easy-change filter using filter

wrench.2. Clean sealing surface on filter head.3. Slightly lubricate seal on the easy-change

filter.4. Screw on easy-change filter by hand until

the seal connects and tighten manually.5. Vent fuel system (→ Page 84).6. Replace other easy-change filters in the

same way.


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7.8.2 Fuel prefilter cleaning


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuelSealing ring (→ Spare Parts Catalog)


Fuel prefilter cleaning1. Shut off fuel supply.2. Remove nuts from filter head.3. Take off filter housing and drain fuel into

appropriate container.4. Remove filter-element securing nut and re‐

move filter element by pulling it downwards.5. Wash filter element in clean fuel using a

smooth brush.6. Wash filter housing with clean fuel.7. Insert filter element into filter housing and

secure with nut.8. Place new sealing ring into groove in filter

head.9. Fit cover with seal and secure it with nuts

crosswise.10. Open fuel supply.


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7.8.3 Fuel prefilter – Differential pressure gauge check and adjustment



Adjusting differential pressuregauge

1. When installing the new filter element: alignadjustable pointer (2) with pressure-indicat‐ing pointer (3) of pressure gauge (1).

2. Check differential pressure.

Checking differential pressure of fuel prefilter1. With the engine running at full load or rated power, read off pressure at gauge (1).2. 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 89).


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7.8.4 Fuel prefilter – Draining


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuelGasket (→ Spare Parts Catalog)


Fuel prefilter – Draining1. Cut out filter to be drained.

I Left filter cut inII Right filter cut in

2. Open threaded vent plug (5) of filter to bedrained.

3. Unlock drain valve (6) by pressing toggleand open it.

4. Drain water and contaminants from filter un‐til pure fuel emerges.

5. Close drain valve (6).6. Remove screws for cover and take off cov‐

er (2).7. Fill filter housing with clean fuel.8. Place new gasket in cover (2).9. Fit cover with gasket and secure it with

screws.10. Cut in the cut-out filter again.11. Close threaded vent plug (5) when fuel

emerges.


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7.8.5 Fuel prefilter ‒ Flushing

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuelGasket (→ Spare Parts Catalog)




Fuel prefilter ‒ Flushing1. Cut out clogged filter.



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2. Open threaded vent plug (5) of filter to beflushed.

3. Unlock drain valve (6) by pressing toggle,open it and drain fuel.

Result: Fuel flows from filtered side back to the un‐filtered side, flushing the filter depositsdownwards out of the filter.

4. Close threaded vent plug (5) and drainvalve (6).

Fuel prefilter – Topping up with fuel1. Stop engine (→ Page 35) and disable engine start.2. Remove screws for cover and take off cover (2).3. Fill filter housing with clean fuel.4. Place new gasket in cover (2).5. Fit cover with gasket and secure it with screws.6. Check differential pressure (→ Page 87).

Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefil‐ter (→ Page 91).


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7.8.6 Fuel prefilter – Filter element replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuelFilter element (→ Spare Parts Catalog)Gasket (→ Spare Parts Catalog)


Replacing filter element1. Cut out filter to be drained.



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2. Open threaded vent plug (5) of contaminat‐ed filter.

3. Unlock drain valve (6) by pressing toggleand open it.

4. Drain water and dirt from filter.5. Close drain valve (6).6. Remove screws securing the cover and

take off cover (2).7. Remove spring housing (4) and filter ele‐

ment (3).8. Insert new filter element (3) and spring

housing (4).9. Fill filter housing with clean fuel.

10. Place new gasket in cover (2).11. Fit cover with gasket and secure it with

screws.12. Cut in the cut-out filter again.13. Close threaded vent plug (5) when fuel

emerges.14. Adjust the differential pressure gauge

(→ Page 87).


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7.9 Charge-Air Cooling7.9.1 Intercooler – Check drain for coolant leakage and obstruction



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

Intercooler – Check drain forcoolant leakage and obstruction

1. Verify that air emerges from condensatedrain bore(s) on left and right engine sidesat driving end when engine is running. If noair emerges:• Clean drain bore(s)• Blow out with compressed air

2. If a large amount of coolant is continuouslydischarged, the intercooler is leaking. Con‐tact Service.

Emergency measures prior to engine start with a leaking intercooler1. Remove injectors (→ Page 79).2. Bar engine manually (→ Page 63).3. Crank engine on starting system to blow out combustion chambers (→ Page 64).4. Install injectors (→ Page 79).


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7.10 Air Filter7.10.1 Air filter – Replacement

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Air filter (→ Spare Parts Catalog)

Air filter – Replacement1. Remove air filter and install new one (→ Page 95).2. Reset signal ring of service indicator (→ Page 97).


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7.10.2 Air filter – Removal and installation


Air filter – Removal and installation1. Release clamp (2).2. Remove air filter (3) and clamp (2) from

flange of intake housing (1).3. Verify that there are no objects in the flange

of the intake housing (1) and clean it.4. Place new air filter (3) with clamp (2) onto

intake housing (1).5. Tighten clamp (2).


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7.10.3 Rubber sleeves between air intake elbow and turbocharger – Replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Rubber sleeve (→ Spare Parts Catalog) 4

Also applicable to 12 V

Preparatory stepsu Remove air filter (→ Page 94).

Replacing rubber sleeves1. Remove screws (3), loosen clamps (1) and take off elbow (4).2. Pull off rubber sleeve (2) from turbocharger intake flange.3. Clean connecting flange of turbocharger and check for obstructions.4. Fit new rubber sleeve (2) on turbocharger intake flange.5. Fit both clamps (1) on rubber sleeve (2), slide on elbow (4) and secure with screws (3).6. Align clamps (1) and tighten.7. Replace further rubber sleeves in the same way.

Final stepsu Install air filter (→ Page 94).


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7.11 Air Intake7.11.1 Contamination indicator – Signal ring position check


Checking signal ring position1. If the signal ring is completely visible in the

control window (2), replace air filter(→ Page 94).

2. After installation of new filter, press resetbutton (1).

Result: Engaged piston with signal ring moves backto initial position.


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7.11.2 Emergency air-shutoff flaps – Functional check with electric actuation


WARNING Air flaps close abruptly.Risk of injury!• Before actuating, ensure that nobody is in the danger zone.


Emergency air-shutoff flaps –Functional check with electricactuation

1. Start engine (→ Page 32).2. Activate the appropriate function to trigger

emergency air-shutoff flaps (depending oninstallation), e.g. by carrying out overspeedtest. Check the following items:• The emergency air-shutoff flaps must

close as soon as the set point isreached.

• The levers must be in position B.• Emergency engine stop must be initiat‐

ed.3. Open the emergency air-shutoff flaps man‐

ually after completion of test so that the lev‐ers are in position A.

4. Observe fault message.


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7.11.3 Rubber sleeves in air pipework before intercooler – Replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Rubber sleeve (→ Spare Parts Catalog)O-ring (→ Spare Parts Catalog)

Also applicable to 12 V

Preparatory stepsu Remove air filter (→ Page 94).

Replacing rubber sleeves on right engine side1. Release clamps (1).2. Remove screws from elbow (8), remove elbow and pull off rubber sleeves (2).3. Remove charge-air pipe (9), pull off rubber sleeve (2).4. Clean charge-air pipe and elbow and check for obstructions.5. Fit new rubber sleeves on exhaust turbocharger and charge-air pipe.6. Slide clamps onto all rubber sleeves.7. Insert elbow (8) and charge-air pipe (9) ends into rubber sleeves.8. Secure elbow (8) with new O-ring on intercooler.9. Align clamps (1) and secure.


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Replacing rubber sleeves on left engine side1. Release clamps (3).2. Remove retainer (5) on charge-air pipe.3. Remove screws from elbow (7) and remove elbow.4. Pull off charge-air pipe (6).5. Clean charge-air pipe and elbow and check for obstructions.6. Slide new rubber sleeves (4) onto exhaust turbocharger and charge-air pipe (6).7. Slide clamps onto all rubber sleeves.8. Insert elbow (7) and charge-air pipe (6) ends into rubber sleeves.9. Secure elbow (7) with new O-ring on intercooler.

10. Align clamps (3) and secure.11. Install retainer (5) on charge-air pipe (6).

Final stepsu Install air filter (→ Page 94).


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7.12 Starting Equipment7.12.1 Air starter – Manual operation



Air starter – Manual operation1. Operate pushbutton for manual start (ar‐

row) and hold.2. Allow compressed air to enter the air start‐

er, until the engine fires evenly.3. Release pushbutton.


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7.13 Lube Oil System, Lube Oil Circuit7.13.1 Engine oil level – Check

Preconditions☑ Engine shut down and starting disabled.

Checking oil level prior to enginestart

1. Withdraw oil dipstick from guide tube andwipe it.

2. Insert oil dipstick into guide tube up to stop,withdraw after approx. 10 seconds andcheck oil level.

Note: After extended standstill, the oil level mayexceed the mark (1) by up to 2 cm. Thiscan be caused by oil flowing from e.g. oil fil‐ter or heat exchanger back to the oil pan.

3. The oil level must reach mark (1) or exceedmark (1) by up to 2 cm.

4. Top up with oil to mark (1) as necessary(→ Page 103).

5. Insert oil dipstick into guide tube up to thestop.

Checking oil level after the engine is stopped1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.2. Insert oil dipstick into guide tube up to stop, withdraw after approx. 10 seconds and check oil level.3. Oil level must be between marks (1) and (2).4. Top up with oil to mark (1) as necessary (→ Page 103).5. Insert oil dipstick into guide tube up to the stop.


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7.13.2 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 partsDesignation / Use Part No. Qty.Torque wrench, 40-200 Nm F30027337 1Ratchet adapter F30027341 1Engine oilSealing ring (→ Spare Parts Catalog)


Procedure without pump: Draining oil via drain plug(s) on oil pan1. Provide a suitable container to collect the oil.2. Remove drain plug(s) and drain oil.3. Install drain plug(s) with new sealing ring.

Procedure with pump: Oil extraction1. Provide a suitable container to collect the oil.2. Extract all oil from oil pan using the pump.

Draining residual oil at equipmentcarrier

1. Provide a suitable container to collect theoil.

2. Remove drain plug (1) and drain oil (ap‐prox. 7 liters) from oil heat exchanger andoil filter.

3. Remove drain plugs (2) and (3) and drainoil:• at drain plug (2) approx. 12 liters• at drain plug (3) approx. 5 liters

4. Install drain plug(s) with new sealing ring.


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5. Tighten drain plugs (2) and (3) with torque wrench to the specified torque.


Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm

Filling with new oil1. Open cover on filler neck.2. Fill oil through filler neck up to "max." mark

at oil dipstick.3. Close cover on filler neck.4. Check engine oil level (→ Page 102).


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7.13.3 Engine-oil – Sample extraction and analysis

Preconditions☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.MTU test kit 5605892099/00 1




Engine-oil sample extraction andanalysis, variant A

1. With the engine running at operating tem‐perature, open screw on flange of centrifu‐gal oil filter by 1 to 2 rotations.

2. Drain approx. 2 liters engine oil to flush outthe oil sludge.

3. Drain approx. 1 liter engine oil into a cleancontainer.

4. Close screw.5. Using the equipment and chemicals of the

MTU test kit, examine oil for:• Dispersion capability (spot test);• Water content;• Dilution by fuel.


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Engine-oil sample extraction andanalysis, variant B

1. With the engine running at operating tem‐perature, open screw on automatic oil filterby 1 to 2 rotations.

2. Drain approx. 2 liters engine oil to flush outthe oil sludge.

3. Drain approx. 1 liter engine oil into a cleancontainer.

4. Close screw.5. Using the equipment and chemicals of the

MTU test kit, examine oil for:• Dispersion capability (spot test);• Water content;• Dilution by fuel.


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7.14 Oil Filtration / Cooling7.14.1 Engine oil filter – Replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Filter wrench F30379104Engine oilOil filter (→ Spare Parts Catalog)


Engine oil filter – Replacement1. Remove engine oil filter using filter wrench.2. Clean sealing surface on connecting piece.3. Check condition of new engine oil filter

sealing ring and coat it with engine oil.4. Screw on and tighten new engine oil filter

by hand.5. Replace further engine oil filters in the

same way.6. Check engine oil level (→ Page 102).7. After oil change and oil filter replacement,

bar engine with starting system(→ Page 64).


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7.14.2 Automatic oil filter – Oil filter candles replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1Engine oilO-ring (→ Spare Parts Catalog)Oil filter candles (→ Spare Parts Catalog)


CAUTION Contamination of components.Damage to component!• Observe manufacturer's instructions.• Check components for special cleanness.

Oil filter candles – Removal1. Remove nuts (2) from oil filter cover (1).2. Remove oil filter cover.


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3. Withdraw filter insert (1).4. Remove O-ring.

5. Remove screw (2).6. Withdraw spinner (1) with spring.7. Remove nut (3).8. Take off spring washer and washer.9. Remove screw (4).

10. Remove flushing arm (5) from screenplate (6).

11. Turn filter insert upside down and use ap‐propriate tool to push out filter candles (1).

12. Turn filter insert by 180° and insert new fil‐ter candles (1) with chamfer facing down‐wards.


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Oil filter candles – Installation1. For installation follow reverse sequence of working steps.2. In addition, the following work must be performed:

• Replace all sealing elements with new parts.• Coat O-rings with grease.• Insert O-rings in grooves.• Pay attention to installation position of fillister-head screw to slot in shaft.


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7.14.3 Oil indicator filter – Check


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Strainer (→ Spare Parts Catalog)Square-section ring (→ Spare Parts Catalog)O-ring (→ Spare Parts Catalog)



CAUTION Unsuitable cleaning tool.Damage to component!• Observe manufacturer's instructions.• Use appropriate cleaning tool.

Removing strainer1. Clean oil indicator filter before disassem‐

bling it.2. Remove screws (1).3. Take off cover (2) with O–ring (3).4. Take strainer (5) from filter housing.


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Checking strainerItem Findings TaskStrainer Metallic residues • Clean

• Monitor engine operation• Check strainer daily• Contact Service.

Strainer Damaged ReplaceSquare-section ring Damaged ReplaceO-ring Damaged Replace

Cleaning strainer1. Wash strainer (5) with cleaner.2. Remove stubborn deposits with soft brush.3. Blow out strainer (5) with compressed air from inside.

Installing strainer1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).2. Coat O–ring (3) with engine oil and fit in filter housing.3. Fit cover (2) and secure with screws (1) and washers.


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7.14.4 Centrifugal oil filter – Cleaning and filter-sleeve replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench 6-50 Nm F30027336 1Filter wrench F30379104 1Cold cleaner (Hakutex 60) 50602 1Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1Filter sleeve (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)




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Cleaning centrifugal oil filter andreplacing filter sleeve, variant A

1. Remove clamp (3).2. Release screw of cover (1) and take off

cover (2).3. Carefully lift rotor (6), allow oil to drain and

remove from housing.4. Holding the rotor (6) firmly, release rotor

cover nut (7).5. Take off rotor cover (8).6. Remove filter sleeve (10).7. Measure thickness of oil residues on filter

sleeve (10).8. If maximum layer thickness of oil residues

exceeds 45 mm, shorten maintenance in‐terval.

9. Disassemble rotor tube (11), conicaldisk (12) and rotor base (14).

10. Wash rotor cover (8), rotor tube (11), coni‐cal disk (12) and rotor base (14) with clean‐er. Do not use sharp objects for cleaning.

11. Blow out with compressed air.12. Check sealing ring (13), fit new one if nec‐

essary.13. Assemble rotor tube (11), conical disk (12)

and rotor base (14) with sealing ring (13).14. Insert new filter sleeve (10) in rotor tube

(11) with the smooth paper surface facingthe wall.

15. Check sealing ring (9), fit new one if neces‐sary.

16. Mount rotor cover (8) with sealing ring (9).17. Tighten rotor cover nut (7) with 35 Nm to

45 Nm.18. Place rotor (6) in housing (5) and check for

ease of movement.19. Check sealing ring (4), fit new one if neces‐

sary.20. Fit sealing ring (4) on housing (5).21. Fit cover (2).22. Tighten screw of cover (1) by hand.23. Install clamp (3) and use torque wrench to

tighten to the specified tightening torque8 Nm +2 Nm.

24. Tighten screw of cover (1) with torquewrench to the specified tightening torque5 Nm +2 Nm.


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Cleaning centrifugal oil filter andreplacing filter sleeve, variant B

1. Release screw (1) and remove.2. Remove clamp (3) and take off cover (2).3. Carefully remove rotor (5) from housing.4. Holding the rotor (5) firmly with the filter

wrench, release knurled nut (7).5. Take off rotor cap (8).6. Remove filter sleeve (9), stiffener plate (10)

and sealing ring (11).7. Measure thickness of oil residues on filter

sleeve.8. If maximum layer thickness of oil residues

exceeds 30 mm, shorten maintenance in‐terval.

9. Take off standpipe (12) from lower rotorsection (13).

10. Wash cover (2), rotor cap (8), stiffener plate(10), standpipe (12), lower rotor section(13) and nozzles (14) with cleaner and blowout with compressed air. Do not use sharpobjects for cleaning.

11. Check nozzles (14) for obstructions.12. Move standpipe (12) over rotor lower sec‐

tion (13).13. Insert new filter sleeve (9) with stiffener

plate (10) into rotor cap (8) with the with thesmooth paper surface of the filter sleeve (9)facing the rotor cap (8).

14. Check sealing ring (11), fit new one if nec‐essary. Coat sealing ring with grease andinsert in the groove of the rotor cap (8).

15. Place rotor cap (8) onto standpipe (12).16. Holding the rotor (5) firmly with the filter

wrench, tighten knurled nut (7).17. Lubricate bearings of rotor (5), insert in

housing (6) and check for ease of move‐ment.

18. Check sealing ring (4), fit new one if neces‐sary. Fit sealing ring on housing (6).

19. Fit cover (2).20. Tighten screw (1) by hand.21. Install clamp (3) and use torque wrench to

tighten to the specified tightening torque6 Nm +1 Nm.

22. Tighten screw (1) with torque wrench to thespecified tightening torque 6 Nm +1 Nm.


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7.15 Coolant Circuit, General, High-Temperature Circuit7.15.1 Engine coolant – Level check


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 engine coolant level at filler neck:1. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to

escape.2. Continue to turn breather valve counterclockwise and remove.3. Check coolant level (coolant must be visible at the lower edge of the cast-in eye).

Checking engine coolant level atremote cooler:

1. Check coolant level (coolant must be visibleat marking plate).

2. Top up coolant if necessary (→ Page 120).3. Check and clean breather valve.4. Place breather valve on filler neck and

close.

Checking engine coolant level via level sensor:1. Switch on engine control system and check readings on the display.2. Top up coolant if necessary (→ Page 120).


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7.15.2 Engine coolant – Change

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

Changing engine coolant1. Drain engine coolant (→ Page 118).2. Fill with engine coolant (→ Page 120).


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7.15.3 Engine coolant – Draining


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Sealing rings (→ Spare Parts Catalog)


Preparatory steps1. Provide an appropriate container to drain the coolant into.2. Switch off preheating unit (if fitted).

Draining engine coolant1. Turn breather valve of filler neck on coolant

expansion tank counterclockwise to firststop and allow pressure to escape.

2. Continue to turn breather valve counter‐clockwise and remove.

3. Draw off precipitated corrosion inhibitor oilfrom the expansion tank through filler neck.

4. Open drain valves and drain plugs anddrain coolant at the following points:• Preheating unit (if fitted)• Thermostat housing (arrow)• Twin elbow (arrow)• Elbow of engine coolant pump• Crankcase, left and right side.


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5. Drain pint on driving end, left and right side.

Final steps1. Close all drain valves and install drain plugs with new sealing rings.2. Set breather valve onto filler neck and close it.


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7.15.4 Engine coolant – Filling


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


CAUTION Cold coolant in hot engine can cause thermal stress.Formation of cracks in components!• Fill / top up coolant only into cold engine.

Preparatory steps1. Turn breather valve of coolant expansion

tank counterclockwise until the first stopand allow pressure to escape.



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Filling coolant with pump1. Connect a suitable pump with a hose to the

drain valve of the engine coolant pump (ar‐row).

2. Release union at distributor (arrow).3. Open drain valve and pump coolant into en‐

gine at 0.5 bar minimum.4. Close venting point when coolant emerges

from the released union.5. Fill expansion tank until overflow edge is

reached.6. Close drain valve.7. Check proper condition of breather valve,

clean sealing faces if required.8. Fit breather valve and close it.9. Start engine (→ Page 32).

10. After the engine has run at unloaded condi‐tion for10 seconds, stop engine(→ Page 35).

11. Turn breather valve of coolant expansiontank counterclockwise until the first stopand allow pressure to escape.


13. Check coolant level (→ Page 116) and topup engine coolant as required:

a) Fill in coolant via filler neck on expan‐sion tank until the coolant level at bot‐tom edge of filler neck remains con‐stant.

b) Check proper condition of breathervalve, clean sealing faces if required.

c) Fit breather valve and close it.14. Repeat the steps from "Start engine"

(→ Step 8) until coolant no longer needs tobe topped up.

15. Disconnect pump and hose.


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Alternatively: Filling coolantthrough filler neck

1. Release union at distributor (arrow).2. Fill in coolant via filler neck on expansion

tank until the coolant emerges from the re‐leased union.

3. Tighten union (arrow).4. Fill expansion tank until overflow edge is

reached.5. Check proper condition of breather valve,

clean sealing faces if required.6. Fit breather valve and close it.7. Start engine (→ Page 32).8. After the engine has run at unloaded condi‐

tion for10 seconds, stop engine(→ Page 35).

9. Turn breather valve of coolant expansiontank counterclockwise until the first stopand allow pressure to escape.

10. Turn breather valve counterclockwise andremove.

11. Check coolant level (→ Page 116) and topup via filler neck if required:



c) Fit breather valve and close it.12. Repeat the steps from "Start engine"

(→ Step 7) until coolant no longer needs tobe topped up.

Final steps1. Start the engine and operate it unloaded for some minutes.2. Check coolant level (→ Page 116) and top up if required.


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7.15.5 Engine coolant pump – Relief bore check



Engine coolant pump – Relief borecheck

1. Check relief bore for oil and coolant dis‐charge.

2. Shut down engine (→ Page 35) and disableengine start, observe general safety instruc‐tions “Maintenance and Repair”.

3. Clean the relief bore with a wire if it is dirty.• Permissible coolant discharge: up to 10

drops per hour;• Permissible oil discharge: up to 5 drops

per hour.4. If discharge exceeds the specified limits:

Contact Service.


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7.15.6 Engine coolant – Sample extraction and analysis

Preconditions☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.MTU test kit 5605892099/00 1




Engine coolant – Sample extractionand analysis

1. With the engine running, open drain valve(1).

2. Flush sample-extraction point by drainingapprox. 1 liter coolant.

3. Drain approx. 1 liter coolant into a cleancontainer.

4. Close drain valve (1).5. Using the equipment and chemicals of the

MTU test kit, check the coolant for:• Antifreeze concentration• Corrosion inhibitor concentration• pH value.

6. For engine coolant change intervals, referto (→ MTU Fluids and Lubricants Specifica‐tions).


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7.15.7 Coolant filter – Replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Filter wrench F30379104 1Engine oilCoolant filter (→ Spare Parts Catalog)


Coolant filter – Replacement1. Close shut-off cocks (1).2. Remove coolant filter (2) with filter wrench.3. Clean sealing surface on connecting piece.4. Coat seal on new coolant filter with engine

oil.5. Screw on coolant filter and tighten hand-

tight.6. Open shut-off cocks (1).


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7.16 Low-Temperature Circuit7.16.1 Charge-air coolant – Level check



Checking charge-air coolant levelat filler neck:

1. Turn breather valve on coolant expansiontank counterclockwise to the first stop andallow pressure to escape.


3. Check coolant level (coolant must be visibleat marking plate).

4. Top up coolant if necessary (→ Page 129).5. Check proper condition of breather valve,

clean sealing faces if required.6. Fit breather valve and close it.

Checking charge-air coolant level by means of level sensor:1. Switch on engine control system and check display (coolant level is automatically monitored by engine

control system).2. Top up coolant if necessary (→ Page 129).


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7.16.2 Charge-air coolant – Change

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Charge-air coolant

Charge-air coolant – Change1. Drain charge-air coolant (→ Page 128).2. Fill with charge-air coolant (→ Page 129).


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7.16.3 Charge-air coolant – Draining


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Sealing ring (→ Spare Parts Catalog)


Draining charge-air coolant1. Provide an appropriate container to drain

the coolant into.2. Turn breather valve of filler neck on coolant



4. Draw off precipitated corrosion inhibitor oilfrom the expansion tank through filler neck.

5. Open drain valves and drain plugs anddrain coolant at the following points:• Charge-air coolant pump• Thermostat housing

6. Draining of residual coolant:• Intercooler

7. Close all drain valves and install drain plugswith new sealing rings.

8. Set breather valve onto filler neck and closeit.


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7.16.4 Charge-air coolant – Filling


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Charge-air coolant


CAUTION Cold coolant in hot engine can cause thermal stress.Formation of cracks in components!• Fill / top up coolant only into cold engine.

Preparatory steps1. Turn breather valve of filler neck on coolant




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Filling with charge-air coolant usingpump

1. Connect a suitable pump with a hose to thedrain valve (arrow).

2. Release union at distributor (arrow).3. Open drain valve and pump coolant into en‐

gine at 0.5 bar minimum.4. Close venting point when coolant emerges

from the released union.5. Fill expansion tank until overflow edge is

reached.6. Close drain valve.7. Check proper condition of breather valve,

clean sealing faces if required.8. Set breather valve onto filler neck and close

it.9. Start engine (→ Page 32).

10. After the engine has run at unloaded condi‐tion for 10 seconds, stop engine(→ Page 35).

11. Turn breather valve of filler neck on coolantexpansion tank counterclockwise to firststop and allow pressure to escape.


13. Check coolant level (→ Page 126) and topup if required:



c) Fit breather valve and close.14. Repeat the steps from "Start engine"

(→ Step 8) until coolant is no longer neededto be topped up.

15. Disconnect pump and hose.


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Alternatively: Filling coolantthrough filler neck

1. Open venting point at distributor (arrow).2. Fill in coolant in expansion tank until the

coolant level at top edge of filler neck re‐mains constant.

3. Close venting point when coolant emerges.4. Check proper condition of breather valve,

clean sealing faces if required.5. Set breather valve onto filler neck and close

until first stop is reached.6. Start engine (→ Page 32).7. After the engine has run at unloaded condi‐

tion for 10 seconds, stop engine(→ Page 35).

8. Turn breather valve counterclockwise andremove.

9. Check coolant level (→ Page 126) and topup if required:

a) Repeat the steps from "Start engine"(→ Step 6) until coolant is no longerneeded to be topped up.


c) Set breather valve onto filler neck andclose it.

Final steps1. Start the engine and operate it at unloaded condition for some minutes.2. Check coolant level (→ Page 126) and top up if required.


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7.16.5 Charge-air coolant pump – Relief bore check



Charge-air coolant pump – Reliefbore check

1. Check relief bore for oil and coolant dis‐charge.

2. Shut down engine (→ Page 35) and disableengine start, observe general safety instruc‐tions “Maintenance and Repair”.

3. Clean the relief bore with a wire if it is dirty.• Permissible coolant discharge: up to 10

drops per hour;• Permissible oil discharge: up to 5 drops

per hour.4. If discharge exceeds the specified limits:

Contact Service.


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7.17 Belt Drive7.17.1 Drive belt – Condition check

Preconditions☑ Engine is stopped and starting disabled.☑ Guard is removed.

Drive belt – Condition check

Item Findings ActionDrive belt A Singular cracks NoneDrive belt Belt is oily, shows signs of over‐

heatingReplace(→ Page 136)

Drive belt B Cracks on entire circumferenceDrive belt C Chunking


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7.18 Battery-Charging Generator7.18.1 Battery-charging generator – Check



Checking battery-charging generatorItem Findings MeasureVentilation area (arrow) Clean NoneVentilation area (arrow) Contaminated Clean

Cleaning battery-charging generatorNote: Dry-clean battery-charging generator only.

1. Remove coarse dirt from battery-charging generator.2. Blow out ventilation area (arrow) with compressed air until all dust is cleared.


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7.18.2 Battery-charging generator drive – Drive belt tension adjustment


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 20-100 Nm F30026582 1Ratchet adapter F30027340 1

WARNING Spring/circlip/tensioning roller preload.Risk of injury!• Only use specified tool and equipment.

Adjusting belt tension1. Undo screw (arrow) and remove protective

cover (3).2. Slacken screws (1) and (2) by half a turn.

Result: Belt tensioner moves against the drive beltand tensions it.

3. Tighten screw (2) to specified torque using a torque wrench.


Screw M10x1.5 Tightening torque 60 Nm +5 Nm

4. Tighten screw (1) to specified torque using a torque wrench.


Screw M10x1.5 Tightening torque 42 Nm

5. Install protective cover (3).


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7.18.3 Battery-charging generator drive – Drive belt and belt tensioner replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 20-100 Nm F30026582 1Ratchet adapter F30027340 1

WARNING Heavy object.Risk of crushing!• Use appropriate lifting devices and appliances.

Replacing drive belt and belttensioner

1. Undo screws (1), (2) and (3).2. Remove protective cover (8).3. Slacken screws (4) and (5) by half a turn.4. Place socket adapter or box wrench on

screw (6) and press belt tensioner in the di‐rection indicated by the arrow as far as itwill go.

5. Tighten screw (4).6. Remove drive belt (7).7. Screw on screw (5) and replace belt ten‐

sioner.8. Fit new drive belt (7).

Tensioning drive belt1. Slacken screw (4) by half a turn.

Result: Belt tensioner moves against the drive belt and tensions it.2. Use torque wrench to tighten screw (4) to specified tightening torque.


Screw M10x1.5 Tightening torque 60 Nm +5 Nm

3. Use torque wrench to tighten screw (5) to specified tightening torque.


Screw M10x1.5 Tightening torque 42 Nm

4. Install protective cover (8).5. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 135).


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7.19 Fan Drive7.19.1 Fan drive – Drive belt check / adjustment


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Optibell 2 belt tension tester Y4345711 1

Preparatory steps1. Remove protective cover.2. Check belt condition visually (→ Page 133).

Result: For drive belt replacement, (→ Page 139).

Checking Vee belt tension1. Switch on belt tension tester.2. Hold measuring tip of belt tension tester over belt drive. Tap drive belt (arrow) with a suitable tool.3. Hold belt tension tester over belt drive until the measured value is indicated.

Initial operation with fan Belt tension adjustment58 Hz ± 5 Hz 51 Hz ± 5 Hz


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Adjusting drive belt tension1. Release screws (2) until fan coupling can

be moved.2. Tighten stud (1) until the required frequency

is achieved.3. Tighten screws (2) to 100 Nm ± 10 Nm.


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7.19.2 Fan drive – Drive belt replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Drive belt (→ Spare Parts Catalog)

Preparatory steps1. Remove protective cover.2. Remove fan.

Replacing drive belt1. Release screws (2).2. Slacken off stud (1) until drive belt can be

removed.3. Clean belt pulleys.4. Fit new drive belt on belt pulleys, ensuring

that it is not under tension.5. Adjust belt tension (→ Page 137).


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7.20 Wiring (General) for Engine/Gearbox/Unit7.20.1 Engine wiring – Check


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Isopropyl alcohol X00058037 1

Engine wiring – Check1. Check securing screws of cable clamps on engine and tighten loose threaded connections.2. Ensure that cables are fixed in their clamps and cannot swing freely.3. Check that cable ties are firm, tighten loose cable ties.4. Replace faulty cable ties.5. Visually inspect the following electrical line components for damage:

• connector housings;• contacts;• sockets;• cables and terminals;• plug-in contacts.

6. (→ Contact Service) if cable conductors are damaged.Note: Close male connectors that are not plugged in with the protective cap supplied.

7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.8. Ensure that all sensor connectors are securely engaged.


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7.21 Accessories for (Electronic) Engine Governor / ControlSystem

7.21.1 Engine governor and connectors – Cleaning


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Isopropyl alcohol X00058037 1

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

Engine governor and connectors – Cleaning1. Remove coarse dirt from housing surface with isopropyl alcohol.2. Remove dirt from connector and cable surfaces with isopropyl alcohol.3. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning severely contaminated connectors on the engine governorNote: Seal unused connectors with the supplied protective cap.

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


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7.21.2 EMU and connectors – Cleaning


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Isopropyl alcohol

EMU and connectors – Cleaning1. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol.2. Remove dirt from connector and cable surfaces with isopropyl alcohol.3. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning severely contaminated EMU connectors1. Release latches of connectors and withdraw connectors.2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.3. When connectors, sockets and all contacts are dry: Fit connectors and secure latches.


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7.21.3 Engine governor – Checking plug-in connections


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

Checking plug-in connections on engine governor1. Check all plug-in connections for secure seating.2. Latch connectors if loose.


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7.21.4 EMU – Checking plug-in connections


EMU – checking plug-in connections1. Verify that all plug-in connections are securely seated.2. Secure loose connectors and latch.


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7.21.5 ECU 7 engine governor – Removal and installation


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 fromengine

1. Note or mark assignment of cables andconnectors.

2. Remove all screws (2).3. Undo latches (3) of the connectors.4. Remove all connectors.5. Remove screws (1).6. Take off engine governor.

Installing engine governor on engine1. Install in reverse order. In doing so, ensure correct assignment of connectors and sockets.2. Check rubber mount before installation.

Result: If the rubber mount is porous or defective, replace it.


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7.21.6 EMU 7 – Removal and installation


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 ECU with EMU fromengine

1. Note or mark assignment of cables andconnectors.

2. Remove all screws (2).3. Undo clips (3) on connectors.4. Disconnect all connectors.5. Remove screws (1).6. Remove ECU (1) with EMU (4).

Removing EMU1. Undo screws on base of EMU (4).2. Remove EMU (4) from ECU (1).

Installing EMU1. Place EMU (4) on ECU (1).2. Screw in and tighten screws on base of EMU (4).

Installing ECU with EMU on engine1. Install in reverse order. Ensure correct assignment of connectors and sockets in so doing.2. Check resilient mount before installing.

Result: Replace resilient mount if porous or defective.


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8 Appendix A8.1 Abbreviations

Abbreviation Meaning ExplanationA/D Analog/Digital Transformer: transforms sensor voltages into

numeric valuesADEC Advanced Diesel Engine Controller Engine management systemAFRS Air Filter Restriction SensorANSI American National Standards Institute Association of American standardization or‐

ganizationsATL Abgasturbolader Exhaust turbocharger (ETC)ATS Air Temperature SensorBR Baureihe SeriesBV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications,

Publication No. A01061/..CAN Controller Area Network Data bus system, bus standardCDC Calibration Drift Compensation Setting of drift compensation in engine gov‐

ernor with DiaSysCEL Stop Engine Light 1st function: Warning lamp (rectify fault as

soon as possible)2nd function: Read out fault codes

CKT CircuitCLS Coolant Level Sensor Monitors coolant levelCPS Coolant Pressure Sensor Monitors coolant pressureCTS Coolant Temperature Sensor Monitors coolant temperatureDDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Die‐

selDDL Diagnostic Data Link Diagnostic linesDDR Diagnostic Data Reader Diagnostic unitDIN Deutsches Institut für Normung e. V. At the same time identifier of German stand‐

ards (DIN = “Deutsche Industrie-Norm”)DL Default Lost Alarm: Default CAN bus failureDOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel

particulate filterDPF Diesel Particulate FilterDT Diagnostic Tool Diagnostic unitECM Electronic Control Module Electronic control unit of the DDEC systemECU Engine Control Unit Engine governorEDM Engine Data Module Memory module for engine dataEEPROM Electrically Erasable Programmable

Read Only MemoryEFPA Electronic Foot Pedal Assembly

MS150054/02E 2012-02 | Appendix A | 147

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Abbreviation Meaning ExplanationEGR Exhaust Gas RecirculationEMU Engine Monitoring UnitETK Ersatzteilkatalog Spare Parts Catalog (SPC)EUI Electronic Unit InjectorFPS Fuel Pressure Sensor Monitors fuel pressureFRS Fuel - Differential Pressure SensorFTS Fuel Temperature Sensor Monitors fuel temperatureFWCP Fire Water Control Panel Control cabinetGND GroundHD Hochdruck High Pressure (HP)HI High Alarm: Measured value exceeds 1st maxi‐

mum limitHIHI High High Alarm: Measured value exceeds 2nd maxi‐

mum limit valueHT High TemperatureIDM Interface Data Module Memory module for interface dataINJ InjectorISO International Organization for Stand‐

ardizationInternational umbrella organization for all na‐tional standardization institutes

KGS Kraftgegenseite Engine free end in accordance with DIN ISO1204

KS Kraftseite Engine driving end in accordance with DINISO 1204

LED Light Emitting DiodeLO Low Alarm: Measured value lower than 1st mini‐

mum limit valueLOLO Low Low Alarm: Measured value lower than 2nd mini‐

mum limit valueLSG Limiting Speed GovernorN/A Not ApplicableLP Low PressureOEM Original Equipment ManufacturerOI Optimized IdleOLS Oil Level Sensor Monitors oil levelOPS Oil Pressure Sensor Monitors oil pressureOTS Oil Temperature Sensor Monitors oil temperatureOT Oberer Totpunkt Top Dead Center (TDC)PAN Panel Control panelPIM Peripheral Interface ModulePWM Modulated signalP-xyz Pressure-xyz Pressure measuring point, xyz specifies the

measuring point designationRL Redundancy Lost Alarm: Redundant CAN bus failure

148 | Appendix A | MS150054/02E 2012-02

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Abbreviation Meaning ExplanationSAE Society of Automotive Engineers U.S. standardization organizationSD Sensor Defect Alarm: Sensor failureSEL Stop Engine Light 1st function: Warning lamp (stop engine and

rectify fault)2nd function: Read out fault codes

SID System IdentifierSRS Synchronous Reference Sensor TDC cylinder 1SS Safety System Safety system alarmTBS Turbocharger Boost Sensor Monitors charge-air pressureTCI Turbo Compressor InletTCO Turbo Compressor OutletTD Transmitter Deviation Alarm: Deviation in transmitter valuesTPS Throttle Position SensorTRS Timing Reference SensorT-xyz Temperature-xyz Temperature measuring point, xyz specifies

the measuring point designationUT Unterer Totpunkt Bottom Dead Center (BDC)VNT Variable Nozzle TurbineVSG Variable-Speed GovernorVSS Vehicle Speed SensorWZK Werkzeugkatalog Tool Catalog (TC)

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8.2 MTU contacts/service partners

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

Local supportExperienced 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 hotlineWith 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 changedoperating conditions, or for spare parts supply.Your contact at Headquarters:[email protected]

Spare parts serviceFast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right sparepart 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 depot at Headquarters, as well as decentralized depots among our subsidiaries, representa‐tives and contractual workshops.Your contact at Headquarters:E-mail: [email protected]: +49 7541 908555Fax: +49 7541 908121

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9 Appendix B9.1 Special Tools

Barring device

Part No.: F6555766Qty.:Used in:

1 7.1.1 Engine – Barring manually (→ Page 63)

Feeler gauge

Part No.: Y20010128Qty.:Used in:

1 7.4.2 Valve clearance – Check and adjustment (→ Page 73)

Filter wrench


1 7.8.1 Fuel filter – Replacement (→ Page 85)

Qty.:Used in:

7.14.1 Engine oil filter – Replacement (→ Page 107)

Qty.:Used in:

1 7.14.4 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 113)

Qty.:Used in:

1 7.15.7 Coolant filter – Replacement (→ Page 125)

Installation/removal tool


1 7.6.2 Injector – Removal and installation (→ Page 79)

Milling cutter



MTU test kit

Part No.: 5605892099/00Qty.:Used in:

1 7.13.3 Engine-oil – Sample extraction and analysis (→ Page 105)

Qty.:Used in:

1 7.15.6 Engine coolant – Sample extraction and analysis (→ Page 124)

Optibell 2 belt tension tester


1 7.19.1 Fan drive – Drive belt check / adjustment (→ Page 137)

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Ratchet adapter


1 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check andreplacement (→ Page 70)

Qty.:Used in:

1 7.18.2 Battery-charging generator drive – Drive belt tension adjustment (→ Page 135)

Qty.:Used in:

1 7.18.3 Battery-charging generator drive – Drive belt and belt tensioner replacement (→Page 136)

Ratchet adapter


1 7.13.2 Engine oil – Change (→ Page 103)

Ratchet with extension


1 7.1.1 Engine – Barring manually (→ Page 63)

Rigid endoscope


1 7.2.1 Cylinder liner – Endoscopic examination (→ Page 66)

Ring socket, 24 mm



Torque wrench 6-50 Nm


1 7.14.4 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 113)

Torque wrench, 0.5-5 Nm

Part No.: 0015384230Qty.:Used in:


Torque wrench, 10-60 Nm


1 1.4 Crankshaft transport locking device (→ Page 8)

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1 7.18.2 Battery-charging generator drive – Drive belt tension adjustment (→ Page 135)

Qty.:Used in:

1 7.18.3 Battery-charging generator drive – Drive belt and belt tensioner replacement (→Page 136)



1 7.13.2 Engine oil – Change (→ Page 103)



1 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check andreplacement (→ Page 70)



1 1.4 Crankshaft transport locking device (→ Page 8)

Qty.:Used in:





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9.2 Index12, 16V 4000 G73 engine data, emissions-optimized

(EPA - Tier 2) 25

AAbbreviations 147Actuators– Overview 21After stopping the engine – Engine remains ready for op‐

eration 37After stopping the engine – putting the engine out of

service 38Air filter– Removal and installation 95– Replacement 94Air starter – Manual operation 101Automatic oil filter– Oil filter candles replacement 108

BBattery-charging generator– Check 134Battery-charging generator drive – Drive belt and belt

tensioner replacement 136Battery-charging generator drive – Drive belt tension ad‐

justment 135

CCentrifugal oil filter – Cleaning and filter-sleeve replace‐

ment 113Charge-air coolant– Change 127– Filling 129– Level check 126Charge-air coolant level– Check 126Charge-air coolant pump– Relief bore check 132Charge-air coolant – Draining 128Connectors– Cleaning 141Contact persons 150Contamination indicator– Signal ring position check 97Coolant - charge air– Level check 126Coolant - charge-air– Change 127Coolant filter– Replacement 125Crankcase breather– Diaphragm check 70– Oil separator element replacement 70Crankshaft transport locking device– Removal/installation 8Cylinder– Designations 19

Cylinder head cover– Removal and installation 76Cylinder liner– Endoscopic examination 66– Instructions and comments on endoscopic and visual

examination 68

DDrive belt– Condition check 133

EECU 7 engine governor– Removal and installation 145Emergency air-shutoff flaps – Functional check with elec‐

tric actuation 98Emergency stop– Engine 36EMU 7– Removal and installation 146EMU and connectors – Cleaning 142EMU – Checking plug-in connections 144Engine– Barring manually 63– Barring with starting system 64– Emergency stop 36– Test run 65– Wiring check 140Engine coolant– Change 117– Filling 120– Level check 116– Sample extraction and analysis 124Engine coolant pump– Relief bore check 123Engine coolant – Draining 118Engine governor– Checking plug-in connections 143– Cleaning 141Engine governor ADEC (ECU 7) for Series 4000 Oil

&Gas engines – Fault messages 43Engine layout 20Engine oil– Change 103Engine oil filter– Replacement 107Engine oil level– Check 102Engine side– Designations 19Engine wiring– Check 140Engine – Main dimensions 29Engine-oil – Sample extraction and analysis 105

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FFan drive– Drive belt check / adjustment 137– Drive belt replacement 139Fire prevention and environmental protection 16Firing order 28Fluids and lubricants 16Fuel– Prefilter

– Flushing 89Fuel filter– Replacement 85Fuel prefilter– Differential pressure gauge

– Check and adjustment 87– Draining 88– Filter element

– Replacement 91– Flushing 89Fuel prefilter cleaning 86Fuel system– Venting 84

GGeneral conditions 5

HHP pump– Filling with engine oil 77

IInjector– Removal and installation 79– Replacement 78Injectors– Overview 21Inspection port cover– Explosion hazard 12Intercooler– Drain, coolant leakage 93

MMaintenance and repair work– Safety regulations 13MTU contact persons 150

OOil indicator filter – Check 111Operational checks 34

PPersonnel and organizational requirements 6Putting engine into operation– Preparation after extended out-of-service periods (>3

months) 30Putting into operation– After scheduled out-of-service period

– Preparation 31

Putting the engine into operation after scheduled out-of-service-period 31

RRubber sleeves between air intake elbow and turbo‐

charger– Replacement 96Rubber sleeves in air pipework before intercooler– Replacement 99

SSafety instructions 18Sensors– Overview 21Service partners 150Start engine in manual mode (testing mode) 32Starting the engine in emergency situations (override

mode) 33Startup and operation– Safety regulations 11Stop engine in manual mode (testing mode) 35

TTransport 7Troubleshooting 40

VValve clearance– Adjustment 73– Check 73Valve gear– Lubrication 72

WWiring - engine– Check 140

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operating instructions diesel engine · 2018-02-01 · written permission of mtu friedrichshafen...

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