MTU Technical Documentation

MTU_ValueService
Technical Documentation
Diesel engine
12 V 4000 P63, P83
16 V 4000 P63, P83
20 V 4000 P63, P83
Application group 3A
Operating Instructions
MS150051/01E
Printed in Germany
2011 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation,
microfilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Commissioning Note
Important
Please complete and return the Commissioning Note card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support
(warranty, spare parts, etc.).
Postcard
MTU Friedrichshafen GmbH
Technical Information Management
Dept. VOT
88040 Friedrichshafen
GERMANY

Commissioning Note
Please use block capitals!
Engine No.: MTU works order no.:

Commissioning
Note
Engine model: Date put into operation:
*
Application : * Type : Tick appropriate box
Marine Rail
Genset ......................... Manufacturer:
End user`s address:
Remarks:
Table of Contents MS150051/01E
1 Safety 9
1.1 General conditions 9
1.2 Personnel and organizational requirements 10
1.3 Transport 11
1.4 Crankshaft transport locking device 12
1.5 Safety regulations for startup and operation 15
1.6 Explosion hazard when removing inspection port cover on engine 16
1.7 Safety regulations for maintenance and repair work 17
1.8 Auxiliary materials, fire prevention and environmental protection 19
1.9 Conventions for safety instructions in the text 21
1.10 ATEX (where applicable) 22
2 General Information 23
2.1 Engine layout 23
2.2 Engine side and cylinder designations 24
2.3 Sensors, actuators and injectors Overview 25
3 Technical Data 31
3.1 12 V 4000 P63, P83 engine data 31
3.2 16 V 4000 P63, P83 engine data 35
3.3 20 V 4000 P63, P83 engine data 38
3.4 Firing order 41
3.5 Engine Main dimensions 42
4 Operation 43
4.1 Putting the engine into operation after extended out-of-service-periods (>3 months) 43
4.2 Putting the engine into operation after scheduled out-of-service-period 44
4.3 Start engine in manual mode (testing mode) 45
4.4 Starting the engine in emergency situations (override mode) 46
4.5 Operational checks 47
4.6 Stop engine in manual mode (testing mode) 48
4.7 Emergency stop 49
4.8 After stopping the engine putting the engine out of service 50
4.9 Plant Cleaning 51
5 Maintenance 53
5.1 Maintenance task reference table [QL1] 53
MTU Friedrichshafen GmbH 2011-04 5

MS150051/01E Table of Contents
6 Troubleshooting 55
6.1 Troubleshooting 55
6.2 Engine governor ADEC (ECU 7) for Series 4000 Oil &Gas engines Fault messages 58
7 Task Description 75
7.1 Engine 75
7.1.1 Engine Barring manually 75
7.1.2 Engine Barring with starting system 76
7.1.3 Engine test run 77
7.2 Cylinder Liner 78

7.2.1 Cylinder liner Endoscopic examination 78
7.2.2 Instructions and comments on endoscopic and visual examination of cylinder lin 80
ers
7.3 Crankcase Breather 81

7.3.1 Crankcase breather Oil separator replacement, diaphragm check and replace 81
ment
7.4 Valve Drive 83

7.4.1 Valve gear Lubrication 83
7.4.2 Valve clearance Check and adjustment 84
7.4.3 Cylinder head cover Removal and installation 89
7.5 Injection Pump / HP Pump 90

7.5.1 HP fuel pump Filling with engine oil 90
7.6 Injection Valve / Injector 91

7.6.1 Injector Replacement 91
7.6.2 Injector Removal and installation 92
7.7 Fuel System 98

7.7.1 Fuel system Venting 98
7.8 Fuel Filter 99

7.8.1 Fuel filter Replacement 99
7.8.2 Fuel prefilter Draining 100
7.8.3 Fuel prefilter Flushing 102
7.8.4 Fuel prefilter filter element replacement 104
7.8.5 Fuel prefilter Differential pressure check and adjustment of gauge 106
7.9 Charge-Air Cooling 107

7.9.1 Intercooler checking condensate drains for coolant discharge and obstruction 107
7.10 Air Filter 108

7.10.1 Air filter Replacement 108
7.10.2 Air filter Removal and installation 109
7.11 Air Intake 110

7.11.1 Service indicator Signal ring position check 110
7.12 Starting Equipment 111

7.12.1 Air starter Manual operation 111
7.13 Lube Oil System, Lube Oil Circuit 112
6 2011-04 MTU Friedrichshafen GmbH

Table of Contents MS150051/01E
7.13.1 Engine oil Level check 112

7.13.2 Engine oil Change 113
7.13.3 Engine oil Sample extraction and analysis 115
7.14 Oil Filtration / Cooling 116

7.14.1 Automatic oil filter Filter candles replacement 116
7.14.2 Oil indicator filter Check 119
7.14.3 Centrifugal oil filter Cleaning and filter-sleeve replacement 121
7.15 Coolant Circuit, General, High-Temperature Circuit 123

7.15.1 Engine coolant Level check 123
7.15.2 Engine coolant - Change 124
7.15.3 Engine coolant Draining 125
7.15.4 Engine coolant Filling 127
7.15.5 Engine coolant pump Relief bore check 130
7.15.6 Coolant filter Replacement 131
7.15.7 Engine coolant Sample extraction and analysis 132
7.16 Low-Temperature Circuit 133

7.16.1 Charge-air coolant Level check 133
7.16.2 Charge-air coolant Change 134
7.16.3 Charge-air coolant Draining 135
7.16.4 Charge-air coolant Filling 136
7.16.5 Charge-air coolant pump Relief bore check 139
7.17 Engine Mounting / Support 140

7.17.1 Engine mounting Check 140
7.18 Belt Drive 141

7.18.1 Drive belt Condition check 141
7.19 Battery-Charging Generator 142

7.19.1 Battery-charging generator Check 142
7.19.2 Battery-charging generator drive Drive belt tension adjustment 143
7.19.3 Battery-charging generator drive Drive belt and belt tensioner replacement 144
7.19.4 Battery-charging generator - Removal and installation 145
7.20 Wiring (General) for Engine/Gearbox/Unit 147
7.20.1 Engine wiring Check 147
7.21 Accessories for (Electronic) Engine Governor / Control System 148

7.21.1 Engine governor Checking plug-in connections 148
7.21.2 Engine governor and connectors Cleaning 149
8 Appendix A 151
8.1 Abbreviations 151
8.2 MTU Contact/Service partners 153
9 Appendix B 155
9.1 Special Tools 155
9.2 Index 156

MS150051/01E Table of Contents

Safety MS150051/01E
1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory reg
ulations regarding accident prevention must be observed. This state-of-the-art engine has been designed to meet all
applicable laws and regulations. The engine may nevertheless present a risk of injury or damage in the following
cases:
Incorrect use
Operation, maintenance and repair by unqualified personnel
Modifications or conversions
Non-compliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envisaged for it on
delivery. Any other use is considered improper use. The engine manufacturer accepts no liability whatsoever for
resultant damage or injury in such case. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. The engine manufacturer accepts
no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided
in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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MS150051/01E Safety
1.2 Personnel and organizational requirements

Personnel requirements
All work on the engine shall be carried out by trained and qualified personnel only.
The specified legal minimum age must be observed.
The operator must specify the responsibilities of the operating, maintenance and repair personnel.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and transport
personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on explaining
safety-relevant instructions.
This is particularly important in the case of personnel which only occasionally performs work on or around the engine.
This personnel must be instructed repeatedly.
For the identification and layout of the spare parts during maintenance or repair work, take photos or use the spare
parts catalog.
Working clothes and protective equipment
Wear proper protective clothing for all work.
Use the necessary protective equipment for the given work to be done.
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Safety MS150051/01E
1.3 Transport
Engine transport
Lift the engine only with the lifting eyes provided.

Use only the transport and lifting equipment approved by MTU.
Take note of the engine center of gravity.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the transport pallet or
transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and engine
mounts.
Secure the engine against tilting during transportation. The engine must be especially secured against slipping or
tilting when going up or down inclines and ramps.
Setting the engine down after transport
Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.
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MS150051/01E Safety
1.4 Crankshaft transport locking device

Special tools
Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30510423 1
Material
Engine oil
Transport locking device

Note:
The locking device protects the crankshaft bearings from shocks and vibration damage during engine transport.
For installation and removal of the transport locking device, follow the instructions below:
1. The transport locking device must remain installed as long as possible during engine installation in order to avoid
damage.
2. Starting or barring the engine is allowed only with the transport locking device removed. If the generator is already
mounted on the engine, ensure that the transport locking device of the generator is also removed.
3. Prior to every engine transport, the transport locking device must be reinstalled on both sides according to the
instructions.
4. If the engine is to be moved together with the generator, the transport locking device for the generator must also
be installed.
Removing guard plates and engine mounting brackets (if applicable) on driving end (KS)
1. Remove screws (4) om both sides and take off with
washers (3), guard plates (1) and engine mounting
brackets (2).
2. Store the removed parts of the transport locking
device carefully for possible reuse.
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Note:
Always use the screws supplied with or installed in the transport locking device to secure it on the engine.

Safety MS150051/01E
Fitting the transport locking device on driving end (KS)

1. Secure the two plates (2) with screws (6) and wash
ers (5) at the bores on both sides of the flywheel
housing and tighten to the specified tightening tor
que.
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 locking device from driving end (KS)

1. Release the locknuts (3) on both sides of the 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 transport locking
device carefully for possible reuse.
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MS150051/01E Safety
Note:
Always use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure
them on the engine.
Installing guard plates and engine mounting brackets (if applicable) on driving end (KS)
1. Install engine mounting brackets (2) on both sides
with guard plates (1) washers (3), and screws (4).
2. Tighten screws (4).
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Safety MS150051/01E
1.5 Safety regulations for startup and operation

Safety precautions when putting the equipment into operation
Prior to initial operation of the unit, install the assembly or unit according to the specifications and check the installation
according to the MTU specifications.
Before putting the device or the unit into operation, always ensure:
that all maintenance and repair work is completed,
that all loose parts have been removed from rotating machine components,
that all persons are clear of the danger zone of moving machine components.
Immediately after putting the device or system into operation, make sure that all control and display instruments as
well as the signaling and alarm systems work properly.
Safety precautions for operation
Emergency procedures must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to present
operating status, violation of limit values and warning or alarm messages.
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 operation
The 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 pipework 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 equipment
When operating electrical equipment, certain components of this equipment are live.
Observe the safety instructions for these devices.
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MS150051/01E Safety
1.6 Explosion hazard when removing inspection port cover on engine

Cautions
Explosion hazard due to oil vapors.
Risk of serious injury - danger to life!
DANGER Allow the engine to cool down before opening the crankcase!
Avoid naked flames, electrical sparks and ignition sources.
Safety instructions
1. 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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Safety MS150051/01E
1.7 Safety regulations for maintenance and repair work

Safety regulations for maintenance and repair work
Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing vent screws or plugs from engine. In order to avoid discharge of highly pres
surized liquids, hold a cloth over the screw or plug.
Take special care when draining hot fluids Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately venti
lated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do so.
Lock-out/tag-out the engine to preclude undesired 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 air starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other components to avoid
contact with them. 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 properly
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 components 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 assembly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. After completing work on the
engine, check that all protective devices/safety guards have been installed and that all tools and loose parts
have been removed from 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 hazards caused
by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or the starter with com
pressed air. Clean the flywheel housing inside with a class H dust extraction device as an additional measure.
Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when welding in
its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise
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induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal
Check the function and safe operating condition of tools and fixtures to be used. Use only the specified fixtures for
hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.

MS150051/01E Safety
Do not attempt to bend or apply force to lines.

Before starting work, pay attention to the following:
Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the equipment to
be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
For hydraulic installation, screw on the tool with the piston retracted.
For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft end until
correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the component
to be installed/removed.
Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair work or switching
off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that cabling is not damaged during operation
by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack defective elec
tronic components and assemblies in a suitable manner when dispatched for repair, i.e. particularly protected against
moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles Heavily focused radiation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to type and appli
cation.
For conducting light-beam procedures and measurement work, only the following laser devices must be used:
Laser devices of classes 1, 2 or 3A.
Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a
maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
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Safety MS150051/01E
1.8 Auxiliary materials, fire prevention and environmental protection

Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires - therefore
always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying on or near the
assembly or unit. Do not store inflammable material near the assembly or unit.
Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first. To avoid
sparks in the vicinity of the battery, connect the ground lead from the external power source to the ground lead of the
engine or to the ground terminal of the starter.
Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating danger are
drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal
Modification or removal of mechanical or electronic components or the installation of additional components as well
as the execution of calibration processes that might affect the emission characteristics of the engine are prohibited
by emission regulations. Emission control units/systems may only be maintained, exchanged or repaired if the com
ponents used for this purpose are approved by MTU or equivalent components. Noncompliance with these guidelines
might represent a violation of the Clean Air Act and involves the termination of the operating license by the emission
authorities. MTU does not accept any liability for violations of the emission regulations. MTU will provide assistance
and advice if emission-relevant components are intended to be modified. The MTU Maintenance Schedules ensure
the reliability 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 Friedrichshafen / MTU Onsite Energy, where they are
subjected to proper recycling procedures.
Auxiliary materials
Use 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 and other chemical
substances, follow the safety instructions that apply to the product. Take special care when using hot, chilled or caustic
materials. When using flammable materials, avoid all sparks and do not smoke.
Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.
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.
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Switch on extraction system.

Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:

MS150051/01E Safety
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 permitted pres
sure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve
(set to permitted pressure) must form an intermediate connection.
Hose couplings and connections must be securely attached.
Wear goggles when blowing off components or blowing away chips.
Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
First shut off compressed air lines before compressed air equipment is disconnected from the supply line, or
before equipment or tool is to be replaced.
Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers,
results in a risk of explosion.
Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying
purposes or to check for leaks, results in a risk of bursting.
Carry out leak test in accordance with the specifications.
Painting
When painting in other than spray booths equipped with extractors, ensure good ventilation. 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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Safety MS150051/01E
1.9 Conventions for safety instructions in the text

Cautions
In the event of immediate danger
Consequences: Death or serious injury.
DANGER Preventive measures
In the event of possibly dangerous situations.

Consequences: Death or serious injury.
WARNING Preventive measures
In the event of dangerous situations.

Consequences: Slight injury or material damage.
CAUTION Preventive measures
Note:
This publication contains especially emphasized safety instructions in accordance with the American standard ANSI
Z535, which begin with one of the above signal words according to the degree of danger:
Safety notes
1. Read and familiarize yourself with all safety warnings 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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MS150051/01E Safety
1.10 ATEX (where applicable)

The following additional precautions must be taken to comply with the requirements of the ATEX explosion protection
directives:
Unoccupied connections for the wiring harness must be sealed with protective caps.
The two limit switches for the position of the flywheel (start lock) must have an intrinsically safe supply or be
removed.
The entire engine wiring harness must be covered with metal guards to protect it from mechanical impact and
UV radiation.
Continuous power supply to the engine must be ensured when the engine is in the hazardous zone.
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General Information MS150051/01E
2 General Information
2.1 Engine layout
Illustration is also valid for 12/16/20V engines
1 Oil cooler 9 Lifting eye 17 Fuel filter

2 Crankcase breather 10 Starter 18 Oil pan
3 Combustion air inlet connection 11 Charge-air pipe 19 HP fuel pump
4 Exhaust turbocharger 12 Engine mounting 20 Automatic oil filter
5 Exhaust gas outlet connection 13 Oil filler neck 21 Coolant filter
6 Engine governor 14 Cylinder head 22 Centrifugal oil filter
7 Intercooler 15 Exhaust pipe
8 Flywheel 16 Fuel priming pump
Engine model designation

Key to the engine model designations 12/16/20V 4000 Pxy
12/16/20 Number of cylinders
V Cylinder arrangement: V engine
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4000 Series
P Application
x Application segment (6,8 )
y Design index (3)

MS150051/01E General Information
2.2 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 ISO 1204). The
cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
1 KGS = Free end 3 KS = Driving end

2 Right engine side 4 Left engine side
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2.3 Sensors, actuators and injectors Overview

Illustrations are also applicable to 12/16/20 V
Item Description Monitoring of

1 B13.2 (option) Crankshaft speed
2 S37.2 Start interlock, B side
3 S37.1 Start interlock, A side
4 B13.1 Crankshaft speed
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1 F46 Fuel leak
2 B34.1 Fuel pressure after filter
3 B34.2 Fuel pressure before filter
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1 B50 Crankcase pressure
2 B05.3 Engine oil pressure before filter
3 B05.1 Engine oil pressure
4 B33 Fuel temperature (rail)
5 B48 Fuel pressure (rail)
6 B01 Camshaft speed
7 B43 Charge-air coolant pressure
8 B26 Charge-air coolant temperature
9 B06.1 Coolant temperature
10 B06.2 (option) Coolant temperature
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1 B44 Turbocharger speed
2 B16 Coolant pressure
3 B10 Charge-air pressure
4 B09 Charge-air temperature
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1 B04.1 to B04n (option) Exhaust temperature after cylinder, A side
2 B04.21 Exhaust bulk temperature, A side
3 B.03 Intake air temperature
4 B05.2 (option) Engine oil pressure
5 B07 Engine oil temperature
6 B04.22 Exhaust bulk temperature, B side
7 B04.10 to B04nn (option) Exhaust temperature after cylinder, B side
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Technical Data MS150051/01E
3 Technical Data
3.1 12 V 4000 P63, P83 engine data
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
Reference conditions
Engine model 12V4000 P63 12V4000 12V4000 P83 12V4000 P83
TAL opti P63 IMO Tier IMO IMO Tier II
mized II
Application group 3A 3A 3A 3A
Intake air temperature C 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 12 12 12 12
Rated engine speed A rpm 1500 1500 1800 1800
Continuous power ISO 3046 (10% over A kW 1350 1350 1455 1455
load capability, design power DIN 6280,
ISO 8528)
GENERAL CONDITIONS (for maximum power)

Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 50 50 50 30
Exhaust overpressure A mbar 30 30 30 30
Exhaust overpressure, max. L mbar 85 85 85 85
MODEL RELATED DATA (basic design)

TIM ID: 0000022492 - 001
Cylinder arrangement: V angle Degrees () 90 90 90 90

Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77 4.77
Total displacement Liters 57.2 57.2 57.2 57.2

MS150051/01E Technical Data
Compression ratio 16.4 16.4 16.4 16.4
Number of inlet valves per cylinder 2 2 2 2
Number of exhaust valves per cylinder 2 2 2 2
COMBUSTION AIR / EXHAUST GAS

Charge air pressure before cylinder, BL R bar abs 2.7 2.7 2.9 2.8
COOLANT SYSTEM (HT circuit)

Coolant temperature (at engine connec A C 100 100 100 95
tion: outlet to cooling system)
Coolant temperature after engine, warning R C 102 102 102 102
Coolant temperature after engine, shut L C 104 104 104 104
down
Coolant antifreeze content, max. L % 50 50 50 50
Pressure loss in off-engine cooling sys L bar 0.7 0.7 0.7 0.7
tem, max.
COOLANT SYSTEM (LT circuit)

Coolant temperature before intercooler (at A C 45 45 45 45
engine connection: inlet from cooling sys
tem)
Coolant antifreeze content, max. L % 50 50 50 50
Pressure loss in off-engine cooling sys L bar 0.7 0.7 0.7 0.7
tem, max.
LUBE-OIL SYSTEM
Lube oil operating temperature before R C 90 86 92 92
engine, from
Lube oil operating temperature before R C 93 90 95 95
engine, to
Lube oil temperature before engine, warn R C 99 99 99 99
ing
Lube oil temperature before engine, shut L C 102 102 102 102
TIM ID: 0000022492 - 001
down
Lube oil operating pressure before engine 5.6 5.1 6.2 5.7
(measurement block)
Lube oil operating pressure before engine, R bar 5.1 4.0 5.7 4.5
from

Lube oil operating pressure before engine, R bar 6.1 6.0 6.7 6.5
to
FUEL SYSTEM
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
GENERAL OPERATING DATA

Cold start capability: air temperature (w/o R C 0 0 0 0
start aid. w/o preheating) - (case A)
Coolant preheating: preheating tempera R C 40 40 35 35
ture (min.)
Firing speed, from R rpm 80 80 80 80
Firing speed, to R rpm 120 120 120 120
CAPACITIES
Engine coolant, engine side (without cool R Liters 212 212 212 212
ing system)
Charge-air coolant, engine side R Liters 47 47 47 47
Engine oil on initial filling (standard oil sys R Liters 245 245 245 245
tem) (option: max. operating inclinations)
Oil change quantity, max. (standard oil sys R Liters 190 190 190 190
tem) (option: max. operating inclinations)
Oil pan capacity at dipstick mark min. L Liters 150 150 150 150
(standard oil system) (option: max. operat
ing inclinations)
Oil pan capacity at dipstick mark max. L Liters 190 190 190 190
(standard oil system) (option: max. operat
ing inclinations)
WEIGHTS / MAIN DIMENSIONS

Engine weight, dry (basic engine config R kg 7300 7300 7300 7300
TIM ID: 0000022492 - 001
uration acc. to scope of delivery specifi

cation)

ACOUSTICS
Exhaust noise, unsilenced - DL (sound R dB(A) 123 123 124 124
power level LW, ISO 6798+3dB(A)
TIM ID: 0000022492 - 001

3.2 16 V 4000 P63, P83 engine data

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 16V4000 P63 16V4000 P83
TAL optimized IMO
Application group 3A 3A
Intake air temperature C 25 25
Charge-air coolant temperature C 45 45
Barometric pressure mbar 1000 1000
Site altitude above sea level m 100 100
Number of cylinders 16 16
Rated engine speed A rpm 1500 1800
Continuous power ISO 3046 (10% overload capability, design A kW 1800 1940
power DIN 6280, ISO 8528)

Intake depression (new filter) A mbar 15 15
Intake depression, max. L mbar 50 50
Exhaust overpressure A mbar 30 30
Exhaust overpressure, max. L mbar 85 85

Cylinder arrangement: V angle Degrees () 90 90
Bore mm 170 170
TIM ID: 0000022516 - 001
Stroke mm 210 210

Cylinder displacement Liters 4.77 4.77
Total displacement Liters 76.3 76.3
Compression ratio 16.4 16.4
Number of inlet valves per cylinder 2 2

Number of exhaust valves per cylinder 2 2

Charge air pressure before cylinder, BL R bar abs 2.9 3.1

Coolant temperature (at engine connection: outlet to cooling sys A C 100 100
tem)
Coolant temperature after engine, warning R C 102 102
Coolant temperature after engine, shutdown L C 104 104
Coolant antifreeze content, max. L % 50 50
Pressure loss in off-engine cooling system, max. L bar 0.7 0.7

Coolant temperature before intercooler (at A C 45 45
engine connection: inlet from cooling sys
tem)
Pressure loss in off-engine cooling system, L bar 0.7 0.7
max.
LUBE-OIL SYSTEM
Lube oil operating temperature before engine, from R C 82 85
Lube oil operating temperature before engine, to R C 92 95
Lube oil temperature before engine, warning R C 99 99
Lube oil temperature before engine, shutdown L C 102 102
Lube oil operating pressure before engine, from R bar 4 4.5
Lube oil operating pressure before engine, to R bar 5.5 6
FUEL SYSTEM
Fuel pressure at engine inlet connection, min. (when engine is L bar -0.1 -0.1
TIM ID: 0000022516 - 001
starting)
Fuel pressure at engine inlet connection, max. (when engine is L bar 1.5 1.5
starting)


Coolant preheating: preheating temperature (min.) R C 35 35
Firing speed, from R rpm 80 80
Firing speed, to R rpm 120 120
CAPACITIES
Engine coolant, engine side (without cooling system) R Liters 260 260
Charge-air coolant, engine side R Liters 50 50
Engine oil on initial filling (standard oil system) (option: max. oper R Liters 300 300
ating inclinations)
Oil change quantity, max. (standard oil system) (option: max. oper R Liters 240 240
ating inclinations)
Oil pan capacity at dipstick mark min. (standard oil system) L Liters 210 210
(option: max. operating inclinations)
Oil pan capacity at dipstick mark max. (standard oil system) L Liters 240 240

Engine weight, dry (basic engine configuration acc. to scope of R kg 8800 8800
delivery specification)
ACOUSTICS
Exhaust noise, unsilenced - DL (sound power level LW, ISO R dB(A) 124 125
6798+3dB(A)
Engine surface noise with attenuated intake noise (filter) - DL R dB(A) 128 128
(sound power level LW, ISO 6798+2dB(A) tolerance)
TIM ID: 0000022516 - 001

3.3 20 V 4000 P63, P83 engine data

Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 20V4000 P63 20V4000 P83
TAL optimized IMO
Application group 3A 3A
Intake air temperature C 25 25
Charge-air coolant temperature C 45 45
Barometric pressure mbar 1000 1000
Site altitude above sea level m 100 100
Rated engine speed A rpm 1500 1800
Continuous power ISO 3046 (10% overload capability, design A kW 2245 2425
power DIN 6280, ISO 8528)

Intake depression (new filter) A mbar 15 15
Intake depression, max. L mbar 50 50
Exhaust overpressure A mbar 30 30
Exhaust overpressure, max. L mbar 85 85

Cylinder arrangement: V angle Degrees () 90 90
Bore mm 170 170
TIM ID: 0000022523 - 001
Stroke mm 210 210

Cylinder displacement Liters 4,77 4,77
Total displacement Liters 95,5 95,5
Compression ratio 16.4 16.4
Number of inlet valves per cylinder 2 2

Number of exhaust valves per cylinder 2 2

Charge air pressure before cylinder, BL R bar abs 2,9 2.9

Coolant temperature (at engine connection: outlet to cooling sys A C 100 100
tem)
Coolant temperature after engine, warning R C 102 102
Coolant temperature after engine, shutdown L C 104 106
Pressure loss in off-engine cooling system, max. L bar 0,7 0,7

Coolant temperature before intercooler (at engine connection: inlet A C 45 45
from cooling system)
Pressure loss in off-engine cooling system, max. L bar 0,7 0,7
LUBE-OIL SYSTEM
Lube oil operating temperature before engine, from R C 88 88
Lube oil operating temperature before engine, to R C 98 98
Lube oil temperature before engine, warning R C 99 99
Lube oil temperature before engine, shutdown L C 102 102
Lube oil operating pressure before engine, from R bar 4,5 4,5
Lube oil operating pressure before engine, to R bar 6 6
FUEL SYSTEM
Fuel pressure at engine inlet connection, min. (when engine is L bar -0,1 -0,1
starting)
Fuel pressure at engine inlet connection, max. (when engine is L bar 1,6 1,6
TIM ID: 0000022523 - 001
starting)

Coolant preheating: preheating temperature (min.) R C 33 35

Firing speed, from R rpm 80 80
Firing speed, to R rpm 120 120
CAPACITIES
Engine coolant, engine side (without cooling system) R Liters 290 290
Charge-air coolant, engine side R Liters 70 70
Engine oil on initial filling (standard oil system) (option: max. oper R Liters 335 335
ating inclinations)
Oil change quantity, max. (standard oil system) (option: max. oper R Liters 300 300
ating inclinations)
Oil pan capacity at dipstick mark min. (standard oil system) L Liters 205 205
Oil pan capacity at dipstick mark max. (standard oil system) L Liters 300 300

Engine weight, dry (basic engine configuration acc. to scope of R kg 10680 10680
delivery specification)
ACOUSTICS
Exhaust noise, unsilenced - DL (sound power level LW, ISO R dB(A) 123 124
6798+3dB(A)
Engine surface noise with attenuated intake noise (filter) - DL R dB(A) 105 109
(sound power level LW, ISO 6798+2dB(A) tolerance)
TIM ID: 0000022523 - 001

3.4 Firing order

Firing order
Number of Firing order
cylinders
8V A1-B4-A4-A2-B3-A3-B2-B1
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
TIM ID: 0000002796 - 002

3.5 Engine Main dimensions

Main engine dimensions
Length (A) 12V approx. 2650 mm

Width (B) 12, 16, 20V approx. 1580 mm
Height (C) 12, 16, 20V approx. 2060 mm
TIM ID: 0000010033 - 002

Operation MS150051/01E
4 Operation
4.1 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 the engine into operation after extended out-of-service-periods (>3 months)
Item Task
Engine Depreserve ( MTU Fluids and Lubricants Specifications A001061/..).
Valve drive Lubricate valve gear every 6 months ( Page 83).
Lube oil system Check engine oil level ( Page 112).
Fuel prefilter Fill with fuel (if fitted).
Coolant circuit If engine is out of service for more than one year, change engine coolant ( Page 124);
Change charge-air coolant ( Page 134).
Coolant circuit Check engine coolant level ( Page 123);
Check charge-air coolant level ( Page 133).
Coolant circuit Preheat coolant with preheating unit, if fitted.
Engine governor Check plug-in connections ( Page 148).
HP fuel pump Only for engines without oil priming pump:
Fill HP fuel pump with new engine oil ( Page 90).
TIM ID: 0000002200 - 001

MS150051/01E Operation
4.2 Putting the engine into operation after scheduled out-of-service-period

Preconditions
Putting into operation
Item Action
Lube oil system Check engine oil level ( Page 112).
Coolant circuit Check engine coolant level ( Page 123), check charge-air coolant level ( Page 133).
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.
TIM ID: 0000010642 - 002

4.3 Start engine in manual mode (testing mode)

Preconditions
Generator (if provided) not connected to network.
External start interlock is not activated.
Cautions
Unguarded rotating and moving engine components.
Risk of serious injury danger to life!
DANGER Before barring or starting the engine, make sure that nobody is in the danger zone.
Engine noise above 85 dB (A).

Risk of damage to hearing!
WARNING Wear ear protectors.
Preparation
Item Task
Operating mode selector switch (if Change to manual mode.
provided)
Preheating pump (if provided) Switch ON.
Starting the engine
Item Task
Switchgear cabinet, control panel If coolant temperature is
etc. (depending on manufacturer) > 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 operating temperature )
Item Task
Switchgear cabinet, control panel Close the generator circuit breaker.
etc. (depending on manufacturer)
Engine Apply full load only after engine has reached operating temperature (coolant temperature
approx. 75 C).
TIM ID: 0000002226 - 001

4.4 Starting the engine in emergency situations (override mode)

Cautions
Safety functions and engine shutdown alarms will be disregarded.
Serious damage to plant!
CAUTION Initiate emergency start only in emergency situations.
Preparation
Item Task
Operating mode switch Set to emergency mode.
Starting the engine in emergency situations
Item Task
Control 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 completed.
Connecting the generator (if fitted) to mains
Item Task
Control cabinet If generator is not connected to mains: Close generator circuit breaker.
Engine Operate engine at rated power.
TIM ID: 0000010665 - 001

4.5 Operational checks

Cautions
DANGER Take special care when working on a running engine.

Operational checks
Item Task
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine oil Check engine oil level ( Page 112).
Engine operation Check engine visually for leaks and general condition;
Check for abnormal running noise, exhaust discoloration and vibrations ( Page 55).
Battery-charging generator Check battery-charging generator for contamination, clean as necessary ( Page 142).
Air filter Check differential pressure indication at gauge (if fitted).
Exhaust system Check exhaust color ( Page 55).
Fuel prefilter Drain water and contaminants at the drain cock of fuel prefilter (if fitted) ( Page 100)
Check reading on vacuum gauge of fuel prefilter (if fitted).
Intercooler Check condensate drain(s) for water discharge and obstruction ( Page 107).
Engine coolant pump Check relief bore ( Page 130).
Charge-air coolant pump Check relief bore ( Page 139).
TIM ID: 0000028413 - 001

4.6 Stop engine in manual mode (testing mode)

Preconditions
Generator (if provided) not connected to network.
Engine is running in manual mode.
Cautions
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
CAUTION 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 Task
Engine 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 Task
Engine Allow to cool down for approx. 5 minutes at reduced engine speed. Observe natural reso
nance of engine (installation-dependent)!
Stopping the engine
Item Task
Switchgear cabinet, control panel Press stop button.
etc. (depending on manufacturer) Automatic stopping sequence is performed;
Engine is stopped.
After stopping the engine
Item Task
Coolant pump Allow to run on for sufficient time after stopping.
TIM ID: 0000002285 - 001

4.7 Emergency stop

Cautions
An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to components!
CAUTION Initiate emergency stop only in emergency situations.
Emergency stop
Item Action
Emergency stop pushbutton 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 stop
Item Action
Switchgear cabinet, control panel Press pushbutton for alarm acknowledgment.
etc. (depending on manufacturer) Audible and visual signalization stops.
Engine Manually open emergency air shutoff flaps (if provided).
Engine is ready for starting.
TIM ID: 0000002307 - 002

4.8 After stopping the engine putting the engine out of service
Preconditions
MTU Fluids and Lubricants Specifications (A001061/..) is available.
After stopping the engine
Item Task
Cooling system Drain engine coolant ( Page 125);
Drain charge-air coolant ( Page 135) 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 temperature;
antifreeze concentration is 50 % and engine-room temperature is below -40C.
Engine/generator/pump controller Switch OFF.
Air intake and exhaust system If the engine is to remain out of service for more than 1 week, seal the engine's air and exhaust
sides. If the engine is to remain out of service for more than 1 month, preserve engine
( MTU Fluids and Lubricants Specifications A001061/.. ).
TIM ID: 0000002706 - 001

4.9 Plant Cleaning

Preconditions
Operating voltage is not applied.
Special tools
Steam jet cleaner - 1
Material
Cleaner (Hakupur 312) 30390 1
Cautions
Compressed air
Risk of injury!
WARNING Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
Water jet.
Risk of injury and scalding!
WARNING Do not direct water jet at persons.
Wear protective clothing, gloves, and goggles / safety mask.
Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION Observe manufacturer's instructions.
Plant Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit care
fully and observe the safety precautions.
3. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
4. Carry out external cleaning as follows:
4.1 Remove coarse dirt.
4.2 Spray on cleaner sparingly and leave it for 1 to 5 minutes.
4.3 Use the high-pressure jet to remove the loosened dirt.
4.4 During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must
be observed. The temperature of the cleaning medium must not exceed 80C.
TIM ID: 0000010171 - 011

TIM ID: 0000010171 - 011

Maintenance MS150051/01E
5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance
Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
Task
W0500 ( Page 47)
W0501 ( Page 47)
W0502 ( Page 47)
W0503 ( Page 47)
W0505 ( Page 47)
W0506 ( Page 47)
W0507 ( Page 47)
W0508 ( Page 47)
W0525 ( Page 142)
W0534 ( Page 77)
W1001 ( Page 99)
W1002 ( Page 84)
W1005 ( Page 108)
W1006 ( Page 91)
W1009 ( Page 121)
W1011 ( Page 78)
W1036 ( Page 131)
W1047 ( Page 119)
W1209 ( Page 145)
W1241 ( Page 141)
W1463 ( Page 140)
W1478 ( Page 116)
Table 1: Maintenance task reference table [QL1]
TIM ID: 0000022417 - 001

MS150051/01E Maintenance
TIM ID: 0000022417 - 001

Troubleshooting MS150051/01E
6 Troubleshooting
6.1 Troubleshooting
Engine does not turn when starter is actuated
Component Probable Cause Task

Battery Low or defective Charge or replace (see manufacturer's documen
tation).
Cable connections defective Check if cable connections are properly secured
(see manufacturer's documentation).
Starter Engine wiring or starter defective Check if cable connections are properly secured,
contact Service.
Engine wiring Defective Check ( Page 147).
Engine/generator control Secure seating of assemblies or connectors not Perform visual inspection (see manufacturer's
system provided documentation).
Engine governor Plug-in connections are loose Check plug-in connections ( Page 148)
Engine Running gear blocked (engine cannot be barred Contact Service.
manually)
Engine turns but does not fire

Starter Poor rotation by starter: Battery low or defective Charge or replace battery (see manufacturer's
documentation).
Fuel system Not vented Vent fuel system ( Page 98)
Engine governor Defective Contact Service.
Engine fires unevenly

Fuel injection equipment Injector defective Replace ( Page 91).
TIM ID: 0000002545 - 001

MS150051/01E Troubleshooting
Engine does not reach nominal speed

Fuel supply Fuel prefilter clogged Replace
Fuel filter clogged Replace ( Page 99).
Air supply Air filter clogged Check position of contamination indicator signal
ring (if fitted) ( Page 110).
Engine Overloaded Contact Service.
Engine speed not steady

Speed sensor Defective Contact Service.
Charge-air temperature too high

Engine coolant Incorrect coolant concentration Check (MTU test kit).
Intercooler Contaminated Contact Service.
Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts.
Charge air pressure too low

Intercooler Contaminated Contact Service.
Exhaust turbocharger Defective Contact Service.
Coolant leaks on intercooler

Intercooler Leaking, major coolant discharge Contact Service.
TIM ID: 0000002545 - 001

Exhaust gas black

Engine Overloaded Contact Service.
Exhaust gas blue

Engine oil Too much oil in engine Drain engine oil ( Page 113).
Oil separator of crankcase breather contaminated Replace ( Page 81).
Exhaust turbocharger, cyl Defective Contact Service.
inder head, piston rings,
cylinder liner
Exhaust gas white

Engine Not at operating temperature Run engine to reach operating temperature.
Fuel system Water in fuel Check fuel system on fuel prefilter.
Drain fuel prefilter.
Intercooler Leaking Contact Service.
TIM ID: 0000002545 - 001

6.2 Engine governor ADEC (ECU 7) for Series 4000 Oil &Gas engines 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/actuators tested
and replaced as necessary if troubleshooting as described in the table below proves unsuccessful.
The table below lists possible fault codes:
Related
Fault code No. Designation Meaning Task parameter No.
Preliminary warning: Fuel tempera
003 HI T-Fuel ture too high. Contact Service. 2.0122.931
Main warning: Fuel temperature too
004 SS T-Fuel high; engine shutdown. Contact Service. 2.0122.932
Preliminary warning: Charge-air 1. Reduce power.

005 HI T-Charge Air temperature too high 2. Check intercooler. 2.0121.931
Main warning: Charge-air tempera 1. Reduce power.

006 SS T-Charge Air ture too high; engine shutdown. 2. Check intercooler. 2.0121.932
Charge-air coolant temperature too
009 HI T-Coolant Intercooler high (1st limit value). Reduce power. 2.0124.931
Main warning: Intercooler coolant
temperature too high; engine shut
010 SS T-Coolant Intercooler down. Reduce power. 2.0124.932
Check oil level, top up as
TIM ID: 0000016865 - 001
necessary
015 LO P-Lube Oil Oil pressure too low (1st limit value). ( Page 112). 2.0100.921

Related
1. Check oil level, top up
as necessary
( Page 112).
Oil pressure too low (2nd limit 2. Attempt to restart
016 SS P-Lube Oil value), automatic engine shutdown. engine ( Page 45). 2.0100.922
1. Check cabling
Exhaust temperature of cylinder ( Page 147).
019 HI T-Exhaust A bank A too high (1st limit value). 2. Contact Service. 2.0126.931
1. Check cabling
020 SS T-Exhaust A bank A too high (2nd limit value). 2. Contact Service. 2.0126.932
1. Check cabling
021 HI T-Exhaust B bank B too high (1st limit value). 2. Contact Service. 2.0127.931
1. Check cabling
022 SS T-Exhaust B bank B too high (2nd limit value). 2. Contact Service. 2.0127.932
Check coolant level in
Coolant level too low (1st limit expansion tank
023 LO Coolant Level value). ( Page 123). 2.0152.921
Check coolant level in
Coolant level too low (2nd limit expansion tank
024 SS Coolant Level value). ( Page 123). 2.0152.912
Oil filter differential pressure too Replace oil filter candles
025 HI P-Diff-Lube Oil high (1st limit value). ( Page 116). 2.0154.931
Alarm configuration limit value 1;
Preliminary warning: Oil filter differ Replace oil filter candles
026 SS P-Diff-Lube Oil ential pressure too high. ( Page 116). 2.0154.932
Leak fuel level too high (1st limit 1. Check fuel system.
027 HI Level Leakage Fuel value). 2. Contact Service. 2.0151.931
029 HI ETC Idle Speed too High Idle speed of ETC 2 too high. Contact Service. 1.8004.206
1. Acknowledge alarm.
Engine overspeed; automatic 2. Attempt to restart
030 SS Engine Overspeed engine shutdown. engine. 2.2510.932
preliminary warning: speed of pri
031 HI ETC1 Overspeed mary turbocharger too high. Contact Service. 2.3011.931
Automatic power reduc
TIM ID: 0000016865 - 001
tion by engine control

032 SS ETC1 Overspeed ETC 1 overspeed (2nd limit value) system. Check air filters. 2.3012.932
preliminary warning: speed of sec 1. Reduce power.
036 HI ETC2 Overspeed ondary turbocharger too high. 2. Contact Service. 2.3013.931

Related
main warning: speed of secondary
turbocharger too high. Fuel limita 1. Reduce power.
037 SS ETC2 Overspeed tion to a fixed value. 2. Contact Service. 2.3013.912
Synchronization error between 1. Reduce power.

038 AL ETC Speed Deviation ETCs 1 and 2. 2. Contact Service. 1.8004.205
1. Reduce power.
039 AL ETC2 Cutin Failure ETC2 failed to cut in. 2. Contact Service. 1.8004.204
Charge-air coolant level too high/ Check coolant level
044 L1 Coolant Level Intercooler low (1st limit). ( Page 133). 2.0153.921
Lube oil temperature too high
051 HI T-Lube Oil (1st limit). Reduce power. 2.0125.931
1. Reduce power.
Lube oil temperature too high 2. Check engine oil level
052 SS T-Lube Oil (2nd limit). ( Page 112). 2.0125.932
057 LO P-Coolant Coolant pressure too low (1st limit). Check coolant circuit. 2.0101.921
Automatic engine shut
down. Check coolant
058 SS P-Coolant Coolant pressure too low (2nd limit). level ( Page 123). 2.0101.922
1. Reduce power.
2. Replace filter element
Preliminary warning: Crankcase of oil separator
063 HI P-Crank Case pressure too high. ( Page 81). 2.0106.931
1. Contact Service.
2. Replace filter element
Main warning: Crankcase pressure of oil separator
064 SS P-Crank Case too high; engine shutdown. ( Page 81). 2.0106.932
Check fuel lines for
leaks.
Clean fuel prefilter.
Flush fuel prefilter.
Replace filter element of
fuel prefilter.
Fuel supply pressure too low Replace fuel filter
065 LO P-Fuel (1st limit). ( Page 99). 2.0102.921
Check fuel lines for
leaks.
Clean fuel prefilter.
Flush fuel prefilter.
TIM ID: 0000016865 - 001
Replace filter element of

fuel prefilter.
Fuel supply pressure too low Replace fuel filter
066 SS P-Fuel (2nd limit). ( Page 99). 2.0102.922
Coolant temperature too high
067 HI T-Coolant (1st limit). Reduce power. 2.0120.931

Related
1. Allow the engine to
cool down;
2. Contact Service.
3.
Check coolant cooler,
clean if necessary.
Coolant temperature too high 4. Restart engine
068 SS T-Coolant (2nd limit). ( Page 45). 2.0120.932
Pressure gradient in rail is too low
during starting or too high during
stopping; HP system leaky, air in
081 AL Rail Leakage system). Contact Service. 1.8004.046
Rail pressure > set value; DBR fuel
limitation, start of injection read
justed towards late; (suction restric
tor of HP fuel block jamming or HP
082 HI P-Fuel (Common Rail) fuel control block wiring faulty) Contact Service. 2.0104.931
Rail pressure <set value; DBR fuel
limitation; (suction restrictor of HP
fuel control block defective or leak
083 LO P-Fuel (Common Rail) age in HP fuel system) Contact Service. 2.0104.921
Preliminary warning: Recirculation
085 HI T-Recirculation temperature too high. Reduce power. 2.0128.931
Main warning: Recirculation tem
086 SS T-Recirculation perature too high. Reduce power. 2.0128.932
Engine speed did not attain 200 Check for additional
089 SS Engine Speed too Low rpm. A stop is activated. messages. 2.2500.030
Alarm configuration limit value;
090 SS Idle Speed Not Reached Idling speed was not attained. Contact Service. 2.1090.925
SS Release Speed Not Alarm configuration limit value;
091 Reached Runup speed was not attained. Contact Service. 2.1090.924
Starter speed was not attained; Ter
mination of starting sequence;
SS Starter Speed Not Starter rotates too slowly or does
092 Reached not rotate at all. Contact Service. 2.1090.923
Main warning: preheating tempera
ture too low; coolant temperature
too low for engine start; engine start
TIM ID: 0000016865 - 001
093 SS T-Preheat interlock active. Check preheater. 2.1090.922

Preheating temperature too low;
coolant temperature too low for
094 LO T-Preheat engine start. Check preheater. 2.1090.921

Related
Alarm configuration; Oil priming Check oil priming sys
095 AL Prelubrication Fault fault. tem. 2.1090.920
Invalid fuel consumption display,
checksum error in EDM/EEPROM 1
102 AL Cons. Counter Defect (redundant data record 1). Contact Service. 1.8004.624
Checksum error of hour meter in
104 AL Eng Hours Counter Defect EDM/EEPROM 1 . Contact Service. 18004.623
Check ECU supply volt
LO ECU Power Supply Volt Supply voltage too low (1st limit age.
118 age value). Contact Service. 2.0140.921
LOLO Power ECU Supply Supply voltage too low (2nd limit age.
119 Voltage value). Contact Service. 2.0140.922
Supply voltage too high (1st limit age.
120 HI ECU Power Supply Voltage value). Contact Service. 2.0140.931
Supply voltage too high (2nd limit Check ECU supply volt
HIHI ECU Power Supply Volt value); automatic engine shutdown age.
121 age (configurable). Contact Service. 2.0140.932
1. Improve engine room
Temperature in ECU housing too ventilation.
122 HI T-ECU high (1st limit value). 2. Reduce power. 2.0132.921
Internal voltage (-15 VDC) faulty; Replace engine gover
134 15V POS ECU DEFECT automatic engine shutdown. nor.
Internal voltage (-15 VDC) missing;
136 15V NEG ECU DEFECT automatic engine shutdown. Contact Service.
Contact Service. Check
Supply voltage of temperature sen sensors; Replace
139 L1 TE BUFFER TEST sors faulty. engine governor.
Supply voltage of temperature sen sensors; Replace
140 TE BUF. ECU DEFECT sors faulty. engine governor.
Power output stage for control of the
solenoid valves on bank 1 is faulty; Replace engine gover
142 BANK1 ECU DEFECT Engine does not start. nor.
Power output stage for control of the
solenoid valves on bank 2 is faulty; Replace engine gover
144 BANK2 ECU DEFECT Engine does not start. nor.
TIM ID: 0000016865 - 001
Power supply faulty; automatic Replace engine gover

145 15V_GOOD ECU DEFECT engine shutdown. nor.
Supply voltage A/D converter too Replace engine gover
146 L1 AD-TEST1 SUPPLY low. nor.
Electronic fault; automatic engine Replace engine gover
147 AD-TEST1 ECU DEFECT shutdown. nor.

Related
Supply voltage A/D converter too Replace engine gover
148 L1 AD-TEST2 SUPPLY low. nor.
Internal electronic fault; automatic Replace engine gover
149 AD-TEST2 ECU DEFECT engine shutdown. nor.
150 L1 AD-TEST3 SUPPLY engine shutdown. nor.
151 AD-TEST3 ECU DEFECT engine shutdown. nor.
Alarm configuration; No (appropri
ate) LifeData backup system avail
able, ECU reset after expiration of
176 AL LifeData not available time-out period. Contact Service. 2.4000.004
Alarm configuration; This error mes
sage is generated if a CRC is faulty
AL LifeData restore incom during a data upload to ADEC (indi
177 plete cated for each indiv. module). Contact Service. 2.4000.006
Alarm configuration; Connection to
180 AL CAN1 Node Lost a node on CAN bus 1 failed. Contact Service. 2.0500.680
Alarm configuration; Connection to
181 AL CAN2 Node Lost a node on CAN bus 2 failed. Contact Service. 2.0500.681
Alarm configuration; Incorrect
parameter values entered in data
182 AL CAN Wrong Parameters record. Contact Service. 2.0500.682
Alarm configuration; A CAN mode
has been selected in which commu
nication with the PU data module is
initialized. However, the required
PU data module is not available or
183 AL CAN No PU-Data not valid. Contact Service. 2.0500.683
Alarm configuration; A program
ming error occurred when attempt
ing to copy a received PU data mod
184 AL CAN PU-Data Flash Error ule into the Flash module. Contact Service. 2.0500.684
Contact Service. Inspect
CAN bus for short circuit
and rectify short circuit
CAN 1 in Bus-Off state: Either short as necessary. Check
circuit on bus. Or massive magnetic shielding, improve as
186 AL CAN1 Bus Off fields disrupting the bus. necessary. 2.0500.686
TIM ID: 0000016865 - 001
that at least one CAN

station is available.
Check cabling as
CAN 1 in Error-Passive state, minor required. Check shield
bus disruption or CAN station miss ing, improve as neces
187 AL CAN1 Error Passive ing. sary. 2.0500.687

Related
Contact Service. Inspect
CAN bus for short circuit
and rectify short circuit
CAN 2 in Bus-Off state: Either short as necessary. Check
circuit on bus. Or massive magnetic shielding, improve as
188 AL CAN2 Bus Off fields disrupting the bus. necessary. 2.0500.688
that at least one CAN
station is available.
Check cabling as
CAN 2 in Error-Passive state, minor required. Check shield
bus disruption or CAN station miss ing, improve as neces
189 AL CAN2 Error Passive ing. sary. 2.0500.689
AL EMU Parameter Not Sup Alarm configuration; EMU parame
190 ported ters are not supported. Contact Service. 2.0500.690
Sensor B06 faulty (coolant temper 1. Check cabling.

201 SD T-Coolant ature). 2. Replace if necessary. 1.8004.570
Sensor B33 faulty (fuel tempera 1. Check cabling.

202 SD T-Fuel ture). 2. Replace if necessary. 1.8004.572
Sensor B09 faulty (charge-air tem 1. Check cabling.

203 SD T-Charge Air perature) A side. 2. Replace if necessary. 1.8004.571
Sensor B26 faulty (charge-air cool 1. Check cabling.

204 SD T-Coolant Intercooler ant temperature). 2. Replace if necessary. 1.8004.574
Sensor B4.21 faulty (exhaust tem 1. Check cabling

205 SD T-Exhaust A perature) engine A side. 2. Replace if necessary. 1.8004.576
Sensor B4.22 faulty (exhaust tem 1. Check cabling.

206 SD T-Exhaust B perature) engine B side. 2. Replace if necessary. 1.8004.577
Check sensor and
cabling, replace as nec
essary. Error cleared
Sensor B10 faulty (charge-air pres after restarting the
208 SD P-Charge Air sure), short circuit or wire break engine. 1.8004.566
Sensor B05 faulty (lube oil pres 1. Check cabling.

211 SD P-Lube Oil sure). 2. Replace if necessary. 1.8004.563
Sensor B16 faulty (coolant pres 1. Check cabling.

212 SD P-Coolant sure). 2. Replace if necessary. 1.8004.564
Sensor B43 faulty (intercooler cool 1. Check cabling.

213 SD P-Coolant Intercooler ant pressure). 2. Replace if necessary. 1.8004.569
TIM ID: 0000016865 - 001
Sensor B50 faulty (crankcase pres 1. Check cabling.

214 SD P-CrankCase sure). 2. Replace if necessary. 1.8004.568
Sensor B48 faulty (rail pressure, HP 1. Check cabling.

215 SD P-HD regulator); emergency mode active. 2. Replace if necessary. 1.8004.567

Related
Sensor B07 faulty (lube oil temper 1. Check cabling.

216 SD T-Lube Oil ature). 2. Replace if necessary. 1.8004.575
Sensor B03 faulty (intake air tem 1. Check cabling.

219 SD T-Intake Air perature). 2. Replace if necessary. 1.8004.573
1. Switch system OFF
and ON again;
2. Check error message;
3. Check cabling;
4. Contact Service;
220 SD Level Coolant Water Sensor F33 faulty (coolant level 1). 5. Check sensor. 1.8004.584
1. Check sensor and wir
ing.
2. Replace if necessary.
Sensor F25 faulty (lube oil differen Error cleared after
221 SD Diff-Lube Oil tial pressure). restarting the engine. 1.8004.585
ing.
2. Replace if necessary.
222 SD Level Leakage Fuel Sensor F46 faulty (leak fuel). 3. Contact Service. 1.8004.582
Sensor F57 faulty (charge-air cool ing.
223 SD Level Coolant Intercooler ant level). 2. Contact Service. 1.8004.583
Check sensor and
SD alarm configuration; Sensor essary. Error cleared
B5.3 (lube oil pressure before filter) after restarting the
227 SD P-Oil before Filter faulty; short circuit or wire break. engine. 1.8004.620
1. Check cabling.
AL Stop Camshaft Sensor Crankshaft and camshaft speed 2. Contact Service.;
229 Defect sensor faulty. Check sensor. 1.8004.562
Sensor B13 faulty (crankshaft ing.
230 SD crankshaft Speed speed). 2. Contact Service. 1.8004.498
ing.
231 SD Camshaft Speed Sensor B1 faulty (camshaft speed). 2. Contact Service. 1.8004.499
Sensor B44 faulty (turbocharger ing.
TIM ID: 0000016865 - 001
232 SD Charger 1 Speed speed 1). 2. Contact Service. 1.3011.128

Sensor B44.2 faulty (turbocharger ing.
233 SD Charger 2 Speed speed 2). 2. Contact Service. 1.3011.129

Related
ing.
240 SD P-Fuel Sensor B34 faulty (fuel pressure). 2. Contact Service. 1.8004.565
Sensor B49 faulty (recirculation ing.
241 SD T-Umblasen temperature). 2. Contact Service. 1.8004.581
Redundant coolant temperature ing.
242 SD T-Coolant (R) sensor faulty. 2. Contact Service. 1.8004.622
Check sensor and
SD alarm configuration; Redundant essary. Error cleared
lube oil pressure sensor faulty; after restarting the
244 SD P-Lube Oil (R) Short circuit or wire break. engine. 1.8004.621
SD ECU Power Supply Volt Sensor fault (ECU operating volt Replace engine gover
245 age age). nor. 2.8006589
1. Check cabling.
2. Check speed
266 SD Speed Demand External speed demand faulty. demand. 2.8006.586
Check cabling, replace
SD alarm configuration; Filtered as necessary.
analog signal of load pulse missing; Error cleared after
269 SD Loadp.Analog filt short circuit or wire break. restarting the engine. 2.8006.588
1. Check cabling.
2. Contact Service.;
Check setpoint speed
270 SD Frequency Input Frequency setting sensor faulty. transmitter. 2.8006.590
Replace injector con
cerned if the fault mes
Timing Bank 1 (solenoid valve 1) ... sage appears frequently
301 AL Timing Cylinder (A1-A10) Timing Bank 1 (solenoid valve 10) ( Page 91). 1.8004.500
302 1.8004.501
303 1.8004.502
304 1.8004.503
305 1.8004.504
306 1.8004.505
307 1.8004.506
308 1.8004.507
TIM ID: 0000016865 - 001
309 1.8004.508
310 1.8004.509

Related
Replace injector con
cerned if the fault mes
Timing Bank 2 (solenoid valve 1) ... sage appears frequently
311 AL Timing Cylinder (B1- B10) Timing Bank 2 (solenoid valve 10) ( Page 91). 1.8004.510
312 1.8004.511
313 1.8004.512
314 1.8004.513
315 1.8004.514
316 1.8004.515
317 1.8004.516
318 1.8004.517
319 1.8004.518
320 1.8004.519
Wiring Bank 1 (solenoid valve 1) ... 1. Check solenoid valve.

321 AL Wiring Cylinder (A1- A10) Wiring Bank 1 (solenoid valve 10) 2. Contact Service. 1.8004.520
322 1.8004.521
323 1.8004.522
324 1.8004.523
325 1.8004.524
326 1.8004.525
327 1.8004.526
328 1.8004.527
329 1.8004.528
330 1.8004.529
Wiring Bank 2 (solenoid valve 1) ... 1. Check solenoid valve.

331 AL Wiring Cylinder (B1- B10) Wiring Bank 2 (solenoid valve 10) 2. Contact Service. 1.8004.530
332 1.8004.531
333 1.8004.532
334 1.8004.533
335 1.8004.534
336 1.8004.535
337 1.8004.536
338 1.8004.537
339 1.8004.538
TIM ID: 0000016865 - 001
340 1.8004.539
Open Load Bank 1 (solenoid valve
AL Open Load Cylinder (A1- 1) ... Open Load Bank 1 (solenoid 1. Check solenoid valve.
341 A10) valve 10) 2. Contact Service. 1.8004.540
342 1.8004.541

Related
343 1.8004.542
344 1.8004.543
345 1.8004.544
346 1.8004.545
347 1.8004.546
348 1.8004.547
349 1.8004.548
350 1.8004.549
Open Load Bank 2 (solenoid valve
AL Open Load Cylinder (B1- 1) ... Open Load Bank 2 (solenoid 1. Check solenoid valve.
351 B10) valve 10) 2. Contact Service. 1.8004.550
352 1.8004.551
353 1.8004.552
354 1.8004.553
355 1.8004.554
356 1.8004.555
357 1.8004.556
358 1.8004.557
359 1.8004.558
360 1.8004.559
Alarm configuration; Internal elec
tronic fault (electronics possibly
faulty: Start ITS). If the ITS diagno 1. Check solenoid valve
sis result is "electronics OK", note cabling.
further fault messages (e.g. cabling 2. Replace engine gov
361 AL Power Stage Low faults). ernor. 1.8004.496
Alarm configuration; Internal elec
tronic fault (electronics possibly
faulty: Start ITS). If the ITS diagno 1. Check solenoid valve
sis result is "electronics OK", note cabling.
further fault messages (e.g. cabling 2. Replace engine gov
362 AL Power Stage High faults). ernor. 1.8004.497
Alarm configuration; Internal elec 1. Check cabling.

tronic fault (electronics possibly 2. Attempt to restart
363 AL Stop Power Stage faulty: Start ITS). engine. 1.8004.560
TIM ID: 0000016865 - 001

Related
Alarm configuration; Injector cabling
fault. If bit "1.1020.021" (Power
Stage Failure: Stop Engine) is set,
engine will be shut down as addi
tional measure. 1. Short circuit of
positive connection of one or more
injectors to ground 2. Short circuit of 1. Check cabling.
negative connection of one or more 2. Attempt to restart
365 AL Stop MV-Wiring Ground injectors to ground . engine. 1.8004.561
1. Check turbocharger
valve/cabling, repair as
Alarm configuration; Short circuit or necessary
wire break on transistor output 1 2. Replace engine gov
371 AL Wiring TO 1 (TO 1). ernor. 1.8004.634
1. Check recirculation
valve/cabling, repair as
Alarm configuration; Short circuit or necessary
wire break on transistor output 2 2. Replace engine gov
372 AL Wiring TO 2 (TO 2). ernor. 1.8004.635
Alarm configuration; Short circuit or
wire break on transistor output 3
373 AL Wiring TO 3 (TO 3). - 1.8004.636
wire break on transistor output 4
374 AL Wiring TO 4 (TO 4). - 1.8004.637
wire break on transistor output,
381 AL Wiring TOP 1 plant-side 1 (TOP 1). Check cabling to plant. 2.8006.638
1. If alarm is only tempo
rary, no action required;
2. <if alarm is continu
Alarm configuration; DBR/MCR ously active, contact
TIM ID: 0000016865 - 001
390 AL MCR exceeded function: MCR has been exceeded. Service. 1.1085.009
Preliminary warning: Redundant
coolant temperature reading too 1. Check cabling.
392 HI T-Coolant Red high. 2. Contact Service. 2.0129.931

Related
Main warning: Redundant coolant 1. Check sensor and wir
temperature reading too high; ing.
393 SS T-Coolant Red engine shutdown. 2. Contact Service. 2.0129.932
Alarm configuration limit value 1; 1. Check sensor and wir

Preliminary warning: Redundant ing.
394 LO P-Lube Oil Red lube oil pressure reading too low. 2. Contact Service. 2.0112.921
Alarm configuration limit value 2; 1. Check sensor and wir

Main warning: Redundant lube oil ing.
395 SS P-Lube Oil Red pressure reading too low. 2. Contact Service. 2.0112.922
Alarm configuration; Maximum cool ing.
396 AL T-Coolant Max Deviation ant temperature deviation. 2. Contact Service. 1.8004.626
Alarm configuration; Maximum lube ing.
397 AL P-Oil Max Deviation oil pressure deviation. 2. Contact Service. 1.8004.625
1. Check cabling.
Alarm configuration; Line disruption 2. Contact Service.;
on digital input 1; Cabling faulty or 3. Check input of target
400 AL Open Load Digital Input 1 no resistance over switch. device. 2.8006.625
1. Check cabling.
on digital input 2; Cabling faulty or Check input of target
1. Check cabling.
1. Check cabling.
1. Check cabling.
1. Check cabling.
TIM ID: 0000016865 - 001
1. Check cabling.

Related
1. Check cabling.
Alarm configuration; Line disruption 1. Check cabling.

on the input for emergency stop; 2. Contact Service.;
AL Open Load Emerg. Stop Cabling faulty or no resistance over Check input of target
408 Input ESI switch. device. 2.8006.633
Alarm configuration limit value 1; 1. Check cabling.

Preliminary warning: Injector volt 2. Check power supply.
410 LO U-PDU age too low. 3. Contact Service. 2.0141.921

Main warning: Injector voltage too 2. Check power supply.
411 LOLO U-PDU low. 3. Contact Service. 2.0141.922

Preliminary warning: Injector volt 2. Check power supply.
412 HI U-PDU age too high. 3. Contact Service. 2.0141.931
1. Check cabling.
Alarm configuration limit value; Main 2. Check power supply.
413 HIHI U-PDU warning: Injector voltage too high. 3. Contact Service. 2.0141.932
Warning: water level in fuel prefilter
414 HI Level Water Fuel Prefilter too high. Drain water. 2.0156.931
Preliminary warning: Coolant pres Top up coolant
415 LO P-Coolant Intercooler sure in intercooler too low. ( Page 136). 2.0107.921
Main warning: Coolant pressure in
intercooler too low. engine shut Top up coolant
416 SS P-Coolant Intercooler down. ( Page 136). 2.0107.922
Check sensor and
SD alarm configuration; Sensor for essary. Error cleared
water level in fuel prefilter faulty; after restarting the
417 SD Level Water Fuel Prefilter short circuit or wire break. engine. 1.8004.594
Input signal of Aux 1 has exceeded/ Determine and rectify
not attained limit value 1, depending reason for limit value vio
420 L1 Aux 1 on configuration. lation. 2.0160.921
TIM ID: 0000016865 - 001

Input signal of Aux 1 has exceeded/ Determine and rectify
not attained limit value 2, depending reason for limit value vio
421 L2 Aux 1 on configuration. lation. 2.0160.922

Related
Preliminary warning: Temperature
signal of Aux 1 has exceeded / not Determine and rectify
attained limit value 1, depending on reason for limit value vio
428 L1 T-Aux 1 configuration. lation. 2.0130.921
Preliminary warning: Pressure sig
nal of Aux 1 has exceeded / not Determine and rectify
440 L1 P-Aux 1 configuration. lation. 2.0110.921
Preliminary warning: Pressure sig
nal of Aux 1 has exceeded / not Determine and rectify
442 L2 P-Aux 1 configuration. lation. 2.0110.931
SD alarm configuration; Injector
power stage sensor defect; Internal
444 SD U-PDU fault in ECU7. Replace ADEC (ECU 7). 1.8004.578
SD alarm configuration; Ambient air Replace engine gover
445 SD P-Ambient Air pressure sensor faulty. nor. 1.8004.580
Preliminary warning: Charge-air
448 HI P-Charge Air pressure too high. Contact Service. 2.0103.931
Main warning: Charge-air pressure
449 SS P-Charge Air too high. Contact Service. 2.0103.932
Check signal sensor and
SD alarm configuration; Input signal essary.
for initial/final torque faulty; Short Error cleared after
450 SD Idle/end Torque Input [%] circuit or wire break. restarting the engine. 2.8006.592
1. Note further fault mes
sages.
2. Determine and rectify
Alarm configuration; power reduc reason for power reduc
454 SS Power Reduction Active tion is active. tion. 2.7000.011
Input signal of Aux 1 (plant side) has Determine and rectify
exceeded/not attained limit value 1, reason for limit value vio
455 AL L1 Aux 1 Plant depending on configuration. lation. 2.8006.650
TIM ID: 0000016865 - 001

Input signal of Aux 1 (plant side) has Determine and rectify
exceeded/not attained limit value 2, reason for limit value vio
456 AL L2 Aux 1 Plant depending on configuration. lation. 2.8006.651

Related
EMU exhaust temperature value too 1. Check cabling.
460 HI T-Exhaust EMU high. 2. Contact Service. 2.8006.652
EMU exhaust temperature value too 1. Check cabling.
461 LO T-Exhaust EMU low. 2. Contact Service. 2.8006.653
EMU coolant temperature value too Check configuration with
462 AL L1 T-Coolant EMU high/low. DiaSys. 2.8006.654
SD alarm configuration; Analog essary.
input signal for Aux 2 faulty; Short Error cleared after
463 SD AUX 2 circuit or wire break. restarting the engine. 1.8004.591
Check pressure sensor
SD alarm configuration; Analog and cabling.
input signal for Aux 1 pressure Error cleared after
464 SD P-AUX 1 faulty; Short circuit or wire break. restarting the engine. 1.8004.589
Check pressure trans
mitter and cabling,
SD alarm configuration; Analog replace as necessary.
input signal for Aux 2 pressure Error cleared after
465 SD P-AUX 2 faulty; Short circuit or wire break. restarting the engine. 1.8004.588
Check temperature sen
sor and cabling, replace
SD alarm configuration; Analog as necessary. Error
input signal for Aux 2 temperature cleared after restarting
466 SD T-AUX 2 faulty; Short circuit or wire break. the engine. 1.8004.586
Preliminary warning: Temperature
signal of Aux 1 has exceeded / not Determine and rectify
467 AL L2 T-Aux 1 configuration. lation. 2.0130.922
SD alarm configuration; Analog Replace engine gover
468 SD T-AUX 1 input for Aux 1 temperature faulty. nor. 1.8004579
SD alarm configuration; Analog essary. Error cleared
input signal for Aux 1 faulty; Short after restarting the
469 SD AUX 1 circuit or wire break. engine. 1.8004.590
TIM ID: 0000016865 - 001
Check sensor and

SD alarm configuration; Tempera essary. Error cleared
ture sensor for ECU faulty; Short cir after restarting the
470 SD T-ECU cuit or wire break. engine. 1.8004.587

Related
Check sensor and
SD alarm configuration; Control of essary. Error cleared
HP fuel control block faulty; Short after restarting the
471 SD Coil Current circuit or wire break. engine. 1.8004.592
Alarm configuration; Engine stop,
since all shutdown channels have 1. Check cabling.
472 AL Stop SD "sensor faulty". 2. Contact Service. 2.8006.593
Alarm configuration; Cable break or 1. Check cabling.

473 AL Wiring PWM_CM2 short circuit on channel PWM_CM2. 2. Contact Service. 1.8004.593
Alarm configuration; Cable break or 1. Check cabling.

474 AL Wiring FO short circuit on channel FO. 2. Contact Service. 2.8006.655
Alarm configuration; initiated when Determine and rectify
crash recorder is triggered due to cause of triggering /
475 AL CR Trigger Engine Stop engine shutdown. engine shutdown. 1.8010.009
Alarm configuration; Crash recorder Check setting with Dia
476 AL Crash Rec. Init. Error initialization error. Sys. 1.8010.007
Alarm configuration; YELLOW sum Note further fault mes
478 AL Comb. Alarm Yel (Plant) mary alarm from plant. sages. 2.8006.001
Alarm configuration; RED summary Note further fault mes
479 AL Comb. Alarm Red (Plant) alarm from plant. sages. 2.8006.002
Input signal has exceeded/not Determine and rectify
attained limit value, depending on reason for limit value vio
480 AL Ext. Engine Protection configuration. lation. 2.0291.921
TIM ID: 0000016865 - 001

Task Description MS150051/01E
7 Task Description
7.1 Engine
7.1.1 Engine Barring manually
Preconditions
Special tools
Barring device F6555766 1
Ratchet with extension F30006212 1
Cautions
Risk of serious injury Danger to life!
DANGER Before barring the engine, ensure that nobody is in the danger zone.
Engine Barring manually

1. Remove guard plate.
2. Engage barring device (2) with ring gear (3) and
install on flywheel housing.
3. Set ratchet (1) onto barring device (2).
4. Rotate crankshaft in engine direction of rotation.
Apart from the normal compression resistance, there
should be no resistance.
5. For barring device removal, follow reverse sequence
of working steps.
TIM ID: 0000000917 - 002

MS150051/01E Task Description
7.1.2 Engine Barring with starting system

Cautions
DANGER before barring or starting the engine, ensure that nobody is in the danger zone.
After working on the engine, check that all protective devices have been reinstalled
and all tools removed from the engine.
Engine Barring with starting system

1. Release latch of connector X4.
2. Disconnect 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 is expired. If necessary, re-start the
engine after approx. 20 seconds.
6. Connect connector X4 to engine governor and latch in position.
TIM ID: 0000000918 - 002

7.1.3 Engine test run

Cautions

Engine test run

1. Start engine ( Page 45).
2. Perform test run at not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks ( Page 47).
4. Stop engine ( Page 48).
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7.2 Cylinder Liner

7.2.1 Cylinder liner Endoscopic examination
Preconditions
Special tools
Rigid endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover ( Page 89).
2. Remove injector ( Page 92).
Positioning crankshaft at BDC

1. Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached BDC.
2. Insert endoscope into cylinder liner through injector seat.
Cylinder liner Endoscopic examination
Findings Task
Thin carbon coating on carbon scraper ring No action required
Slight localized additive deposits at top edge
Localized smooth areas at bottom edge
Carbon deposits on entire circumference 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
Faultless, even honing pattern
First signs of marks left by lower cooling bores
Running pattern seems darker
Dark areas with even or varying degrees of discoloration Further endoscopic examination
Beginning and end of the discoloration are not sharply defined and do not cover required as part of maintenance work
the entire stroke area
Dark areas in the upper section of the cooling bore, remaining circumference can
not be faulted
Piston rings cannot be faulted
On the entire circumference, apart from light areas of discoloration (do not impair Cylinder liner must be replaced; Serv
operation) clearly darker stripes that start at the top piston ring ice must be contacted
Heat discoloration in the direction of stroke and honing pattern damage
Heat discoloration of piston rings
1. Compile endoscopy report using the table.

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2. Use technical terms for description of the liner surface ( Page 80).
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.

Final steps
1. Install injector ( Page 92).
2. Install cylinder head cover ( Page 89).
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7.2.2 Instructions and comments on endoscopic and visual examination of cylinder

liners
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report.
Finding Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, bro
ken-off burrs). Removed cylinders clearly show such scoring on the running surface under endo
scope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores from hard particles. They usually start in the TDC area and cross through the
hone pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one another. In most cases,
they are found at the 6-o'clock and 12-o'clock positions (inlet/exhaust) along the transverse engine
axis.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern is still visible.
Smoothened areas appear brighter and more brilliant than the surrounding running surface.
Polished area Polished areas are on the running surface and show local removal of the honing pattern. Grooves
from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and temperature differences
around the liner. It appears rather darker within the honed structure in contrast to the bright metallic
running surface. The honing pattern is undisturbed. Discolorations extend in stroke direction and
may be interrupted.
Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves in the overlap (open)
position. They are clearly visible due to the dark color of the honing groove bottom.
This corrosion is not critical unless there are corrosion pittings.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discoloration from TDC
to BDC in the running surface and the start of localized damage to the honing pattern.
Cylinders with a number of black lines around the running surface have limited service life and
should be replaced.
Discolorations (Heat) These are caused by a disturbance in the liner / ring tribosystem. Usually they run over the whole
ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the sec
ond TDC-ring onwards and less pronounced from TDC-ring 1. The honing pattern is usually no
longer visible and displays a clearly defined (straight) edge to the undisturbed surface. The dam
aged surface is usually discolored. The circumferential length varies.
Liners with heat discoloration starting in the TDC-ring 1 have to be replaced.
Seizures, Seizure marks Irregular circumference lengths and depths. Can be caused either by the piston skirt or the piston
crown. Material deposits on the liner (smear), heavy discoloration. Severe, visible scoring.
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Replace liner.
Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough investigation
and compliance with the above evaluation criteria allows a definite evaluation. To avoid unnecessary disassembly
work, it is recommended that another inspection be carried out after further operation of the engine.

7.3 Crankcase Breather

7.3.1 Crankcase breather Oil separator replacement, diaphragm check and replace
ment
Preconditions
Special tools
Ratchet adapter F30027340 1
Material
Engine oil
Spare parts
Filter insert Spare Parts Catalog
Diaphragm Spare Parts Catalog
Seal Spare Parts Catalog
Cautions
Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
Avoid contact with skin.
Do not inhale oil vapor.
Replacing filter element of oil separator

1. 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.
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Screw Tightening torque Engine oil 10 Nm 2 Nm
6. Replace further oil separator elements in the same way.
Checking diaphragm
1. Remove cover (4).
2. Remove spring (5), seal (2) and diaphragm (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 Drive

7.4.1 Valve gear Lubrication
Preconditions
Material
Engine oil
Valve gear Lubrication

1. Remove cylinder head covers ( Page 89).
2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjusting screws
with oil.
4. Install cylinder head covers ( Page 89).
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7.4.2 Valve clearance Check and adjustment

Preconditions
Engine coolant temperature is max. 40 C.
Valves are closed.
Special tools
Feeler gauge Y20010128 1
Socket wrench, 24 mm F30039526 1
Material
Engine oil
Preparatory steps
2. Install barring device ( Page 75).
3. The OT mark (1) (if fitted) on the flywheel must not

be used for reference.
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4. Rotate crankshaft with barring device in engine direc

tion of rotation until "OT-A1" mark and pointer are
aligned.
Diagram 8V (Two crankshaft positions)
1 Cylinder A1 is in firing TDC

2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
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I Inlet valve
X Exhaust valve

I Inlet valve
X Exhaust valve
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I Inlet valve
X Exhaust valve
Checking valve clearance at two crankshaft positions

1. 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) as per
diagram.
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.
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Adjusting valve clearance

1. 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 provided.
4. Feeler gauge must just pass through the gap.
5. Tighten locknut (1) with torque wrench to the speci
fied tightening torque, holding the adjusting screw (2)
to prevent it from turning.

Locknut M16 x 1.5 Tightening torque Engine oil 90 Nm +9 Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Final steps
1. Remove barring device ( Page 75).
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7.4.3 Cylinder head cover Removal and installation

Preconditions
Material
Grease (Kluthe Hakuform 30-10/emulsifier)
Spare parts
O-ring Spare Parts Catalog
Cylinder head cover Removal

1. 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).
Cylinder head cover Installation

1. Clean mounting surface.
2. Check O-ring (4) for damage, replace if necessary.
3. Coat O-ring (4) with grease.
4. Place cylinder head cover (3) with O-ring (4) onto cylinder head (5).
5. Install cylinder head cover (3) with screws (1) and washers (2).
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7.5 Injection Pump / HP Pump

7.5.1 HP fuel pump Filling with engine oil
Preconditions
Material
Engine oil
Cautions
Fuels are combustible.
Risk of fire and explosion!
WARNING Avoid open flames, electrical sparks and ignition sources.
Do not smoke.
Oils are combustible.

Risk of fire!
WARNING No open flames, no electric sparks. Do not smoke. Avoid ignition sources.
Fuel system high-pressure pump not filled with engine oil.

Damage to components, major material damage!
CAUTION Make sure that the high-pressure fuel pump is filled with engine oil before installation
or initial operation.
Filling HP fuel pump

1. Fill fresh engine oil into a clean receptacle.
2. Fill HP fuel pump (1) at connection (2).
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7.6 Injection Valve / Injector

7.6.1 Injector Replacement
Spare parts
Fuel injector Spare Parts Catalog
Remove injector and install new one ( Page 92).

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7.6.2 Injector Removal and installation

Preconditions
Special tools
Installation/removal tool F6789889 1
Milling cutter F30452739 1
Torque wrench, 0.5-5 Nm 0015384230 1
Material
Assembly paste (Optimoly Paste White T) 40477 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil
Spare parts
Cautions
Do not smoke.
Preparatory steps
1. Shut off fuel supply to engine.
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Removing injector
1. Disconnect cable connector on injector.
2. Remove HP fuel line (4).

3. Remove return line (5).
Note:
The injector accumulator will be emptied when
removing the adapter.
4. Remove adapter (3).

5. Remove screw (2) and take off hold-down clamp (1).
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6. Install installation/removal tool on cylinder head.

7. Remove injector with installation/removal tool.
8. Remove installation/removal tool.
9. Remove sealing ring (4) from injector or use a self-

made hook to take it out of the cylinder head.
10. Remove O-rings (3), O-ring (2) and damper ring (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 injector
1. Remove plug before installing the injector. (Do not
remove the plug from the HP line before installing the
adapter.)
2. Coat injector with assembly paste at the seat of the
nozzle clamping nut.
3. Fit new sealing ring (4) (included in the scope of sup
ply of the injector) with grease on injector, observe
installation position of sealing ring (4).
4. Fit new O-rings (3) (included in the scope of supply

of the injector), O-ring (2) and damping ring (1) onto
the injector and coat with grease.
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5. Clean sealing face on cylinder head and protective

sleeve with milling cutter.
6. Insert injector into cylinder head, ensuring that the HP
line adapter is correctly aligned.
7. Use installation/removal tool to press in injector.
8. Remove installation/removal tool.
9. Coat screw head mating face (2) and thread with

engine oil.
10. Fit hold-down clamp (1) in the correct position and
use torque wrench to tighten screw (2) to the speci
fied initial tightening torque.

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.
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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 sequence:
1 Rail (6)
2 Adapter (4)

Union nut / thrust screw Tightening torque 30 Nm + 5 Nm
18. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening sequence:
1 Adapter (4)
2 Rail (6)

Union nut / thrust screw Tightening torque 40 Nm + 5 Nm
19. Fit cable connector onto injector.

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Final steps
2. Open fuel supply to engine.

7.7 Fuel System

7.7.1 Fuel system Venting
Preconditions
Material
Diesel fuel
Cautions
Do not smoke.
Venting LP fuel system

1. Open threaded vent plugs (arrows).
2. Unlock fuel priming pump (1), screw out handle by
turning it anticlockwise.
3. Operate handle (1) until bubble-free fuel emerges
from the vent plugs (arrows).
4. Close threaded vent plugs (arrows).
5. Screw in handle by turning it clockwise.
6. Verify that fuel priming pump (1) is locked: Handle
must be tightened.
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7.8 Fuel Filter

7.8.1 Fuel filter Replacement
Preconditions
Special tools
Filter wrench F30379104 1
Material
Engine oil
Spare parts
Easy-change filter Spare Parts Catalog
Cautions
Do not smoke.
Fuel filter Replacement

1. Remove easy-change filter using the 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 98).
6. Replace further easy-change filters in the same way.
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7.8.2 Fuel prefilter Draining

Preconditions
Material
Diesel fuel
Spare parts
Gasket Spare Parts Catalog
Cautions
Do not smoke.
Fuel prefilter Draining

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

II Right filter cut in
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2. Open vent plug (5) of the filter to be drained.

3. Unlock drain cock (6) by pressing toggle and open it.
4. Drain water and contaminants from the filter until pure
fuel emerges.
5. Close drain cock (6).
6. Remove screws securing the cover and take off cover
(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 the cut-out filter in again.
11. When fuel emerges from system, close vent plug (5).
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7.8.3 Fuel prefilter Flushing

Material
Diesel fuel
Spare parts
Cautions

Do not smoke.

Fuel prefilter Flushing

1. Switch off contaminated filter.

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2. Open threaded vent plug (5) of the filter to be flushed.

3. Unlock drain valve (6) by pressing toggle, open it and
drain fuel.
Result: Fuel flows from filtered side back to the unfil
tered side, flushing the filter deposits downwards out
of the filter.
4. Close threaded vent plug (5) and drain valve (6).
Fuel prefilter Filling with fuel

1. Stop engine ( Page 48) and disable engine start.
2. Remove screws securing the cover and take off cover (2).
6. Check differential pressure ( Page 106).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefilter
( Page 104).
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7.8.4 Fuel prefilter filter element replacement

Preconditions
Material
Diesel fuel
Spare parts
Filter element Spare Parts Catalog
Cautions
Do not smoke.
Fuel prefilter filter element replacement

1. Cut out the contaminated filter.

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2. Open vent plug (5) of the contaminated filter.

3. Unlock drain cock (6) by pressing toggle and open it.
4. Drain water and contaminants from the filter.
5. Close drain cock (6).
6. Remove screws securing the cover and take off cover
(2).
7. Remove spring (4) and filter element (3).
8. Insert new filter element (3) and spring (4).
12. Cut the cut-out filter in again.
13. Close vent plug (5) when fuel emerges.
14. Align adjustable pointer of differential pressure
gauge with pressure-indicating pointer.
( Page 106).
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7.8.5 Fuel prefilter Differential pressure check and adjustment of gauge

Cautions

Setting adjustable pointer of differential pressure gauge

1. After installation of a new filter element, align adjust
able pointer (2) with pressure-indicating pointer (3) of
pressure gauge (1).
2. Verify that differential pressure is within the limit.
Fuel prefilter Checking differential pressure

1. 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 102).
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7.9 Charge-Air Cooling

7.9.1 Intercooler checking condensate drains for coolant discharge and obstruction
Cautions

Compressed air
Risk of injury!
Intercooler checking condensate drains for coolant discharge and obstructions

1. With the engine running, verify that air emerges from
the condensate drain(s) at driving end, left and right
engine side. If no air emerges:
2. Clean condensate drain(s) and blow out with com
pressed air.
3. If a large amount of coolant is continuously dis
charged, the intercooler is leaking. Contact Service.
Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors ( Page 92).
2. Bar engine manually ( Page 75).
3. Bar engine with starting system to blow out combustion chambers ( Page 76).
4. Install injectors ( Page 92).
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7.10 Air Filter

7.10.1 Air filter Replacement
Spare parts
Filter insert Spare Parts Catalog
Filter element Spare Parts Catalog
Remove air filters and install new ones ( Page 109).

Reset signal ring of service indicator ( Page 110).
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7.10.2 Air filter Removal and installation

Preconditions
Air filter Removal and installation
1. Loosen clamp (2) of air filter (1).
2. Remove air filter (1) and clamp (2) from connecting
flange.
3. Clean connecting flange and check for obstructions.
4. Position air filter (1) and clamp (2) on connecting
flange.
5. Tighten screw of clamp (2) to 5 Nm.
6. Replace further air filters in the same way.
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7.11 Air Intake

7.11.1 Service indicator Signal ring position check
Preconditions
Signal ring position check
1. If the signal ring is completely visible in the control
window (2), replace air filter.
2. After installation of new filter, press reset button (1).
Result: Engaged piston with signal ring moves back
to initial position.
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7.12 Starting Equipment

7.12.1 Air starter Manual operation
Cautions

Air starter Manual operation

1. Operate pushbutton for manual start (arrow) and
hold.
2. Allow compressed air to enter the air starter, until the
engine fires evenly.
3. Release pushbutton.
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7.13 Lube Oil System, Lube Oil Circuit

7.13.1 Engine oil Level check
Preconditions
Checking oil level prior to engine start
1. Withdraw dipstick from guide tube and wipe it.
2. Insert dipstick into guide tube to stop, withdraw after
approx. 10 seconds and check oil level.
Note:
After extended standstill, the oil level may exceed the
mark (1) by up to 2 cm. This can be caused by oil
flowing from e.g. oil filter or heat exchanger back to
the oil pan.
3. The oil level must reach mark (1) or exceed mark (1)
by up to 2 cm.
4. Top up with oil to mark (1) as necessary
( Page 113).
5. Insert dipstick into guide tube up to the stop.
Checking oil level after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube 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 113).
5. Insert dipstick into guide tube up to the stop.
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7.13.2 Engine oil Change

Preconditions
Engine is at operating temperature.
Special tools
Torque wrench 40-200 Nm F30027337 1
Material
Engine oil
Spare parts
Sealing ring Spare Parts Catalog
Cautions
Hot oil.
Procedure without pump: Draining oil at drain plug(s) on oil pan

1. Provide a suitable container in which 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 extraction

2. Extract all oil from oil pan using the pump.
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Draining residual oil at the equipment carrier

2. Remove drain plug (1) and drain oil (approx. 7 liters)
from oil heat exchanger and oil filter.
3. Remove drain plug (2) and (3) and drain oil:
approx. 12 liters at (2)
approx. 5 liters at (3)
4. Install drain plug(s) with new sealing ring.
5. Tighten drain plugs (2) and (3) to specified torque 100
Nm +10 Nm using torque wrench.
Filling with new oil

1. Open cover of filler neck.
2. Pour oil in at filler neck up to "max." mark at oil dip
stick.
3. Close cover of filler neck.
4. Check engine oil level ( Page 112).
5. After oil change, bar engine with starting system
( Page 76).
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7.13.3 Engine oil Sample extraction and analysis

Preconditions
Special tools
MTU test kit 5605892099/00 1
Cautions
Hot oil.

Engine oil Sample extraction and analysis

1. With the engine running at operating temperature,
open screw on oil filter by 1 to 2 turns.
2. Drain approx. 2 liters engine oil to flush out the oil
sludge.
3. Drain approx. 1 liter engine oil into a clean container.
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 / Cooling

7.14.1 Automatic oil filter Filter candles replacement
Preconditions
Material
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil
Spare parts
Oil filter candles Spare Parts Catalog
Cautions
Hot oil.
Contamination of components.
Check components for special cleanness.
Removing oil filter candles

1. 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 screen plate (6).
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11. Turn filter insert upside down and use appropriate

tool to push out filter candles (1).
12. Turn filter insert by 180and insert new filter can
dles (1) with chamfer facing downwards.
Installing oil filter candles

1. 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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7.14.2 Oil indicator filter Check

Preconditions
Spare parts
Strainer Spare Parts Catalog
Square-section ring Spare Parts Catalog
Cautions
Hot oil.
Compressed air
Risk of injury!
Unsuitable cleaning tool.

Use appropriate cleaning tool.
Removing strainer
1. Clean oil indicator filter before disassembling it.
2. Remove screws (1).
3. Take off cover (2) with Oring (3).
4. Take strainer (5) from filter housing.
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Checking strainer
Item Findings Task

Strainer Metallic residues Clean
Monitor engine operation
Check strainer daily
Contact Service.
Strainer Damaged Replace
Square-section ring Damaged Replace
O-ring Damaged Replace
Cleaning strainer
1. Wash strainer (5) with cleaner.
2. Remove stubborn deposits with soft brush.
3. Blow out strainer (5) with compressed air from inside.
Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Coat Oring (3) with engine oil and fit in filter housing.
3. Fit cover (2) and secure with screws (1) and washers.
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7.14.3 Centrifugal oil filter Cleaning and filter-sleeve replacement

Preconditions
Special tools
Material
Cold cleaner (Hakutex 60) 50602 1
Spare parts
Filter sleeve Spare Parts Catalog
Cautions
Hot oil.
Compressed air
Risk of injury!
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Centrifugal oil filter Cleaning and filter-sleeve replacement

1. Remove clamp (3).
2. Release Tommy nut (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 interval.
9. Disassemble rotor tube (11), conical disk (12) and
rotor base (14).
10. Wash rotor cover (8), rotor tube (11), conical disk (12)
and rotor base (14) with cold cleaner.
11. Blow out with compressed air.
12. Check sealing ring (13), fit new one if necessary.
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 facing the wall.
16. Mount rotor cover (8) with sealing ring (9).
17. Tighten rotor cover nut (7) with torque wrench to the
specified torque.

Nut Tightening torque 35 Nm to 45 Nm
18. Place rotor (6) in housing (5) and check for ease of movement.
20. Fit sealing ring (4) on housing (5).
21. Fit cover (2).
22. Tighten Tommy nut (1) by hand.
23. Install clamp (3) and tighten with torque wrench to the specified torque.

Clamp Tightening torque 8 Nm to 10 Nm
24. Tighten cover nut (1) with torque wrench to the specified torque.

Screw Tightening torque 5 Nm to 7 Nm
TIM ID: 0000000934 - 003

7.15 Coolant Circuit, General, High-Temperature Circuit

7.15.1 Engine coolant Level check
Preconditions
Cautions
Coolant is hot and under pressure.
WARNING Let the engine cool down.
Checking 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 coolant level at remote cooler:

1. Check coolant level (coolant must be visible at mark
ing plate).
2. Top up coolant if necessary ( Page 127).
3. Check and clean breather valve.
4. Set breather valve onto filler neck and close it.
Checking engine coolant level by means of level sensor:

1. Switch on engine control system and check readings on the display.
TIM ID: 0000000937 - 003

7.15.2 Engine coolant - Change

Material
Engine coolant
Drain engine coolant ( Page 125).

Fill with engine coolant ( Page 127).
TIM ID: 0000000036 - 012

7.15.3 Engine coolant Draining

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

1. Turn breather valve of filler neck on coolant expan
sion tank counterclockwise to first stop and allow
pressure to escape.
2. Continue to turn breather valve counterclockwise and
remove.
3. Draw off precipitated corrosion inhibitor oil from the
expansion tank through filler neck.
4. Open drain valves and drain plugs and drain coolant
at the following points:
Preheating unit;
HT coolant pump elbow;
Crankcase, left and right side.
TIM ID: 0000006739 - 001

5. Drain points at driving end, left and right side.
Final steps
1. Close all open drain points.
TIM ID: 0000006739 - 001

7.15.4 Engine coolant Filling

Preconditions
Material
Engine coolant
Cautions
Cold coolant in hot engine can cause thermal stress.

Formation of cracks in components!
CAUTION Fill / top up coolant only into cold engine.
Preparatory steps
pressure to escape.
remove.
TIM ID: 0000006720 - 001

Filling with coolant using pump

1. Connect a suitable pump with a hose to drain
valve (arrow).
2. Open vent points at distributor, oil heat exchanger

and exhaust turbochargers (arrowed).
3. Open drain valve and pump coolant into engine at 0.5
bar minimum.
4. When coolant emerges from the vents, close vents
successively from bottom to top.
5. Fill expansion tank until overflow edge is reached.
6. Close drain valve.
7. Check proper condition of breather valve and clean
sealing faces if required.
8. Set breather valve onto filler neck and close.
10. After the engine has run without load for 10 seconds,
stop engine ( Page 48).
pressure to escape.
remove.
13. Check coolant level ( Page 123) and top up as
required:
13.1 Fill in coolant in expansion tank until the coolant
level at top edge of filler neck remains constant.
13.2 Set breather valve onto filler neck and close.
13.3 Repeat steps from Start engine ( Step 9.) until
TIM ID: 0000006720 - 001
no more coolant has to be added.

13.4 Disconnect pump and hose.

Alternatively: Filling coolant through filler neck

1. Open vent points at distributor, oil heat exchanger
and exhaust turbochargers (arrowed).
2. Fill in coolant through filler neck on expansion tank
until the coolant level at top edge of filler neck
remains constant.
3. When coolant emerges from the vents, close vents
successively from bottom to top.
5. Set breather valve onto filler neck and close until first
stop is reached.
8. Turn breather valve counterclockwise and remove.
9. Check coolant level ( Page 123) and top up as
required:
9.1 Repeat the steps from Start engine( Step 6.)
until no more coolant has to be added.
9.2 Check proper condition of breather valve and
clean sealing faces if required.
Final steps
1. Start engine and operate it without load for a few minutes.
2. Check coolant level ( Page 123) and top up as required.
TIM ID: 0000006720 - 001

7.15.5 Engine coolant pump Relief bore check

Cautions

Engine coolant pump Relief bore check

1. Check relief bore for oil and coolant discharge.
2. Shut down engine ( Page 48) and disable engine
start, observe general safety instructions Mainte
nance 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.
TIM ID: 0000000939 - 002

7.15.6 Coolant filter Replacement

Preconditions
Special tools
Filter wrench F30379104 1
Material
Engine oil
Spare parts
Coolant filter Spare Parts Catalog
Cautions
Coolant filter Replacement

1. Close shut-off cocks (1).
2. Remove coolant filter (2) with filter wrench.
3. Clean the sealing face on the 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).
TIM ID: 0000006858 - 003

7.15.7 Engine coolant Sample extraction and analysis

Preconditions
Special tools
MTU test kit 5605892099/00 1
Cautions


Engine coolant Sample extraction and analysis

1. With the engine running, open drain valve (1).
2. Flush sample-extraction point by draining approx. 1
liter coolant.
3. Drain approx. 1 liter coolant into a clean container.
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, refer to
( MTU Fluids and Lubricants Specifications).
TIM ID: 0000000938 - 002

7.16 Low-Temperature Circuit

7.16.1 Charge-air coolant Level check
Preconditions
Cautions
Checking charge-air coolant level at filler neck:

1. Turn breather valve on coolant expansion tank coun
terclockwise to the first stop and allow pressure to
escape.
remove.
3. Check coolant level (coolant must be visible at mark
ing plate).
5. Check proper condition of breather valve, clean seal
ing 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).
TIM ID: 0000000042 - 004

7.16.2 Charge-air coolant Change

Material
Charge-air coolant
Drain charge-air coolant ( Page 135).

Fill with charge-air coolant ( Page 136).
TIM ID: 0000000041 - 004

7.16.3 Charge-air coolant Draining

Preconditions
Spare parts
Cautions
Charge-air coolant Draining

1. Provide an appropriate container to drain the coolant
into.
pressure to escape.
remove.
4. Draw off precipitated corrosion inhibitor oil from the
expansion tank through filler neck.
5. Open drain valves and drain plugs and drain coolant
at the following points:
at the LT cooling pump
at the LT thermostat housing.
6. Draining of residual coolant:

at the intercooler
7. Close all drain valves and install drain plugs with new
sealing rings.
TIM ID: 0000007022 - 001

7.16.4 Charge-air coolant Filling

Preconditions
Material
Charge-air coolant
Cautions
Cold coolant in hot engine can cause thermal stress.

Formation of cracks in components!
CAUTION Fill / top up coolant only into cold engine.
Preparatory steps
pressure to escape.
remove.
TIM ID: 0000007012 - 001

Filling with charge-air coolant using pump

1. Connect a suitable pump with a hose to one of the
drain valves (arrow).
2. Open vent on intercooler (arrow).

3. Open drain valve and pump coolant into engine at 0.5
bar minimum.
4. When coolant emerges from the vent, close vent.
5. Fill expansion tank until overflow edge is reached.
6. Close drain valve.
8. Set breather valve onto filler neck and close.
pressure to escape.
remove.
13. Check coolant level ( Page 133) and top up if
required:
13.1 Add coolant to expansion tank until the coolant
level at top edge of filler neck remains constant.
13.3 Repeat steps from Start engine ( Step 9.) until
no more coolant has to be added.
13.4 Disconnect pump and hose.
TIM ID: 0000007012 - 001

Alternatively: Filling coolant through filler neck

1. Open vent on intercooler (arrow).
2. Fill in coolant through filler neck on expansion tank
until the coolant level at top edge of filler neck
remains constant.
3. When coolant emerges from the vent, close vent.
5. Set breather valve onto filler neck and close until first
stop is reached.
8. Turn breather valve counterclockwise and remove.
9. Check coolant level ( Page 133) and top up if
required:
9.1 Repeat the steps from Start engine
( Step 6.) until no more coolant has to be
added.
9.2 Check proper condition of breather valve and
clean sealing faces if required.
Final steps
1. Start engine and operate it without load for a few minutes.
2. Check coolant level ( Page 133) and top up if required.
TIM ID: 0000007012 - 001

7.16.5 Charge-air coolant pump Relief bore check

Cautions

Charge-air coolant pump Relief bore check

1. Check relief bore for oil and coolant discharge.
2. Shut down engine ( Page 48) and disable engine
start, observe general safety instructions Mainte
nance 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.
TIM ID: 0000000943 - 002

7.17 Engine Mounting / Support

7.17.1 Engine mounting Check
Engine mounting Check
Item Findings Task

Visually inspect mounts. Damage Replace
Brittleness ( Instructions for General Overhaul)
Deformation
Crack formation
Swelling
visible
TIM ID: 0000015370 - 001

7.18 Belt Drive

7.18.1 Drive belt Condition check
Preconditions
Guard was removed.
Drive belt Condition check
Item Finding Action

Drive belt A Singular cracks None
Drive belt Belt is oily, shows signs of overheating Replace( Page 144)
Drive belt B Cracks on entire circumference
Drive belt C Chunking
TIM ID: 0000000920 - 003

7.19 Battery-Charging Generator

7.19.1 Battery-charging generator Check
Preconditions
Cautions
Compressed air
Risk of injury!
Battery-charging generator Check
Item Diagnosis Task

Ventilation area (arrow) Clean None
Ventilation area (arrow) Dirty Clean
Cleaning battery-charging generator

Note:
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.
TIM ID: 0000007378 - 001

7.19.2 Battery-charging generator drive Drive belt tension adjustment

Preconditions
Special tools
Cautions
Spring/circlip/tensioning roller preload.
Risk of injury!
WARNING Only use specified tool and equipment.
Adjusting belt tension

1. 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 belt
and tensions it.
3. Use torque wrench to tighten screw (1) to the speci
fied torque 42 Nm and screw (2) to 60 Nm up to 65
Nm.
4. Install protective cover (3).
TIM ID: 0000007386 - 001

7.19.3 Battery-charging generator drive Drive belt and belt tensioner replacement
Preconditions
Special tools
Cautions
Heavy object.
Risk of crushing!
WARNING Use appropriate lifting devices and appliances.
Replacing drive belt and belt tensioner

1. Undo screws (1), (2) and (3).
2. Remove protective cover (8).
4. Place socket adapter or box wrench on screw (6) and
press belt tensioner in the direction indicated by the
arrow as far as it will go.
5. Tighten screw (4).
6. Remove drive belt (7).
7. Screw on screw (5) and replace belt tensioner.
8. Fit new drive belt (7).
Tensioning drive belt

1. 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 (5) to the specified torque 42 Nm and screw (4) to 60 Nm up to 65 Nm.
4. Readjust belt tension after 30 minutes and again after 8 hours engine runtime ( Page 143).
TIM ID: 0000007421 - 001

7.19.4 Battery-charging generator - Removal and installation

Preconditions
Engine is stopped and starting disabled
Special tools
Ratchet F30027340 1
Cautions
Heavy object.
Risk of crushing!
WARNING Use appropriate lifting devices and appliances.
Removing battery-charging generator

1. Undo screws (1), (2) and (3).
2. Remove protective cover (8).
3. Mark electric cables on battery-charging generator
and remove.
4. Protect all cables from damage.
6. Place socket adapter or box wrench on screw (6) and
press belt tensioner in the direction indicated by the
arrow as far as it will go.
7. Tighten screw (4).
8. Remove drive belt (7).
TIM ID: 0000007425 - 002

9. Release screws (arrow).

10. Remove battery-charging generator (1).
11. Clean battery-charging generator (1) thoroughly
( Page 142).
12. Install battery-charging generator (1) following
reverse sequence of working steps.
Tensioning drive belt

1. Fit drive belt (7).
2. Slacken screw (4) by half a turn.
Result: Belt tensioner moves against the drive belt and tensions it.
3. Use torque wrench to tighten screw (5) to the specified torque 42 Nm and screw (4) to 60 Nm up to 65 Nm.
5. Readjust belt tension after 30 minutes and again after 8 hours engine runtime ( Page 143).
TIM ID: 0000007425 - 002

7.20 Wiring (General) for Engine/Gearbox/Unit

7.20.1 Engine wiring Check
Preconditions
Material
Isopropyl alcohol X00058037 1
Checking engine wiring

1. Check securing screws of cable retainers on the engine and tighten loose threaded connections.
2. Make sure cables are fixed in their retainers 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 housing;
contacts;
connector sockets;
cables and terminals;
plug-in contacts.
6. If cable conductors are damaged, ( contact Service)
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
8. Make certain that all sensor connectors are securely latched.
TIM ID: 0000000029 - 008

7.21 Accessories for (Electronic) Engine Governor / Control System

7.21.1 Engine governor Checking plug-in connections
Preconditions
Checking plug-in connections on engine governor
1. Check all plug-in connections for secure seating.
2. Latch connectors if loose.
TIM ID: 0000000048 - 003

7.21.2 Engine governor and connectors Cleaning

Preconditions
Material
Isopropyl alcohol X00058037 1
Engine governor and connectors Cleaning

1. 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.
Heavily contaminated connectors on the engine governor Cleaning

1. Release the clip of the connectors and pull them off.
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 latch.
TIM ID: 0000000047 - 004

TIM ID: 0000000047 - 004

Appendix A MS150051/01E
8 Appendix A
8.1 Abbreviations
Abbreviation Meaning Explanation
AC Alternating Current
ADEC Advanced Diesel Engine Controller ENGINE MANAGEMENT SYSTEM
AL Alarm
ANSI American National Standards Institute Association of American standardization organizations
ETC Exhaust turbocharger
BDM Backup Data Module
BR Series
BV Fluids and Lubricants Specifications MTU Publication No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CRC Cyclic Redundancy Control Check sum procedure to detect data transmission faults
DC Direct Current
DIFF Difference
DIN Deutsches Institut fr Normung e. V. At the same time identifier of German standards (DIN =
Deutsche Industrie-Norm)
DL Default Lost Alarm: Default CAN bus failure
ECU Engine Control Unit Engine governor
SPC Spare Parts Catalog
FO Frequency Output
GND Ground
HP High pressure
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
ID Identification number
ISO International Organization for Standardization International umbrella organization for all national stand
ardization institutes
ITS Integrated Test System
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LED Light Emitting Diode
LO Low Alarm: Measured value lower than 1st minimum limit
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
TIM ID: 0000009959 - 002
MTU Motoren- und Turbinenunion

MV Solenoid valve
OEM Original Equipment Manufacturer
TDC Top Dead Center

MS150051/01E Appendix A
Abbreviation Meaning Explanation

PAU Power Automation Unit Module for monitoring, control and plant-related system
integration of peripheral components
PDU Process Data Unit
POM Power Output Module Module to control starter and battery-charging generator
PU Configuration environment
P-xyz Pressure-xyz Pressure measuring point xyz
SAE Society of Automotive Engineers U.S. standardization organization
SAM Service and Application Module Module for servicing and diagnostics
SD Sensor Defect Alarm: Sensor failure
SS Safety System Safety system alarm
TBO Time Between Overhaul
T-xyz Temperature-xyz Temperature measuring point xyz
U Symbol for electric voltage
UIC Union Internationale des Chemins de Fer International railway association
BDC Bottom Dead Center
TC Tool Catalog
TIM ID: 0000009959 - 002

Appendix A MS150051/01E
8.2 MTU Contact/Service partners

Service
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service centers ensures
fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU internet site:http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you - either during
operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for
spare parts supply.
Your contact at Headquarters: Service-support@mtu-online.com
Spare parts service
Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare part at the
right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system,
- a central depot at Headquarters, as well as decentralized depots among our subsidiaries, representatives and con
tractual workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908555
Fax.: +49 7541 908121
TIM ID: 0000000873 - 005

MS150051/01E Appendix A

Appendix B MS150051/01E
9 Appendix B
9.1 Special Tools
Designation / Use Part No. Qty. Used in
Torque wrench, 10-60 Nm F30510423 1 1.4 Crankshaft transport locking device ( Page 12)
Torque wrench, 60-320 Nm F30047446 1 1.4 Crankshaft transport locking device ( Page 12)
1 7.4.2 Valve clearance Check and adjustment ( Page 84)
Steam jet cleaner - 1 4.9 Plant Cleaning ( Page 51)
Barring device F6555766 1 7.1.1 Engine Barring manually ( Page 75)
Ratchet with extension F30006212 1 7.1.1 Engine Barring manually ( Page 75)
Rigid endoscope Y20097353 1 7.2.1 Cylinder liner Endoscopic examination ( Page 78)
Torque wrench, 6-50 Nm F30027336 1 7.3.1 Crankcase breather Oil separator replacement, dia
phragm check and replacement ( Page 81)
1 7.14.3 Centrifugal oil filter Cleaning and filter-sleeve replace
ment ( Page 121)
Ratchet adapter F30027340 1 7.3.1 Crankcase breather Oil separator replacement, dia
phragm check and replacement ( Page 81)
1 7.19.2 Battery-charging generator drive Drive belt tension
adjustment ( Page 143)
1 7.19.3 Battery-charging generator drive Drive belt and belt
tensioner replacement ( Page 144)
Feeler gauge Y20010128 1 7.4.2 Valve clearance Check and adjustment ( Page 84)
Socket wrench, 24 mm F30039526 1 7.4.2 Valve clearance Check and adjustment ( Page 84)
Installation/removal tool F6789889 1 7.6.2 Injector Removal and installation ( Page 92)
Milling cutter F30452739 1 7.6.2 Injector Removal and installation ( Page 92)
Torque wrench, 0.5-5 Nm 0015384230 1 7.6.2 Injector Removal and installation ( Page 92)
Torque wrench, 10-60 Nm F30452769 1 7.6.2 Injector Removal and installation ( Page 92)
Torque wrench, 60-320 Nm F30452768 1 7.6.2 Injector Removal and installation ( Page 92)
Filter wrench F30379104 1 7.8.1 Fuel filter Replacement ( Page 99)
1 7.15.6 Coolant filter Replacement ( Page 131)
Torque wrench 40-200 Nm F30027337 1 7.13.2 Engine oil Change ( Page 113)
Ratchet adapter F30027341 1 7.13.2 Engine oil Change ( Page 113)
MTU test kit 5605892099/00 1 7.13.3 Engine oil Sample extraction and analysis
( Page 115)
1 7.15.7 Engine coolant Sample extraction and analysis
( Page 132)
Torque wrench 20-100 Nm F30026582 1 7.19.2 Battery-charging generator drive Drive belt tension
adjustment ( Page 143)
1 7.19.3 Battery-charging generator drive Drive belt and belt
tensioner replacement ( Page 144)
Torque wrench, 20-100 Nm F30026582 1 7.19.4 Battery-charging generator - Removal and installation
( Page 145)
Ratchet F30027340 1 7.19.4 Battery-charging generator - Removal and installation
( Page 145)

MS150051/01E Appendix B
9.2 Index
12 V 4000 P63, P83 engine data 31 Cylinder head cover
16 V 4000 P63, P83 engine data 35 , 38 Removal and installation 89
Cylinder liner
A Endoscopic examination 78
Abbreviations 151 Instructions and comments on endoscopic 80
After stopping the engine putting the engine 50 and visual examination
out of service D
Air filter Removal and installation 109
Air filter Replacement 108 Drive belt
Air starter Manual operation 111 Condition check 141
ATEX (where applicable) 22 E
Automatic oil filter
Emergency stop
Filter candles
Engine 49
Replacement 116
Engine
Auxiliary materials 19
Barring manually 75
B Barring with starting system 76
Battery-charging generator Check 142 Emergency stop 49
Battery-charging generator drive Drive belt 144 Wiring
and belt tensioner replacement Check 147
Battery-charging generator drive Drive belt 143 Engine coolant
tension adjustment Change 124 ,
Battery-charging generator - Removal and 145 124
installation Level check 123
Sample extraction and analysis 132
C Engine coolant Draining 125
Centrifugal oil filter Engine coolant Filling 127
Cleaning 121 Engine coolant pump
Charge-air coolant Relief bore check 130
Change 134 Engine governor
Charge-air coolant Draining 135 Cleaning 149
Charge-air coolant Filling 136 Plug-in connections
Charge-air coolant level Check 148
Check 133 Engine governor ADEC (ECU 7) for Series 58
Charge-air coolant pump 4000 Oil &Gas engines Fault messages
Relief bore check 139 Engine layout 23
Connectors Engine Main dimensions 42
Cleaning 149 Engine mounting Check 140
Contact partners 153 Engine oil Change 113
Coolant Engine oil level
Charge-air Check 112
Change 134 Engine oil Sample extraction and analysis 115
Check 133 Engine side and cylinder
Coolant filter Designations 24
Replacement 131 Engine test run 77
Crankcase breather Engine wiring
Oil separator replacement Check 147
Diaphragm check 81 F
Crankshaft transport locking device
Removal/installation 12 Filter

Appendix B MS150051/01E
Automatic oil filter Operational checks 47

Filter candles
P
Replacement 116
Filter sleeve Personnel and organizational requirements 10
Replacement 121 Plant
Fire prevention and environmental protection 19 Cleaning 51
Firing order 41 Putting into operation
Fuel After scheduled out-of-service period
Prefilter Preparation 44
Flushing 102 Putting the engine into operation after 43
Fuel filter extended out-of-service-periods (>3 months)
Replacement 99 Putting the engine into operation after sched 44
Fuel prefilter uled out-of-service-period
Flushing 102 S
Fuel prefilter Differential pressure check and 106
Safety notes 21
adjustment of gauge
Sensors, actuators and injectors Overview 25
Fuel prefilter Draining 100
Service indicator Signal ring position check 110
Fuel prefilter filter element replacement 104
Service partners 153
Fuel system Venting 98
Start engine in manual mode (testing mode) 45
G Starting the engine in emergency situations 46
General conditions 9 (override mode)
Startup and operation
H Safety regulations 15
HP fuel pump Stop engine in manual mode (testing mode) 48
Filling with engine oil 90 T
I Transport 11
Injector Troubleshooting 55
Removal and installation 92 V
Replacement 91
Inspection port cover Valve clearance
Explosion hazard 16 Adjustment 84
Intercooler checking condensate drains for 107 Check 84
coolant discharge and obstruction Valve gear
Lubrication 83
M
W
Maintenance and repair
Safety regulations 17 Wiring
Maintenance schedule 53 Engine
MTU contact partners 153 Check 147
O
Oil indicator filter Check 119

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Please use block capitals!

Engine No.: MTU works order no.:

Engine model: Date put into operation:

End user`s address:

1.1 General conditions 9

1.2 Personnel and organizational requirements 10

1.4 Crankshaft transport locking device 12

1.5 Safety regulations for startup and operation 15

1.6 Explosion hazard when removing inspection port cover on engine 16

1.7 Safety regulations for maintenance and repair work 17

1.8 Auxiliary materials, fire prevention and environmental protection 19

1.9 Conventions for safety instructions in the text 21

1.10 ATEX (where applicable) 22

2.1 Engine layout 23

2.2 Engine side and cylinder designations 24

2.3 Sensors, actuators and injectors Overview 25

3.1 12 V 4000 P63, P83 engine data 31

3.2 16 V 4000 P63, P83 engine data 35

3.3 20 V 4000 P63, P83 engine data 38

3.4 Firing order 41

3.5 Engine Main dimensions 42

4.2 Putting the engine into operation after scheduled out-of-service-period 44

4.3 Start engine in manual mode (testing mode) 45

4.4 Starting the engine in emergency situations (override mode) 46

4.5 Operational checks 47

4.6 Stop engine in manual mode (testing mode) 48

4.7 Emergency stop 49

4.9 Plant Cleaning 51

5.1 Maintenance task reference table [QL1] 53

MTU Friedrichshafen GmbH 2011-04 5

7.2 Cylinder Liner 78

7.3 Crankcase Breather 81

7.4 Valve Drive 83

7.5 Injection Pump / HP Pump 90

7.6 Injection Valve / Injector 91

7.7 Fuel System 98

7.8 Fuel Filter 99

7.9 Charge-Air Cooling 107

7.10 Air Filter 108

7.11 Air Intake 110

7.12 Starting Equipment 111

7.13 Lube Oil System, Lube Oil Circuit 112

6 2011-04 MTU Friedrichshafen GmbH

7.13.1 Engine oil Level check 112

7.14 Oil Filtration / Cooling 116

7.15 Coolant Circuit, General, High-Temperature Circuit 123

7.16 Low-Temperature Circuit 133

7.17 Engine Mounting / Support 140

7.18 Belt Drive 141

7.19 Battery-Charging Generator 142

7.21 Accessories for (Electronic) Engine Governor / Control System 148

8.1 Abbreviations 151

8.2 MTU Contact/Service partners 153

9.1 Special Tools 155

9.2 Index 156

MTU Friedrichshafen GmbH 2011-04 7

8 2011-04 MTU Friedrichshafen GmbH

MTU Friedrichshafen GmbH 2011-04 9

1.2 Personnel and organizational requirements

TIM ID: 0000000874 - 010

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Lift the engine only with the lifting eyes provided.

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