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Operating Instructions: Diesel Engine 12 V 4000 M23F 12 V 4000 M23S 16 V 4000 M23F 16 V 4000 M23S

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0% found this document useful (0 votes)

45 views287 pages

Operating Instructions: Diesel Engine 12 V 4000 M23F 12 V 4000 M23S 16 V 4000 M23F 16 V 4000 M23S

Uploaded by

Eng M Elseaidy

We take content rights seriously. If you suspect this is your content, claim it here.

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Download as PDF, TXT or read online on Scribd

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Operating Instructions

Diesel engine
12 V 4000 M23F
12 V 4000 M23S
16 V 4000 M23F
16 V 4000 M23S

MS150068/01E

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Printed in Germany
© 2014 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, mi-
crofilming 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.

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Commissioning Note

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Table of Contents
1 Safety 3.8 Fuel treatment system – Putting into
operation 81
1.1 Important provisions for all products 7 3.9 Fuel treatment system – Switching on 84
1.2 Personnel and organizational requirements 8 3.10 Fuel treatment system – Shutdown 85
1.3 Transport 9 3.11 Stopping the engine 86
1.4 Safety regulations for maintenance and 3.12 Emergency engine stop 87
repair work 10 3.13 After stopping the engine 88
1.5 Fire prevention and environmental 3.14 Plant – Cleaning 89
protection, fluids and lubricants, auxiliary
materials 13
4 Maintenance
1.6 Standards for safety notices in the text 15
4.1 Maintenance task reference table [QL1] 90
2 Product Summary
5 Troubleshooting
2.1 Engine Layout 16
2.1.1 Product description 16 5.1 Troubleshooting 92
2.1.2 Engine layout 28 5.2 Fuel treatment system – Troubleshooting 95
2.1.3 Overview of sensors and actuators 32
5.3 Engine governor ADEC (ECU 7) fault
2.2 Engine Side and Cylinder Designations 52 messages for Series 4000 engines, marine
2.2.1 Engine side and cylinder designations 52 application 96
5.4 Engine governor ADEC (ECU 7) – Fault
2.3 Main Engine Dimensions 53
2.3.1 Engine – Main dimensions 53 codes 97

2.4 Firing Sequence 55 6 Task Description

2.4.1 Firing order 55

2.5 Technical Data 56 6.1 Engine 162

6.1.1 Engine – Barring manually 162
2.5.1 12V 4000 M23F engine data, RheinSchUO,
6.1.2 Engine – Barring with starting system 164
stage II, IMO Tier II 56
2.5.2 12V 4000 M23S engine data, RheinSchUO, 6.2 Cylinder Liner 165
stage II, IMO Tier II 59 6.2.1 Cylinder liner – Endoscopic examination 165
2.5.3 12V 4000 M23S engine data, IMO Tier II, EPA 6.2.2 Instructions and comments on endoscopic and
Tier 2 62 visual examination of cylinder liners 167
2.5.4 16V 4000 M23F engine data, RheinSchUO,
stage II, IMO Tier II 65 6.3 Crankcase Breather 169
2.5.5 16V 4000 M23S engine data, RheinSchUO, 6.3.1 Crankcase breather – Overview 169
stage II, IMO Tier II 68 6.3.2 Crankcase breather – Oil mist fine separator
2.5.6 16V 4000 M23S engine data, IMO Tier II, EPA replacement 171
Tier 2 71 6.4 Valve Drive 172
6.4.1 Valve gear – Lubrication 172
6.4.2 Valve clearance – Check and adjustment 173
3 Operation
6.4.3 Cylinder head cover – Removal and
3.1 Controls 74 installation 176
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3.2 Putting the engine into operation after 6.5 Injection Pump / HP Pump 177
extended out-of-service periods (>3 months) 75 6.5.1 HP pump – Filling with engine oil 177
3.3 Putting the engine into operation after 6.5.2 HP pump – Relief bore check 178
scheduled out-of-service-period 76
6.6 Injection Valve / Injector 179
3.4 Starting the engine 77 6.6.1 Injector – Replacement 179
3.5 Operational checks 78 6.6.2 Injector – Removal and installation 180
3.6 Tasks after extended out-of-service periods
(>3 weeks) 79 6.7 Fuel Filter 185
6.7.1 Supplementary fuel filter – Overview 185
3.7 Checks prior to start-up 80
6.7.2 Additional fuel filter – Replacement 186

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6.7.3 Fuel filter – Replacement 187 6.15.11 Preheater – Function and leak-tightness check 248
6.7.4 Fuel system – Venting 189
6.7.5 Fuel prefilter – Differential pressure check
6.16 Raw Water Pump with Connections 249
6.16.1 Raw water pump – Relief bore check 249
and adjustment of gauge 190
6.7.6 Fuel prefilter – Draining 191 6.17 Engine Mounting / Support 250
6.7.7 Fuel prefilter – Flushing 193 6.17.1 Engine mounting – Check 250
6.7.8 Fuel prefilter with water separator – Filter
element replacement 195 6.18 Battery-Charging Generator 251
6.7.9 Fuel prefilter with water separator – O-ring 6.18.1 Battery-charging generator drive – Coupling
replacement in rotary slide valve 197 condition check 251

6.8 Exhaust Turbocharger 198 6.19 Auxiliary PTO 252

6.8.1 Overview of turbocharger 198 6.19.1 Bilge pump – Relief bore check 252
6.8.2 Compressor wheel – Cleaning 205 6.20 Fuel Supply System 253
6.9 Charge-Air Cooling 213 6.20.1 Water drain valve – Check 253
6.9.1 Intercooler – Checking condensate drain for 6.20.2 Differential pressure gauge – Check 254
water discharge and obstruction 213 6.20.3 Water level probe (3-in-1 rod electrode) –
Check 255
6.10 Air Filter 214 6.20.4 Pump capacity – Check 256
6.10.1 Air filter – Replacement 214 6.20.5 Coalescer filter element – Replacement 257
6.10.2 Air filter – Removal and installation 215
6.21 Wiring (General) for Engine/Gearbox/Unit 259
6.11 Air Intake 216 6.21.1 Engine wiring harness – Overview 259
6.11.1 Service indicator – Signal ring position check 6.21.2 Engine wiring – Check 265
(optional) 216
6.22 Accessories for (Electronic) Engine
6.12 Starting Equipment 217 Governor / Control System 266
6.12.1 Starter – Condition check 217 6.22.1 CDC parameters – Reset 266
6.13 Lube Oil System, Lube Oil Circuit 218 6.22.2 Limit switch for start interlock ‒ Check 267
6.13.1 Engine oil – Level check 218 6.22.3 Engine Control Unit ECU 7 – Checking plug
6.13.2 Engine oil – Change 219 connections 268
6.13.3 Engine oil – Sample extraction and analysis 221 6.22.4 Engine Monitoring Unit EMU 7 – Plug
connection check 269
6.14 Oil Filtration / Cooling 223 6.22.5 Interface module EIM plug connections –
6.14.1 Engine oil filter ‒ Replacement 223 Check 270
6.14.2 Oil indicator filter – Cleaning and check 225 6.22.6 Engine Control Unit ECU 7 – Removal and
6.14.3 Centrifugal oil filter – Cleaning and filter installation 271
sleeve replacement 227 6.22.7 EMU 7 – Removal and installation 272
6.22.8 Engine Interface Module EIM – Removal and
6.15 Coolant Circuit, General, High-Temperature
installation 273
Circuit 230 6.22.9 Diagnostic features of EIM 274
6.15.1 Drain and vent points 230
6.15.2 Engine coolant level – Check 234
6.15.3 Engine coolant – Change 235 7 Appendix A
6.15.4 Engine coolant – Draining 236
6.15.5 Engine coolant – Filling 239 7.1 Abbreviations 277
6.15.6 HT coolant pump – Relief bore check 241 7.2 MTU contact persons/service partners 279
6.15.7 Engine coolant – Sample extraction and
analysis 242
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8 Appendix B
6.15.8 Engine coolant filter – Replacement 243
6.15.9 Preheating unit 244 8.1 Special Tools 280
6.15.10 Preheater – Overhaul 247 8.2 Index 285

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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.

General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices

Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation. The manufacturer will accept no liability for such damage.

Modifications or conversions
Unauthorized modifications to the product compromise safety.
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The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.

Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.

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1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.

Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.

Working clothes and personal protective equipment

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.

TIM-ID: 0000040531 - 002

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1.3 Transport
Transport

Attach the engine at the lifting eyes provided only.

The lifting eyes are designed for engine transport only, not for the transport of propulsion units (engine
and gearbox).
Use only the transport and lifting gear approved by MTU.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
Take note of the engine center of gravity.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans-
port pallet or transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft
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.
TIM-ID: 0000002621 - 004

Setting the engine down after transport

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

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1.4 Safety regulations for maintenance and repair work
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to below 50°C before starting maintenance work (risk of explosion of oil
vapors, fluids and lubricants, risk of burning).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use
suitable containers of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately venti-
lated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Secure the product against unintentional starting, e.g. with start interlock.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery. Lock contactors.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the product.
The following applies to starters with copper-beryllium alloy pinions:
• Wear breathing protection of filter class P3 during maintenance work. Do not blow out the interior of
the flywheel housing or the starter with compressed air. Clean the flywheel housing inside with a
class H dust extraction device.
• Observe the safety data sheet.

Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assemblies or plants 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.
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Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomer 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 equipment, always use suitable ladders and work platforms. Make sure com-
ponents or assemblies are placed on stable surfaces.

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Ensure particular cleanness during maintenance and repair work on the product. After completion of
maintenance and repair work, make sure that no unattached parts are in/on the product (e.g. cloths
and cable ties).

Safety regulations after completion of maintenance and repair work

Before barring, make sure that nobody is standing in the danger zone of the product.
After working on the product, check that all openings opened for work are closed again.
Check that all guards have been reinstalled and that all tools and loose parts have been removed after
working on the product (in particular, the barring tool).

Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding
in its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is
going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product.
The welding current may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand.

Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only
the specified jigs and fixtures for hydraulic removal/installation procedures.
Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal jig, 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 jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
TIM-ID: 0000040535 - 004

Working with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.
Gases emanating from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come in contact with skin or clothing.
Wear goggles and protective gloves.
Never place tools on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.

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Working on electrical and electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged dur-
ing 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 straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a function check on completion of all repair work. In partic-
ular, check the function of the engine emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack
defective electronic components and assemblies in a suitable manner when dispatched for repair, i.e.
protected, in particular, against moisture and impact and wrapped in anti-static foil if necessary.

Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi-
ly focused radiation).
Laser equipment must be equipped with the protective devices necessary for safe operation according
to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.

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1.5 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore al-
ways keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on
the product. Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power
source to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with
their use.

Noise
Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.
Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A).

Environmental protection and disposal

Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer. Noncompliance with these guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.

Fluids and lubricants and auxiliary materials

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum-
ables and other chemical substances, follow the safety regulations that apply to the product. Take spe-
cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
TIM-ID: 0000040536 - 005

coming into contact with ignition sources and do not smoke.

Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.

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

Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products to be connected must either be designed for that pressure, or, if the permis-
sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.
• Carry out leak test in accordance with the specifications.

Paints and varnishes

• Observe the relevant safety data sheet for all materials.
• When painting in areas other than spray booths equipped with extractors, ensure good ventilation.
Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

Acids/alkaline solutions/urea (AdBlue®, DEF)

TIM-ID: 0000040536 - 005

• Observe the relevant safety data sheet for all materials.

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• If spilled onto clothing, remove the affected clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi-
ble.

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1.6 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.

NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial action.
• Additional product information.

Safety notices
u This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
TIM-ID: 0000040578 - 002

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2 Product Summary
2.1 Engine Layout
2.1.1 Product description
Description of the engine
Engine
The engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from driving
end), with direct injection, sequential turbocharging and charge air cooling.
The engine is monitored by an engine control and monitoring system (ADEC).

Fuel system
Electronically controlled common-rail-injection system with HP pump, pressure accumulator (rail) and
single injectors with integrated individual store.
The electronic control unit controls
• Injection start
• Injection quantity
• Injection pressure

Exhaust system
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
• low surface temperature,
• reduced amount of heat to be dissipated by the coolant,
• absolute gas-tightness.

Turbocharging
Sequential turbocharging with internal, engine-coolant-controlled charge air cooling. The right-hand ex-
haust turbocharger is cut-in and cut-out on 12V and 16V engines with electronically-controlled, hydraul-
ically-actuated flaps.

Cooling system
Split-circuit engine cooling system with remote or engine-mounted heat exchanger.
Heating of the charge air in idle and low-load operation prevents white smoke formation.
Seawater flows only through engine coolant cooler and fuel cooler as well as the raw water pump (if
fitted).
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Service block
The service components are mounted at the auxiliary PTO end.
The layout permits easy access for maintenance.
Service-components:
• Raw water pump (if fitted), coolant pump
• Centrifugal lube oil filter
• Coolant expansion tank (only on engines with engine-mounted heat exchanger)
• Coolant filter

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Intermittent oil priming for marine genset engines (M23-M43)
The standard configuration of these engines comprises intermittent oil priming.
Oil priming is activated every 30 minutes. The oil priming process ends as soon as oil pressure in the
main oil gallery reaches 0.4 bar or after 180 seconds, at the latest.
If a pressure of at least 0.2 bar is not attained after 180 seconds, an alarm is output.
To avoid engine damage from a hydraulic lock due to excessive oil supply to the combustion chambers,
the engine must be started at least once a month.

Electronic system
Electronic control and monitoring system with integrated safety and test system with interfaces to Re-
mote Control System (RCS) and to Monitoring and Control System (MCS).

Engine Interface Module (EIM)

The Engine Interface Module (EIM) is the central connection box on the engine. It covers the complete
minimum scope of a marine engine. It does not comprise controls of components requiring mainte-
nance.
Functions:
• Starter control (start repetition, tooth alignment, starter protection)
• Monitoring of the battery-charging generator
• Open bus interface to the plant (SAE J1939)
• Emergency stop function with line break monitoring
• Redundant supply voltage input
• Emergency air-shutoff flap control (option)
• Key switch logic
• Interface to ECU and EMU
• MCS5 dialog interface
• Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box)
• Connection facility for an MTU Local Operating Station (LOS)

Serial RS422 interface for diagnosis

The engine interface comprises two parts. The first part of signals is integrated in the engine wiring har-
ness with a 62-pole Tyco connector X52. The second part refers to signals associated with higher cur-
rents. These signals are led out via M threaded pins and also integrated in the engine wiring harness.
Functions
• ECU supply
• EMU supply
• Plant signals (ECU7 connector X1)
• Bus interface (2x MCS5 CAN)
• CAN dialog output (1xMCS5 CAN)
• Emergency stop from EMU and ECU
• Electric starter
• Terminal 45 starter A/B (engaged)
• Pneumatic starter
TIM-ID: 0000010054 - 009

• Starting-air pressure valve

• Start-air pressure sensor
• Barring gear (1 and 2)
• Battery-charging generator (with exciter control)
• Optional emergency-air shutoff flaps
• Activation signal to air shut-off flaps 1+2
• Feedback signal from air shut-off flaps 1+2

MS150068/01E 2014-01 | Product Summary | 17

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Electronic engine governor (ECU)
Functions:
• Engine speed control with fuel and speed limitation dependent on engine status and operating condi-
tions
• Control of sequential turbocharging, cylinder bank cut-out and air recirculation function
• Data processing logistics for analog and binary signals
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring

Electronic Engine Monitoring Unit (EMU)

Functions:
• Data processing logistics for analog and binary signals
• Interface for data transfer to CAN field bus for remote control and ship-side monitoring

Low-load operation
12/16V4000M53R/M53/M63R/M63/M63L engines

1 Low-load operation 2 Cleaning cycle 3 ditto

MTU marine engine Series 4000M53R to …M93L may be operated in low-load operation. State-of-the-
art design and equipment features, e.g. TE coolant circuit, sequential turbocharging, jacketed, coolant-
TIM-ID: 0000010054 - 009

cooled exhaust lines, Common Rail fuel injection and cylinder cutout allow engine operation at low load.
Nevertheless, low-load operation at engine load below 15% of the nominal rating is permitted for max.
100 hours. In order to avoid inadmissible oil carbon and/or carbon particle deposits in the engine, it is
recommended to carry out a cleaning cycle for at least 20 minutes after extended low-load operation
periods. During the cleaning cycle, engine speed (power) must be increased step by step until all ex-
haust turbochargers are running. The figure shows the basic speed/power run-up procedure for the
cleaning cycle to be carried out.

18 | Product Summary | MS150068/01E 2014-01

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12/16V4000M23S/M23F/M33S/M33F/M43S engines

A Engine power B Engine speed ETC Exhaust turbocharger

MTU marine genset engine Series 4000M23/M33/M43 may be operated in low-load operation. State-
of-the-art design and equipment features e.g. TE coolant circuit, jacketed, coolant-cooled exhaust lines,
Common Rail fuel injection and cylinder cutout allow engine operation at low load.
Low-load operation (engine power up to approx. 20% of rated power) takes place in single-ETC mode
(with only one exhaust turbocharger running). To ensure the functionality of the control mechanism and
of the exhaust flap of the turbocharger which does not run in low-load operation, it is recommended to
operate the engine with both exhaust turbochargers running after 100 operating hours in low-load oper-
ation, at the latest.

SOLAS – Fire protection specifications

Fuel system, fuel lines with fuel pressure >1.8 bar
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are
shown.
TIM-ID: 0000010054 - 009

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1 SOLAS clip on the fuel line: after LP
pump

1 SOLAS clip on the fuel line: on fuel

filter head retainer

1 SOLAS clip on the fuel line: on HP

pump
2 SOLAS clip on the fuel line: after fuel
filter head
TIM-ID: 0000010054 - 009

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1 SOLAS clips on the fuel line: on fuel
filter head retainer

1 SOLAS clips on the fuel line: on fuel

filter head

Lube oil system, oil lines with oil pressure >1.8 bar
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are
shown.
TIM-ID: 0000010054 - 009

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1 SOLAS clips on exhaust flap switch-
ing cylinder ETC B1

1 SOLAS clips on air flap switching

cylinder ETC B1
2 SOLAS clips on flap control T adapt-
er ETC B1

1 SOLAS clips on distributor element

2 SOLAS clips on oil return
TIM-ID: 0000010054 - 009

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1 SOLAS clip on oil return

1 SOLAS clip on oil line to ETC

2 SOLAS clip on oil line to flap control
3 SOLAS clip on oil line to recircula-
tion valve
4 SOLAS clips on oil line from main
gallery

1 SOLAS clips on recirculation valve

TIM-ID: 0000010054 - 009

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1 SOLAS clip on HP pump oil supply:
on HP pump

1 SOLAS clip on HP pump oil supply:

on equipment carrier

1 SOLAS clip on ETC oil supply

2 SOLAS clip on ETC oil supply
TIM-ID: 0000010054 - 009

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1 SOLAS clips of oil line on equipment
carrier

1 Cover on oil filter cartridge

Special connections
The following types of union are spray-proof in case of leakage even without covers and have been con-
firmed as being SOLAS-compliant by GL and DNV.
TIM-ID: 0000010054 - 009

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Plugs and sensors (a)
Screw-in plugs (4) are sealed toward the outside either with a copper sealing ring (1), according to DIN,
or an O-ring (ISO).
In case of a loose thread or a defective sealing ring (1), the liquid first has to pass the thread.
The pressure is so greatly reduced by this and the faulty sealing ring (1) that any leakage is not under
pressure.

Plug-in pipe union (b)

The sleeve (3) covers the joint to prevent lateral spray.
Only leak-off along the line is possible, the pressure is decreases significantly if an O-ring (2) defect
occurs.
The union is confirmed as being SOLAS-compliant by DNV and GL.
TIM-ID: 0000010054 - 009

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HP connections

1 Jacket pipe 8 Thrust ring 15 Union nut

2 HP fuel line 9 Union nut 16 Thrust ring
3 O-ring 10 Union nut 17 HP line outer pipe
4 Union nut 11 Connecting piece 18 Internal pipe of HP line
5 Recess for O-ring 12 Snap ring 19 Ball-type seal area
6 Thrust ring 13 Thrust ring 20 Leak-fuel connection
7 Leakage overflow bore 14 Shim washers
The HP fuel line is sealed by the thrust ring (8).
If leakage in the area of the thrust ring (8) or the HP line (2) occurs, the emerging fuel is routed to the
leakage chamber.
The leaking fuel is drained off without pressure via the leakage overflow-bore (7). The leakage chamber
is sealed toward the outside by the O-rings (3).
This prevents leakage egress.
The union is confirmed as being SOLAS-compliant by DNV and GL.
TIM-ID: 0000010054 - 009

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2.1.2 Engine layout
Engines with remote heat exchanger and horizontal air intake

1 Engine management and 10 Recirculation line 19 Battery-charging generator

monitoring 11 Exhaust manifold 20 HP fuel pump
2 Oil cooler 12 Engine mounts 21 Oil filter
3 Centrifugal oil filter 13 Charge-air line 22 Bilge pump (option)
4 Crankcase breather 14 Oil pan 23 Coolant outlet to remote
5 Dry-type air filter 15 Oil filler neck cooling system
6 Exhaust turbocharger 16 Crankcase 24 Coolant inlet from remote
7 Exhaust outlet 17 Cylinder head cooling system
8 Air pipe to intercooler 18 Fuel filter KGS Free end
9 Intercooler
TIM-ID: 0000009990 - 007

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Engines with engine-mounted heat exchanger and horizontal air intake

1 Raw-water outlet 10 Exhaust outlet 19 Cylinder head

2 Engine management and 11 Air pipe to intercooler 20 Crankcase
monitoring 12 Recirculation line 21 Fuel filter
3 Plate-core heat exchanger 13 Exhaust manifold 22 Battery-charging generator
4 Oil cooler 14 Intercooler 23 HP fuel pump
5 Coolant expansion tank 15 Charge-air line 24 Oil filter
6 Centrifugal oil filter 16 Engine mounts 25 Bilge pump (option)
7 Crankcase breather 17 Oil pan 26 Raw-water inlet
8 Dry-type air filter 18 Oil filler neck KGS Free end
9 Exhaust turbocharger
TIM-ID: 0000009990 - 007

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Engines with remote heat exchanger and vertical air intake

1 Coolant outlet to remote 10 Exhaust turbocharger 19 Cylinder head

cooling system 11 Exhaust outlet 20 Fuel filter
2 Coolant inlet from remote 12 Air pipe to intercooler 21 Oil filter
cooling system 13 Intercooler 22 HP fuel pump
3 Engine management and 14 Engine mounts 23 Battery-charging generator
monitoring 15 Charge-air line 24 Bilge pump (option)
4 Oil cooler 16 Oil pan KGS Free end
5 Centrifugal oil filter 17 Oil filler neck
6 Crankcase breather 18 Crankcase
7 Dry-type air filter
8 Exhaust manifold
9 Recirculation line
Overview drawing is also valid for 16V engines. TIM-ID: 0000009990 - 007

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Engines with engine-mounted heat exchanger and vertical air intake

1 Raw-water outlet 10 Recirculation line 19 Crankcase

2 Engine management and 11 Exhaust turbocharger 20 Cylinder head
monitoring 12 Exhaust outlet 21 Fuel filter
3 Oil cooler 13 Air pipe to intercooler 22 Oil filter
4 Plate-core heat exchanger 14 Intercooler 23 HP fuel pump
5 Coolant expansion tank 15 Charge-air line 24 Battery-charging generator
6 Centrifugal oil filter 16 Engine mounts 25 Bilge pump (option)
7 Crankcase breather 17 Oil pan 26 Raw-water inlet
8 Dry-type air filter 18 Oil filler neck KGS Free end
9 Exhaust manifold
Overview drawing is also valid for 16V engines.

Engine model designation

Key to the engine model designations 12/16V 4000 Mxy z
12, 16 Number of cylinders
V Cylinder arrangement: V-engine
4000 Series
TIM-ID: 0000009990 - 007

M Application (M= Marine)

x Application load profile (0, 1, 2, 3...9)
y Design index (0, 1, 2, 3...9)
z R (power / speed reduction)
L (enhanced power / speed)
S (60 Hz)
F (50 Hz)

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2.1.3 Overview of sensors and actuators
Top view of 12V 4000 M with external cooling

1 B49 (charge-air temp., air 2 B4.A1-B4.B6 (single ex- 3 B33 (fuel temperature in
recirculation valve) haust temp., A1-A6, B1- common rail)
Y26 (air recirculation valve B6)
A)

TIM-ID: 0000038758 - 002

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Aux. PTO end, 12V 4000 M, external cooling

1 B7 (engine oil temp.) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (oil pressure up- common rail) sure)
stream of filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (oil pressure down- mon rail) ture)
stream of filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)
TIM-ID: 0000038758 - 002

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Main PTO end, 12V 4000 M, external cooling

1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch)

ture, A bank) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed)
2 B4.22 (exhaust tempera-
ture, B bank)

TIM-ID: 0000038758 - 002

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Left side of engine, 12V 4000 M, external cooling

1 B50 (crankcase pressure) 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure down-
2 B3 (intake air temperature) 5 B34.3 (fuel pressure upstream of filter)
3 B44.1 (turbocharger A stream of filter) 8 F46 (fuel overflow level)
speed) 6 B34.2 (fuel pressure up-
stream of filter)
TIM-ID: 0000038758 - 002

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Right side of engine, 12V 4000 M, external cooling

1 B44.2 (turbocharger B 3 B16 (coolant pressure)

speed) 4 B9 (charge-air tempera-
2 Y27 (turbocharger control ture)
valve)

TIM-ID: 0000038758 - 002

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Top view, 12V 4000 M, integral cooling

1 B4.A1-B4.B6 (single ex- 2 B33 (fuel temperature in 3 F33 (coolant level)

haust temp., A1-A6, B1- common rail)
B6)
TIM-ID: 0000038758 - 002

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Aux. PTO end, 12V 4000 M, integral cooling

TIM-ID: 0000038758 - 002

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Main PTO end, 12V 4000 M, integral cooling

1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch)

ture, A bank) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed)
2 B4.22 (exhaust tempera-
ture, B bank)
TIM-ID: 0000038758 - 002

MS150068/01E 2014-01 | Product Summary | 39

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Left side of engine, 12V 4000 M, integral cooling

1 B50 (crankcase pressure) 4 B44.1 (turbocharger A 7 B34.2 (fuel pressure up-

2 B49 (charge-air temp., air speed) stream of filter)
recirculation valve) 5 B10 (charge-air pressure) 8 B34.1 (fuel pressure down-
Y26 (air recirculation valve 6 B34.3 (fuel pressure upstream of filter)
A) stream of filter) 9 F46 (fuel overflow level)
3 B3 (intake air temperature)

TIM-ID: 0000038758 - 002

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Right side of engine, 12V 4000 M, integral cooling

1 B44.2 (turbocharger B 3 B16 (coolant pressure) 5 B9 (charge-air tempera-

speed) 4 B21 (raw water pressure) ture)
2 Y27 (turbocharger control
valve)
TIM-ID: 0000038758 - 002

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Top view of 16V 4000 M with external cooling

1 B49 (charge-air temp., air 2 B4.A1-B4.B8 (single ex- 3 B33 (fuel temperature in
recirculation valve) haust temp., A1-A8, B1- common rail)
Y26 (air recirculation valve B8)
A)

TIM-ID: 0000038758 - 002

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Aux. PTO end, 16V 4000 M, external cooling

MS150068/01E 2014-01 | Product Summary | 43

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Main PTO end, 16V 4000 M, external cooling

1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch)

ture, A bank) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed)
2 B4.22 (exhaust tempera-
ture, B bank)

TIM-ID: 0000038758 - 002

44 | Product Summary | MS150068/01E 2014-01

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Left side of engine, 16V 4000 M, external cooling

MS150068/01E 2014-01 | Product Summary | 45

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Right side of engine, 16V 4000 M, external cooling

1 B44.2 (turbocharger B 3 B16 (coolant pressure)

speed) 4 B9 (charge-air tempera-
2 Y27 (turbocharger control ture)
valve)

TIM-ID: 0000038758 - 002

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Top view, 16V 4000 M, integral cooling

1 B4.A1-B4.B8 (single ex- 2 B33 (fuel temperature in 3 F33 (coolant level)

haust temp., A1-A8, B1- common rail)
B8)
TIM-ID: 0000038758 - 002

MS150068/01E 2014-01 | Product Summary | 47

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Aux. PTO end, 16V 4000 M, integral cooling

TIM-ID: 0000038758 - 002

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Main PTO end, 16V 4000 M, integral cooling

1 B4.21 (exhaust tempera- 3 B13 (crankshaft speed) 5 S37.1 (safety switch)

ture, A bank) 4 S37.2 (safety switch) 6 B13.2 (crankshaft speed)
2 B4.22 (exhaust tempera-
ture, B bank)
TIM-ID: 0000038758 - 002

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Left side of engine, 16V 4000 M, integral cooling

1 B50 (crankcase pressure) 4 B44.1 (turbocharger A 7 B34.2 (fuel pressure up-

TIM-ID: 0000038758 - 002

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Right side of engine, 16V 4000 M, integral cooling

1 B44.2 (turbocharger B 3 B16 (coolant pressure) 5 B9 (charge-air tempera-

speed) 4 B21 (raw water pressure) ture)
2 Y27 (turbocharger control
valve)
TIM-ID: 0000038758 - 002

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2.2 Engine Side and Cylinder Designations
2.2.1 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS) (4).
For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on
the left-hand side of the engine and the letter "B" (3) to refer to the cylinders on the right-hand side. The
cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
The numbering of other engine components also starts with no. 1 at the driving end.

1 Left-hand side of engine 3 Right-hand side of engine

2 Free end 4 Driving end

TIM-ID: 0000002185 - 012

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2.3 Main Engine Dimensions
2.3.1 Engine – Main dimensions

Engines with horizontal air intake

With remote heat exchanger
Engine model Length (A) Width (B) without Width (B) with si- Height (C)
silencer lencer
16V 4000 approx. 3108 mm approx. 1690 mm approx. 1850 mm approx. 2064 mm
M23S/23F/33S/33F/
TIM-ID: 0000010043 - 004

43S
16V 4000 M53R/
53/63R/63/63L

With engine-mounted heat exchanger

Engine model Length (A) Width (B) without Width (B) with si- Height (C)
silencer lencer
16V 4000 approx. 3388 mm approx. 1690 mm approx. 1850 mm approx. 2064 mm
M23S/23F/33S/33F/
43S

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Engine model Length (A) Width (B) without Width (B) with si- Height (C)
silencer lencer
16V 4000 M53R/
53/63R/63/63L

Engines with vertical air intake

With remote heat exchanger
Engine model Length (A) Width (B) Height (C) without Height (C) with si-
silencer lencer
12V 4000 approx. 2628 mm approx. 1602 mm approx. 2368 mm approx. 2448 mm
M23S/23F/33S/
33F
12V 4000 M53R/
53/63
16V 4000 approx. 3108 mm approx. 1602 mm approx. 2361 mm approx. 2441 mm
M23S/23F/33S/33F/
43S
16V 4000 M53R/
53/63R/63/63L

With engine-mounted heat exchanger

Engine model Length (A) Width (B) Height (C) without Height (C) with si-
silencer lencer
12V 4000 approx. 2857 mm approx. 1602 mm approx. 2368 mm approx. 2448 mm
M23S/23F/33S/
33F
12V 4000 M53R/
53/63
16V 4000 approx. 3388 mm approx. 1602 mm approx. 2361 mm approx. 2441 mm
M23S/23F/33S/33F/
43S
16V 4000 M53R/
53/63R/63/63L

TIM-ID: 0000010043 - 004

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2.4 Firing Sequence
2.4.1 Firing order
Cylinders Firing order
12 V 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
TIM-ID: 0000023263 - 002

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2.5 Technical Data
2.5.1 12V 4000 M23F engine data, RheinSchUO, stage II, IMO Tier II
Explanation:
DL Ref. value: Continuous power
BL Ref. 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 settings).
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

mounted separate
Application group 3A 3A 3A 3A
Intake-air temperature °C 25 32 25 32
Charge-air coolant temperature °C - - - -
Raw-water inlet temperature °C 25 45 25 45
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100

POWER DATA (power ratings are net brake power as per ISO 3046)
Heat exchanger Heat exchanger
mounted separate
Rated engine speed A rpm 1500 1500 1500 1500
Continuous power ISO 3046 (10% over- A kW 1140 1140 1140 1140
load capability, design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
mounted separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

TIM-ID: 0000022715 - 001

Heat exchanger Heat exchanger

mounted separate
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

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Heat exchanger Heat exchanger
mounted separate
Number of inlet valves per cylinder 2 2 2 2
Number of exhaust valves per cylinder 2 2 2 2

RAW-WATER CIRCUIT (open circuit)

Heat exchanger Heat exchanger
mounted separate
Raw-water pump: Inlet pressure, min. L bar -0.4 -0.4 -- --
Raw-water pump: Inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in engine-external raw-water L bar N N -- --
system, max.

LUBE-OIL SYSTEM
Heat exchanger Heat exchanger
mounted separate
Lube-oil operating temperature before en- R °C 81 81 81 81
gine, from
Lube-oil operating temperature before en- R °C 89 89 89 89
gine, to
Lube-oil operating pressure before engine, R bar 5.0 5.0 5.0 5.0
from
Lube-oil operating pressure before engine, R bar 6.0 6.0 6.0 6.0
to
Lube-oil operating pressure (low idle) R bar
(meas. point: before engine)

FUEL SYSTEM
Heat exchanger Heat exchanger
mounted separate
Fuel pressure at supply connection to en- L bar -0.1 -0.1 -0.1 -0.1
gine, min. (when engine is starting)
Fuel pressure at supply connection to en- L bar -0.3 -0.3 -0.3 -0.3
gine, min. (when engine is running)
Fuel pressure at supply connection to en- L bar 1.5 1.5 1.5 1.5
gine, max. (when engine is starting)
Fuel supply flow, max. A Liters/
min
TIM-ID: 0000022715 - 001

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
mounted separate
Firing speed, from R rpm 80 80 80 80
Firing speed, to R rpm 120 120 120 120

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STARTING SYSTEM (electric)
Heat exchanger Heat exchanger
mounted separate
Rated starter voltage (standard design) R V= 24 24 24 24

STARTING (with compressed air/hydraulic starter)

Heat exchanger Heat exchanger
mounted separate
Starting-air pressure before starter, min. R bar 8 8 8 8
Starting-air pressure before starter, max. R bar 10 10 10 10

CAPACITIES
Heat exchanger Heat exchanger
mounted separate
Engine coolant, engine-side (with cooling R Liters 305 305 -- --
system)
Engine oil, total, for initial filling (standard R Liters N N N N
oil system) (option: max. operating inclina-
tions)
Oil change quantity, max. (standard oil R Liters 265 265 265 265
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark "min." L Liters 195 195 195 195
(standard oil system) (option: max. oper-
ating inclinations)
Oil pan capacity at dipstick mark "max." L Liters 235 235 235 235
(standard oil system) (option: max. oper-
ating inclinations)

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
mounted separate
Engine dry weight (with attached standard R kg 7640 7640 7240 7240
accessories, without coupling)

ACOUSTICS
Heat exchanger Heat exchanger
mounted separate
Exhaust noise, unsilenced - DL (free-field R dB(A) 105 105 105 105
TIM-ID: 0000022715 - 001

sound pressure level Lp, 1m distance, ISO

6798, +3dB(A) tolerance)

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2.5.2 12V 4000 M23S engine data, RheinSchUO, stage II, IMO Tier II
Explanation:
DL Ref. value: Continuous power
BL Ref. 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 settings).
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

mounted separate
Application group 3A 3A 3A 3A
Intake-air temperature °C 25 45 25 45
Charge-air coolant temperature °C - - - -
Raw-water inlet temperature °C 25 32 25 32
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100

POWER DATA (power ratings are net brake power as per ISO 3046)
Heat exchanger Heat exchanger
mounted separate
Rated engine speed A rpm 1800 1800 1800 1800
Continuous power ISO 3046 (10% over- A kW 1380 1380 1380 1380
load capability, design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
mounted separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

Heat exchanger Heat exchanger
mounted separate
TIM-ID: 0000022718 - 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
Number of inlet valves per cylinder 2 2 2 2
Number of exhaust valves per cylinder 2 2 2 2

MS150068/01E 2014-01 | Product Summary | 59

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RAW-WATER CIRCUIT (open circuit)
Heat exchanger Heat exchanger
mounted separate
Raw-water pump: Inlet pressure, min. L bar -0.4 -0.4 -- --
Raw-water pump: Inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in engine-external raw-water L bar N N -- --
system, max.

LUBE-OIL SYSTEM
Heat exchanger Heat exchanger
mounted separate
Lube-oil operating temperature before en- R °C 84 85 84 85
gine, from
Lube-oil operating temperature before en- R °C 92 93 92 93
gine, to
Lube-oil operating pressure before engine, R bar 5.5 5.5 5.5 5.5
from
Lube-oil operating pressure before engine, R bar 6.5 6.5 6.5 6.5
to
Lube-oil operating pressure (low idle) R bar
(meas. point: before engine)

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
mounted separate
Firing speed, from R rpm 80 80 80 80
TIM-ID: 0000022718 - 001

Firing speed, to R rpm 120 120 120 120

STARTING SYSTEM (electric)

Heat exchanger Heat exchanger
mounted separate
Rated starter voltage (standard design) R V= 24 24 24 24

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STARTING (with compressed air/hydraulic starter)
Heat exchanger Heat exchanger
mounted separate
Starting-air pressure before starter, min. R bar 8 8 8 8
Starting-air pressure before starter, max. R bar 10 10 10 10

CAPACITIES
Heat exchanger Heat exchanger
mounted separate
Engine coolant, engine-side (with cooling R Liters 305 305 -- --
system)
Engine oil, total, for initial filling (standard R Liters N N N N
oil system) (option: max. operating inclina-
tions)
Oil change quantity, max. (standard oil R Liters 265 265 265 265
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark "min." L Liters 195 195 195 195
(standard oil system) (option: max. operat-
ing inclinations)
Oil pan capacity at dipstick mark "max." L Liters 235 235 235 235
(standard oil system) (option: max. operat-
ing inclinations)

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
mounted separate
Engine dry weight (with attached standard R kg 7640 7640 7240 7240
accessories, without coupling)

ACOUSTICS
Heat exchanger Heat exchanger
mounted separate
Exhaust noise, unsilenced - DL (free-field R dB(A) 106 106 106 106
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
TIM-ID: 0000022718 - 001

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2.5.3 12V 4000 M23S engine data, IMO Tier II, EPA Tier 2
Explanation:
DL Ref. value: Continuous power
BL Ref. 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 settings).
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
mounted separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

Heat exchanger Heat exchanger
mounted separate
TIM-ID: 0000022719 - 001

Cylinder arrangement: V-angle Degrees 90 90 90 90

62 | Product Summary | MS150068/01E 2014-01

LUBE-OIL SYSTEM
Heat exchanger Heat exchanger
mounted separate
Lube-oil operating temperature before en- R °C 85 85 85 85
gine, from
Lube-oil operating temperature before en- R °C 93 93 93 93
gine, to
Lube-oil operating pressure before engine, R bar 5.5 5.5 5.5 5.5
from
Lube-oil operating pressure before engine, R bar 6.5 6.5 6.5 6.5
to
Lube-oil operating pressure (low idle) R bar
(meas. point: before engine)

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
mounted separate
Firing speed, from R rpm 80 80 80 80
TIM-ID: 0000022719 - 001

Firing speed, to R rpm 120 120 120 120

STARTING SYSTEM (electric)

Heat exchanger Heat exchanger
mounted separate
Rated starter voltage (standard design) R V= 24 24 24 24

MS150068/01E 2014-01 | Product Summary | 63

CAPACITIES
Heat exchanger Heat exchanger
mounted separate
Engine coolant, engine-side (with cooling R Liters 305 305 -- --
system)
Engine oil, total, for initial filling (standard R Liters N N N N
oil system) (option: max. operating inclina-
tions)
Oil change quantity, max. (standard oil R Liters 265 265 265 265
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark "min." L Liters 195 195 195 195
(standard oil system) (option: max. operat-
ing inclinations)
Oil pan capacity at dipstick mark "max." L Liters 235 235 235 235
(standard oil system) (option: max. operat-
ing inclinations)

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
mounted separate
Engine dry weight (with attached standard R kg 7640 7640 7240 7240
accessories, without coupling)

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2.5.4 16V 4000 M23F engine data, RheinSchUO, stage II, IMO Tier II
Explanation:
DL Ref. value: Continuous power
BL Ref. 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 settings).
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

mounted separate
Application group 3A 3A 3A 3A
Intake-air temperature °C 25 45 25 45
Charge-air coolant temperature °C -- -- -- --
Raw-water inlet temperature °C 25 32 25 32
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100

POWER DATA (power ratings are net brake power as per ISO 3046)
Heat exchanger Heat exchanger
mounted separate
Rated engine speed A rpm 1500 1500 1500 1500
Continuous power ISO 3046 (10% over- A kW 1520 1520 1520 1520
load capability, design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
mounted separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

Heat exchanger Heat exchanger
mounted separate
TIM-ID: 0000022717 - 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 76.3 76.3 76.3 76.3
Number of inlet valves per cylinder 2 2 2 2
Number of exhaust valves per cylinder 2 2 2 2

MS150068/01E 2014-01 | Product Summary | 65

LUBE-OIL SYSTEM
Heat exchanger Heat exchanger
mounted separate
Lube-oil operating temperature before en- R °C 80 80 80 80
gine, from
Lube-oil operating temperature before en- R °C 88 88 88 88
gine, to
Lube-oil operating pressure before engine, R bar 5.0 5.0 5.0 5.0
from
Lube-oil operating pressure before engine, R bar 6.0 6.0 6.0 6.0
to
Lube-oil operating pressure (low idle) R bar -- -- -- --
(meas. point: before engine)

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
mounted separate
Firing speed, from R rpm 80 80 80 80
TIM-ID: 0000022717 - 001

Firing speed, to R rpm 120 120 120 120

STARTING SYSTEM (electric)

Heat exchanger Heat exchanger
mounted separate
Rated starter voltage (standard design) R V= 24 24 24 24

66 | Product Summary | MS150068/01E 2014-01

CAPACITIES
Heat exchanger Heat exchanger
mounted separate
Engine coolant, engine-side (with cooling R Liters 350 350 -- --
system)
Engine oil, total, for initial filling (standard R Liters N N N N
oil system) (option: max. operating inclina-
tions)
Oil change quantity, max. (standard oil R Liters 280 280 280 280
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark "min." L Liters 210 210 210 210
(standard oil system) (option: max. operat-
ing inclinations)
Oil pan capacity at dipstick mark "max." L Liters 250 250 250 250
(standard oil system) (option: max. operat-
ing inclinations)

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
mounted separate
Engine dry weight (with attached standard R kg 9020 9020 8590 8590
accessories, without coupling)

ACOUSTICS
Heat exchanger Heat exchanger
mounted separate
Exhaust noise, unsilenced - DL (free-field R dB(A) 108 108 108 108
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
TIM-ID: 0000022717 - 001

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2.5.5 16V 4000 M23S engine data, RheinSchUO, stage II, IMO Tier II
Explanation:
DL Ref. value: Continuous power
BL Ref. 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 settings).
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

POWER DATA (power ratings are net brake power as per ISO 3046)
Heat exchanger Heat exchanger
mounted separate
Rated engine speed A rpm 1800 1800 1800 1800
Continuous power ISO 3046 (10% over- A kW 1840 1840 1840 1840
load capability, design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
mounted separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

Heat exchanger Heat exchanger
mounted separate
TIM-ID: 0000022720 - 001

Cylinder arrangement: V-angle Degrees 90 90 90 90

68 | Product Summary | MS150068/01E 2014-01

LUBE-OIL SYSTEM
Heat exchanger Heat exchanger
mounted separate
Lube-oil operating temperature before en- R °C 84 87 84 87
gine, from
Lube-oil operating temperature before en- R °C 92 95 92 95
gine, to
Lube-oil operating pressure before engine, R bar 5.3 5.3 5.3 5.3
from
Lube-oil operating pressure before engine, R bar 6.3 6.3 6.3 6.3
to
Lube-oil operating pressure (low idle) R bar -- -- -- --
(meas. point: before engine)

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
mounted separate
Firing speed, from R rpm 80 80 80 80
TIM-ID: 0000022720 - 001

Firing speed, to R rpm 120 120 120 120

STARTING SYSTEM (electric)

Heat exchanger Heat exchanger
mounted separate
Rated starter voltage (standard design) R V= 24 24 24 24

MS150068/01E 2014-01 | Product Summary | 69

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
mounted separate
Engine dry weight (with attached standard R kg 9020 9020 8590 8590
accessories, without coupling)

ACOUSTICS
Heat exchanger Heat exchanger
mounted separate
Exhaust noise, unsilenced - DL (free-field R dB(A) 109 109 109 109
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
TIM-ID: 0000022720 - 001

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2.5.6 16V 4000 M23S engine data, IMO Tier II, EPA Tier 2
Explanation:
DL Ref. value: Continuous power
BL Ref. 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 settings).
N Not yet defined value
- Not applicable
X Applicable

Heat exchanger Heat exchanger

POWER DATA (power ratings are net brake power as per ISO 3046)
Heat exchanger Heat exchanger
mounted separate
Rated engine speed A rpm 1800 1800 1800 1800
Continuous power ISO 3046 (10% over- A kW 1840 1840 1840 1840
load capability, design power DIN 6280,
ISO 8528)

GENERAL CONDITIONS (for maximum power)

Heat exchanger Heat exchanger
mounted separate
Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30

MODEL-RELATED DATA (basic design)

Heat exchanger Heat exchanger
mounted separate
TIM-ID: 0000022721 - 001

Cylinder arrangement: V-angle Degrees 90 90 90 90

MS150068/01E 2014-01 | Product Summary | 71

LUBE-OIL SYSTEM
Heat exchanger Heat exchanger
mounted separate
Lube-oil operating temperature before en- R °C 84 83 84 83
gine, from
Lube-oil operating temperature before en- R °C 92 91 92 91
gine, to
Lube-oil operating pressure before engine, R bar 5.3 5.3 5.3 5.3
from
Lube-oil operating pressure before engine, R bar 6.3 6.3 6.3 6.3
to
Lube-oil operating pressure (low idle) R bar -- -- -- --
(meas. point: before engine)

GENERAL OPERATING DATA

Heat exchanger Heat exchanger
mounted separate
Firing speed, from R rpm 80 80 80 80
TIM-ID: 0000022721 - 001

Firing speed, to R rpm 120 120 120 120

STARTING SYSTEM (electric)

Heat exchanger Heat exchanger
mounted separate
Rated starter voltage (standard design) R V= 24 24 24 24

72 | Product Summary | MS150068/01E 2014-01

WEIGHTS / MAIN DIMENSIONS

Heat exchanger Heat exchanger
mounted separate
Engine dry weight (with attached standard R kg 9020 9020 8590 8590
accessories, without coupling)

MS150068/01E 2014-01 | Product Summary | 73

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3 Operation
3.1 Controls
Automation system controls
Refer to automation system operating instructions

TIM-ID: 0000016959 - 003

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3.2 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
☑Engine is stopped and starting disabled.
☑MTU Preservation and Represervation Specifications (A001070/..) are available.

Putting the engine into operation after extended out-of-service-periods (>3

months)
Item Task
Engine Depreserve (→ Preservation and Represervation Specifications A001070/..).
Lube oil system Check engine oil level (→ Page 218);
Preheat engine oil if required.
Fuel prefilter Prime with fuel (→ Page 195)
Fuel prefilter, pressure Align adjustable pointer with position of pressure indicator (→ Page 190).
gauge
HP fuel pump Only for engines without oil priming pump:
Fill HP fuel pump with new engine oil (→ Page 177).
Raw-water pump (if located Prime with water (approx. 3 – 4 l).
above waterline (only appli-
cable to engines with en-
gine-mounted heat exchang-
er or with optional remote
heat exchanger))
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 235).
Coolant circuit Check coolant level (→ Page 234).
Coolant circuit Preheat coolant with preheating unit.
Engine control system Refer to automation system operating instructions.
ECU Check plug connections (→ Page 268).
EMU Check plug connections (→ Page 269)
EIM Check plug connections (→ Page 270).
TIM-ID: 0000010092 - 005

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3.3 Putting the engine into operation after scheduled out-of-
service-period
Preconditions
☑Engine is stopped and starting disabled.

Putting into operation

Item Task
Lube oil system Check engine oil level (→ Page 218);
Preheat engine oil if required.
Coolant system Check coolant level (→ Page 234).
Coolant system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 191);
Check that suction-side pressure indicated at the fuel prefilter pressure
gauge is within the limit (→ Page 190).
Engine control system Refer to automation system operating instructions.
ECU Check plug connections (→ Page 268).
EIM Check plug connections (→ Page 270).
EMU Check plug connections (→ Page 269).

TIM-ID: 0000010655 - 004

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3.4 Starting the engine
Start the engine via the automation system
Refer to automation system operating instructions
TIM-ID: 0000017525 - 003

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3.5 Operational checks
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Operational checks
Item Measure
Engine under load Check engine visually for leaks and general condition; Check air pipework be-
Engine at nominal speed tween air filter and exhaust turbocharger for leaks and damage.
Check for abnormal running noise, vibration, and exhaust color (→ Page 92).
Charge-air cooler Check condensate drain (→ Page 213).
Air filter Check signal ring position of service indicator (→ Page 216).
Replace air filter (→ Page 214), if the signal ring is completely visible in the
service indicator control window.
HP fuel pump Check relief bores for fuel discharge (→ Page 178).
HT coolant pump Check relief bore for oil and coolant discharge and obstructions
(→ Page 241).
Fuel prefilter (optional) Check reading on differential pressure gauge (→ Page 216);
Drain water and contaminants (→ Page 193).
Raw water pump (only on Check relief bore for oil and coolant discharge and obstructions
engines with engine-mount- (→ Page 249).
ed or optional remote heat
exchanger)
Bilge pump (optional) Check relief bore for oil and coolant discharge and obstructions
(→ Page 252).

TIM-ID: 0000018474 - 003

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3.6 Tasks after extended out-of-service periods (>3 weeks)

Tasks after extended out-of-service periods (>3 weeks)

Note: Operate fuel treatment system for at least 5 minutes.
1. Start up fuel treatment system (→ Page 81).
2. Shut down fuel treatment system (→ Page 85).
TIM-ID: 0000007730 - 005

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3.7 Checks prior to start-up

Checks prior to start-up

1. Check tank and the entire pipework for cleanness. If microorganisms are detected:
a) Clean affected components.
b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications
A001061/..).
2. Close drain valves on housing.
3. Open all supply and discharge valves.
4. Switch on fuel treatment system (→ Page 84).
5. Check direction of rotation of pump.
6. Vent bypass and fuel lines of the system.
a) Open ball valve for pressure tank.
b) Open ball valve for overflow tank.
c) Close ball valve at the inlet to the fuel treatment system.
Result: Bypass line is vented via the overflow tank.
d) Open ball valve at the inlet to the fuel treatment system.
7. Check the fuel treatment system for leaks.
Result: The fuel treatment system is ready for operation.

TIM-ID: 0000007736 - 005

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3.8 Fuel treatment system – Putting into operation

Overview of fuel treatment system

1 Pressure-free overflow 9 Ball valve, outlet 17 Automatic water drain

2 Bypass 1 10 Check valve 700 mbar 18 Water level electrode
3 Bypass 2 11 Check valve 5 mbar 19 Ball valve, sample extrac-
4 Safety valve, 3 bar 12 Return to overflow con- tion, inlet
5 Ball valve, inlet tainer 20 Switchgear cabinet
6 Pressure gage 13 Engine 21 Pump
7 Ventilation, sample extrac- 14 Overflow container 22 Coarse filter
tion 15 Water separator filter 23 Fuel supply from tank
8 Differential pressure gage 16 Ball valve, drain 24 Tank

Switching on fuel treatment system

1. Switch on fuel treatment system (→ Page 84).
2. Check differential pressure at differential pressure gage (8). Differential pressure in a new system:
0.1 bar to 0.3 bar.
Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.
TIM-ID: 0000015773 - 006

1. Remove coalescer filter element (→ Page 257).

2. Check sealing surfaces on coalescer filter element and in the pressure tank.

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Initial operation: HAT
1. Replace fuel filter on engine (→ Page 187).
Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.
2. Install pressure gage in fuel supply line from Yard fuel system to engine.
3. Switch on fuel treatment system and operate it for some minutes (→ Page 84).
Result: The fuel is drawn from tank (24), cleaned by the water separator filter (15) and then routed via overflow
tank (14) back to tank (24). Water that collects in the tank is separated.
4. Start engine (→ Page 77).
5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
8. Check suction pressure at the engine-mounted fuel delivery pump.
Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter re-
placement simulation with the engine running as part of the Harbor Acceptance Tests.

Simulation of filter replacement with the engine running: HAT

1. Switch on fuel treatment system (→ Page 84).
2. Start engine (→ Page 77).
3. Run engine at idling speed.
4. Close ball valve (5) at inlet to fuel treatment system.
Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit
opens and fuel flows through bypass (3) and bypass (2).
5. Open ball valve (19) .
Result: Fuel emerges. If no fuel emerges:
• Open ball valve (5) at inlet to fuel treatment system.
• No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3) .
6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
Result: If all engine operating values are within the specified limits, open ball valve (5) at inlet to fuel treatment
system.

Simulation of power failure (emergency): HAT

1. Switch on fuel treatment system (→ Page 84).
2. Start engine (→ Page 77).
3. Run engine at idling speed.
4. Switch off pump (21) at switchgear cabinet (20).
Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
5. Check suction pressure at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
6. Increase engine speed to 1000 rpm and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful.
TIM-ID: 0000015773 - 006

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Simulation of power failure (emergency): SAT
1. Switch on fuel treatment system (→ Page 84).
2. Start engine (→ Page 77).
3. Run engine at idling speed.
4. Switch off pump (21) at switchgear cabinet (20).
Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
5. Check suction pressure at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
6. Operate engine at full load and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful.
TIM-ID: 0000015773 - 006

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3.9 Fuel treatment system – Switching on
Preconditions
☑The on-board power supply is switched on.

NOTICE
Risk of damage to engine/system.
Risk of severe damage to property!
• Before switching on, ensure that the engine/system is ready for operation.
• Before switching on, ensure that all housings are closed.
• Before switching on, ensure that no work is in progress anywhere on the entire system.

Fuel treatment system – Switching on

1. Carry out checks prior to start-up (→ Page 80).
2. Switch on master switch on switchgear cabinet.
Result: Signal lamp “Control voltage present” lights up.
3. Switch on switch for pump.
Result: Signal lamp “Pump running” lights up.

TIM-ID: 0000007731 - 006

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3.10 Fuel treatment system – Shutdown

Shutting down fuel treatment system

1. Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the
outlet stops.
2. Switch off fuel treatment system.
3. Close ball valve at the inlet to the fuel treatment system.
4. Close ball valve at the outlet of the fuel treatment system.
5. Open drain valve until pressure has escaped from fuel treatment system.
TIM-ID: 0000007732 - 005

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3.11 Stopping the engine
Stopping the engine via the automation system
Refer to automation system operating instructions

TIM-ID: 0000017528 - 004

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

Emergency stop
1. Refer to automation system operating instructions.
2. Follow instructions.
TIM-ID: 0000017530 - 005

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3.13 After stopping the engine
Preconditions
☑MTU Preservation and Re-preservation Specifications (A001070/..) are available.

After stopping the engine

Item Measure
Coolant circuit Drain coolant (→ Page 236) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tem-
perature;
• antifreeze concentration is 50% and engine-room temperature is below
-40 °C.
Raw water (only on engines Drain
with engine-mounted heat • if freezing temperatures are expected and the engine is to remain out
exchanger) of service for an extended period.
Engine control system Switch off.
Air intake and exhaust sys- Out-of-service-period > 1 week
tem
• Seal engine on air and exhaust sides.
Out-of-service-period > 1 month
• Preserve engine (→ MTU Preservation and Re-preservation specifica-
tions A001070/..).

TIM-ID: 0000010168 - 004

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3.14 Plant – Cleaning
Preconditions
☑Engine is stopped and starting disabled.
☑Operating voltage is not applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
• Never direct water jet at people.
• Wear protective clothing, protective gloves and safety goggles/face mask.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors
or ECUs.

Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet
unit carefully and observe the safety precautions.
3. For external cleaning of the plant with water or steam-jet cleaners:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 028

• The temperature of the cleaning medium must not exceed 80°C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Note: Never aim compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.

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4 Maintenance
4.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option

Task Maintenance tasks

W0500 Check engine oil level. (→ Page 218)

W0501 Visually inspect engine for leaks and general condition. (→ Page 78)
W0502 Check intercooler drain(s). (→ Page 213)
W0503 Check maintenance indicator of air filter. (→ Page 216)
W0504 Check telltale bores of HP fuel pump . (→ Page 78)
W0505 Check relief bores of water pump(s). (→ Page 241)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 78)
and vibrations.
W0507 Drain water and contaminants from fuel prefilter. (→ Page 78)
W0508 X Check reading on differential pressure gage of fuel prefilter. (→ Page 78)
W1001 Replace fuel filter or fuel filter element. (→ Page 187)
W1005 X Replace air filter. (→ Page 214)
W1006 Replace fuel injectors. (→ Page 179)
W1008 X Replace engine oil filter when changing engine oil, or when (→ Page 223)
the interval (years) is reached, at the latest.
W1009 Check layer thickness of the oil residue, clean out and re- (→ Page 227)
place filter sleeve each time the oil is changed at the latest.
W1011 Perform endoscopic examination. (→ Page 165)
W1016 X Check condition of coupling. (→ Page 251)
W1047 X Check and clean oil indicator filter. (→ Page 225)
W1076 Clean compressor wheel. (→ Page 205)
W1207 Check valve clearance and adjust as necessary. ATTENTION! (→ Page 173)
First adjustment after 1,000 operating hours and after 1,000
operating hours following cylinder head overhaul.
W1244 X Check function of rod electrode. (→ Page 255)
TIM-ID: 0000048360 - 001

W1245 X Check alarm function of differential pressure gage. (→ Page 254)

W1246 X Check pump capacity. (→ Page 256)
W1463 Check general condition of engine mounting (visual inspec- (→ Page 250)
tion).
W1477 X Overhaul preheater. (→ Page 247)
W1481 Replace intermediate fuel filter or intermediate fuel filter ele- (→ Page 186)
ment.
W1581 X Replace impactors. (→ Page 171)

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Option
Task Maintenance tasks

W1675 X Replace fuel prefilter or fuel prefilter element. (→ Page 195)

W1713 Injector: Reset drift correction parameter (CDC). (→ Page 266)

Table 1: Maintenance task reference table [QL1]

TIM-ID: 0000048360 - 001

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5 Troubleshooting
5.1 Troubleshooting
Engine does not turn when starter is actuated
Cause Corrective action
Battery low or faulty u Charge or replace (see separate documentation).
Battery: Cable connections u Check firm seating of cable connections (see separate
faulty documentation).
Engine cabling or starter faulty u Check firm seating of cable connections, contact Service.
Engine cabling defective u Check (→ Page 265).
Loose plug connections on u Check plug connections (→ Page 268).
engine governor
Loose plug connections on u Check plug connections (→ Page 270).
Engine Interface Module (EIM)
Fuse F1 (→ Page 259)in engine u Check fuse (replace if required) and re-start the system by
wiring harness defective (fuse actuating the key switch.
lamp on EIM flashes with
relevant flashing code)
Running gear blocked (engine u Contact Service.
cannot be barred manually)

Engine turns on starting but does not fire

Cause Corrective action
Poor rotation by starter: Battery u Charge or replace battery (see separate documentation).
low or faulty
Engine cabling defective u Check (→ Page 265).
Engine governor defective u Contact Service.

Engine fires unevenly

Cause Corrective action
Injector faulty u Replace (→ Page 179).
Engine cabling defective u Check (→ Page 265).
Engine governor defective u Contact Service.

Engine does not reach nominal speed

TIM-ID: 0000010520 - 004

Cause Corrective action

Easy-change fuel filter clogged u Replace (→ Page 187).
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 216).
Fuel injection: Injector faulty u Replace (→ Page 179).
Engine cabling defective u Check (→ Page 265).
Engine: Overload u Contact Service.

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Engine speed not steady
Cause Corrective action
Fuel injection: Injector faulty u Replace (→ Page 179).
Speed transmitter defective u Contact Service.
Engine governor defective u Contact Service.

Charge-air temperature too high

Cause Corrective action
Incorrect coolant concentration u Check (MTU test kit).
Intercooler dirty u Contact Service.
Engine room: Air-intake u Check fans and air supply/ventilation ducts.
temperature too high

Charge-air pressure too low

Cause Corrective action
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 216).
Intercooler dirty u Contact Service.
Exhaust turbocharger defective u Contact Service.

Coolant leaks at intercooler

Cause Corrective action
Intercooler leaky, major coolant u Contact Service.
discharge

Black exhaust gas

Cause Corrective action
Air supply: Air filter clogged u Check signal ring position of service indicator (→ Page 216).
Fuel injection: Injector faulty u Replace (→ Page 179).
Engine: Overload u Contact Service.

Blue exhaust gas

Cause Corrective action
Too much oil in engine u Drain engine oil (→ Page 219).
Oil separator or oil-preseparator u Replace.
of crankcase breather clogged
TIM-ID: 0000010520 - 004

Exhaust turbocharger, cylinder u Contact Service.

head, piston rings, cylinder liner
defective

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White exhaust gas
Cause Corrective action
Engine is not at operating u Run engine to reach operating temperature.
temperature
Intercooler leaky u Contact Service.

TIM-ID: 0000010520 - 004

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5.2 Fuel treatment system – Troubleshooting
Illuminated pushbutton 'water alarm' is lit.
Cause Corrective action
When the maximum water level 1. Press illuminated pushbutton 'Water alarm' for
is reached, the water level acknowledgment.
electrode opens the water drain 2. In addition to the automatic water drain function, water can also
valve and water is discharged. If be drained manually. To do so, press the illuminated pushbutton
the opening period of the valve 'Water drain' to open the drain valve.
exceeds a preset limit
(4 minutes), the pump will
switch off and an alarm is
initiated.

Signal lamp 'Pump fault' is lit.

Cause Corrective action
The drive motor is equipped with u Reset motor protection relay.
an overload protection. If the
maximum permissible current
consumption is exceeded, e.g. in
case of a blockage or dry-
running, the motor protection
relay triggers and the pump is
switched off.

Signal lamp 'Pre-alarm' is lit.

Cause Corrective action
The differential pressure u Replace coalescer filter element (→ Page 257).
exceeded 1.3 bar.

Illuminated pushbutton 'Replace filter element' is lit.

Cause Corrective action
The max. permissible differential 1. Replace coalescer filter element (→ Page 257).
pressure of 1.5 bar was 2. Press illuminated pushbutton 'Replace filter element' for
exceeded. If the coalescer filter acknowledgment.
element is not replaced,
pressure will increase further
and the safety valve will open.
Fuel will be led via the bypass
directly into the overflow tank.
TIM-ID: 0000007734 - 008

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5.3 Engine governor ADEC (ECU 7) fault messages for Series 4000
engines, marine application
The fault code numbers are generated by the engine governor and transmitted to the display below (if
fitted).

The fault code (1) comprises 3 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 (→ Page 97)
proves unsuccessful.
For explanations of alarm configuration parameters, refer to PR 2.8008.100.
Fault code list (→ Page 97).
TIM-ID: 0000016867 - 006

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5.4 Engine governor ADEC (ECU 7) – Fault codes
3 – HI T-Fuel
ZKP-Number: 2.0122.931
Fuel temperature too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Fuel tank may be exposed to 1. Reduce power.
heat. 2. Contact Service.

4 – SS T-Fuel
ZKP-Number: 2.0122.932
Fuel temperature too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Fuel tank may be exposed to u Contact Service.
heat.

5 – HI T-Charge Air
ZKP-Number: 2.0121.931
Charge-air temperature too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Charge-air cooler not 1. Reduce power.
functioning correctly. 2. Check charge-air cooler.
3. Contact Service.

6 – SS T-Charge Air
ZKP-Number: 2.0121.932
Charge-air temperature too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Charge-air cooler not 1. Check charge-air cooler.
TIM-ID: 0000045495 - 001

functioning correctly. 2. Contact Service.

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9 – HI T-Coolant charge-air cooler
ZKP-Number: 2.0124.931
Coolant temperature in charge-air cooler too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Coolant circuit for charge air 1. Reduce power.
defective. 2. Check charge-air cooler and coolant cooler.
3. Contact Service.

10 – SS T-Coolant charge-air cooler

ZKP-Number: 2.0124.932
Coolant temperature in charge-air cooler too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Coolant circuit for charge air 1. Check charge-air cooler and coolant cooler.
defective. 2. Contact Service.

15 – LO P-Lube Oil
ZKP-Number: 2.0100.921
Lube-oil pressure too low (limit value 1)
Yellow alarm; warning
Cause Corrective action
Insufficient oil. 1. Check oil level, top up as necessary (→ Page 218).
2. Contact Service.

16 – SS P-Lube Oil
ZKP-Number: 2.0100.922
Lube-oil pressure too low (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Insufficient oil. 1. Check oil level, top up as necessary (→ Page 218).
2. Acknowledge alarm.
3. Restart engine (→ Page 77).
4. Contact Service.
TIM-ID: 0000045495 - 001

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19 – HI T-Exhaust A
ZKP-Number: 2.0126.931
Exhaust temperature too high, A-side (limit value 1)
Yellow alarm; warning
Cause Corrective action
Wiring damage. 1. Check air filter and wiring (→ Page 265).
2. Contact Service.

20 – SS T-Exhaust A
ZKP-Number: 2.0126.932
Exhaust temperature too high, A-side (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Wiring damage. 1. Check air filter and wiring (→ Page 265).
2. Contact Service.

21 – HI T-Exhaust B
ZKP-Number: 2.0127.931
Exhaust temperature too high, B-side (limit value 1)
Yellow alarm; warning
Cause Corrective action
Wiring damage. 1. Check air filter and wiring (→ Page 265).
2. Contact Service.

22 – SS T-Exhaust B
ZKP-Number: 2.0127.932
Exhaust temperature too high, B-side (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Wiring damage. 1. Check air filter and wiring (→ Page 265).
2. Contact Service.

23 – LO Coolant Level
TIM-ID: 0000045495 - 001

ZKP-Number: 2.0152.921
Coolant level too low (limit value 1)
Yellow alarm; warning
Cause Corrective action
Leak in coolant circuit. u Check coolant level in expansion tank (→ Page 234).

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25 – HI P-Diff. Lube Oil
ZKP-Number: 2.0154.931
Differential oil pressure at oil filter too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Oil filter not functioning u Replace oil filter (→ Page 223).
correctly.

26 – HI P-Diff. Lube Oil

ZKP-Number: 2.0154.932
Differential oil pressure at oil filter too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Oil filter not functioning 1. Replace oil filter (→ Page 223).
correctly. 2. Contact Service.

27 – HI Level Leakage Fuel

ZKP-Number: 2.0151.931
Leak-off fuel level too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Fuel lines leaking. 1. Check fuel system.
2. Contact Service.

29 – HI ETC Idle Speed Too High

ZKP-Number: 1.8004.206
Yellow alarm; warning
Cause Corrective action
Idling speed of one of the u Contact Service.
secondary turbochargers is too
high.

30 – SS Engine Overspeed
TIM-ID: 0000045495 - 001

ZKP-Number: 2.2510.932
Engine overspeed (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
No fuel injection. 1. Restart engine. Fault can possibly be eliminated by a restart
(→ Page 77).
2. Contact Service.

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31 – HI ETC1 Overspeed
ZKP-Number: 2.3011.931
Speed of primary turbocharger too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Clogged charge-air circuit or 1. Reduce power.
fault in turbocharger. 2. Check air filter.
3. Contact Service.

32 – SS ETC1 Overspeed
ZKP-Number: 2.3012.932
Speed of primary turbocharger too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Clogged charge-air circuit or 1. Check air filter.
fault in turbocharger. 2. Contact Service.

33 – HI P-Diff-Fuel
ZKP-Number: 2.0114.931
Fuel filter differential oil pressure too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Fuel filter not functioning 1. Replace fuel filter (→ Page 187).
correctly. 2. Contact Service.

34 – SS P-Diff-Fuel
ZKP-Number: 2.0114.932
Fuel filter differential oil pressure too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Fuel filter not functioning 1. Replace fuel filter (→ Page 187).
correctly. 2. Contact Service.

36 – HI ETC2 Overspeed
TIM-ID: 0000045495 - 001

ZKP-Number: 2.3013.931
Speed of 1st secondary turbocharger too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Clogged charge-air circuit or 1. Reduce power.
fault in turbocharger. 2. Contact Service.

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37 – SS ETC2 Overspeed
ZKP-Number: 2.3013.912
Speed of 1st secondary turbocharger too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Clogged charge-air circuit or u Contact Service.
fault in turbocharger.

38 – AL ETC Speed Deviation

ZKP-Number: 1.8004.205
Yellow alarm; warning
Cause Corrective action
Synchro fault between primary u Contact Service.
turbocharger and one of the
secondary turbochargers.

39 – AL ETC2 Cut-in Fault

ZKP-Number: 1.8004.204
Yellow alarm; warning
Cause Corrective action
ETC2 failed to cut in. u Contact Service.

44 – LO Coolant Level Charge-Air Cooler

ZKP-Number: 2.0153.921
Coolant level of charge-air cooler too low (limit value 1)
Yellow alarm; warning
Cause Corrective action
Insufficient charge-air coolant, 1. Check coolant level (→ Page 234).
e.g. due to leaks in the charge- 2. Contact Service.
air coolant circuit.

51 – HI T-Lube Oil
ZKP-Number: 2.0125.931
TIM-ID: 0000045495 - 001

Lube oil temperature too high (limit value 1)

Yellow alarm; warning
Cause Corrective action
Insufficient oil. 1. Reduce power.
2. Check engine oil level (→ Page 218).
3. Contact Service.

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52 – SS T-Lube Oil
ZKP-Number: 2.0125.932
Lube oil temperature too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Insufficient oil. 1. Check engine oil level (→ Page 218).
2. Contact Service.

57 – LO P-Coolant
ZKP-Number: 2.0101.921
Coolant pressure too low (limit value 1).
Yellow alarm; warning
Cause Corrective action
Leak in coolant circuit. 1. Check coolant level (→ Page 234).
2. Check coolant circuit.

58 – SS P-Coolant
ZKP-Number: 2.0101.922
Coolant pressure too low (limit value 2)
Red alarm - engine stop or reduced injection quantity
Cause Corrective action
Leak in coolant circuit. 1. Check coolant level (→ Page 234).
2. Check coolant circuit.

59 – SS T-Coolant L3
ZKP-Number: 2.0120.933
Coolant temperature too high / low (limit value 3)
Red alarm; forced idle
Cause Corrective action
Coolant circuit not functioning 1. Activate fan emergency operating mode if required.
correctly (e.g. damage, leaks, 2. Allow engine to cool down.
low coolant level). 3. Check coolant cooler, clean if dirty.
4. Acknowledge alarm.
5. Restart engine (→ Page 77).
TIM-ID: 0000045495 - 001

6. Contact Service.

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60 – SS T-Coolant L4
ZKP-Number: 2.0120.934
Coolant temperature too high / low (limit value 4)
Red alarm; engine shutdown
Cause Corrective action
Coolant circuit not functioning 1. Activate fan emergency operating mode if required.
correctly (e.g. damage, leaks, 2. Allow engine to cool down.
low coolant level). 3. Check coolant cooler, clean if dirty.
4. Acknowledge alarm.
5. Restart engine (→ Page 77).
6. Contact Service.

63 – HI P-Crankcase
ZKP-Number: 2.0106.931
Crankcase pressure too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Crankcase exhaust system 1. Reduce power.
clogged or leaking. 2. Replace oil mist fine separator element.
3. Contact Service.

64 – SS P-Crankcase
ZKP-Number: 2.0106.932
Crankcase pressure too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Crankcase exhaust system 1. Reduce power.
clogged or leaking. 2. Replace oil mist fine separator element.
3. Contact Service.

65 – LO P-Fuel
ZKP-Number: 2.0102.921
Fuel supply pressure too low (limit value 1)
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Leaking or clogged fuel lines or 1. Check fuel lines for leakage.
fuel filter. 2. Check filter, fuel low-pressure side.
3. Replace fuel filter (→ Page 187).

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66 – SS P-Fuel
ZKP-Number: 2.0102.922
Fuel supply pressure too low (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Leaking or clogged fuel lines or 1. Check fuel lines for leakage.
fuel filter. 2. Check filter, fuel low-pressure side.
3. Replace fuel filter (→ Page 187).
4. Contact Service.

67 – HI T-Coolant
ZKP-Number: 2.0120.931
Coolant temperature too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Coolant circuit not functioning 1. Reduce power.
correctly (e.g. damage, leaks, 2. Check coolant circuit.
low coolant level).

68 – SS T-Coolant
ZKP-Number: 2.0120.932
Coolant temperature too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Coolant circuit not functioning u Check coolant circuit.
correctly (e.g. damage, leaks,
low coolant level).

81 – AL Rail Leakage
ZKP-Number: 1.8004.046
Leak
Yellow alarm; warning
Cause Corrective action
During start: Insufficient 1. Check engine for leaks.
TIM-ID: 0000045495 - 001

pressure gradient in rail (HP 2. Contact Service.

system leaking, air in system).
During stop: Pressure gradient 1. Seal engine system.
in rail too high. 2. Contact Service.

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82 – HI P-Fuel (Common Rail)
ZKP-Number: 2.0104.931
Rail pressure > set value
Red alarm - DBR fuel limitation, start of injection retarded;
Cause Corrective action
Suction restrictor of HP fuel 1. Check wiring (→ Page 265).
block jamming or HP fuel control 2. Contact Service.
block wiring faulty.

83 – LO P-Fuel (Common Rail)

ZKP-Number: 2.0104.921
Rail pressure < set value
Red alarm - DBR fuel limitation
Cause Corrective action
HP fuel control block defective u Contact Service.
or leak in HP system.

085 – HI T-Recirculation
ZKP-Number: 2.0128.931
Recirculation temperature too high (limit value 1)
Cause Corrective action
Charge-air temperature before u Reduce power.
recirculation valve too high.

086 – SS T-Recirculation
ZKP-Number: 2.0128.932
Recirculation temperature too high (limit value 2)
Cause Corrective action
Charge-air temperature before u Reduce power.
recirculation valve too high.

89 – SS Engine Speed too Low

ZKP-Number: 2.2500.030
TIM-ID: 0000045495 - 001

Engine speed too low

Red alarm; engine shutdown
Cause Corrective action
Various causes possible. 1. Acknowledge alarm.
2. Check for additional messages.
3. Contact Service.

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90 – SS Starter Speed Not Reached
ZKP-Number: 2.1090.925
Idling speed not attained
Red alarm; warning
Cause Corrective action
Various causes possible. 1. Check for additional messages.
2. Contact Service.

91 – SS Release Speed Not Reached

ZKP-Number: 2.1090.924
Runup speed was not attained
Red alarm; warning
Cause Corrective action
Various causes possible. 1. Check for additional messages.
2. Contact Service.

92 – SS Starter Speed Not Reached

ZKP-Number: 2.1090.923
Starter speed not reached
Red alarm; warning
Cause Corrective action
Starter rotates too slowly or 1. Check for additional messages.
does not rotate at all. 2. Contact Service.

93 – SS T-Preheat
ZKP-Number: 2.1090.922
Preheating temperature too low (limit value 2)
Red alarm; engine start interlock
Cause Corrective action
Preheating unit not functioning. 1. Check preheater.
2. Contact Service.

94 – LO T-Preheat
TIM-ID: 0000045495 - 001

ZKP-Number: 2.1090.921
Preheating temperature too low (limit value 1)
Yellow alarm; warning
Cause Corrective action
Coolant temperature too low for 1. Check preheating unit.
engine start because preheating 2. Contact Service.
unit is not functioning.

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95 – AL Prelubrication Fault
ZKP-Number: 2.1090.920
Oil priming fault
Yellow alarm; warning
Cause Corrective action
Priming oil pressure not 1. Check priming system.
reached. 2. Contact Service.

102 – AL Fuel Cons. Counter Defect

ZKP-Number: 1.8004.624
Error in fuel consumption checksum
Yellow alarm; warning
Cause Corrective action
Consumption meter faulty. u Contact Service.

104 – AL Eng Hours Counter Defect

ZKP-Number: 1.8004.623
Operating hours monitoring system faulty
Yellow alarm; warning
Cause Corrective action
Hour meter faulty. u Contact Service.

118 – LO ECU Power Supply Voltage

ZKP-Number: 2.0140.921
Supply voltage too low (limit value 1)
Yellow alarm; warning
Cause Corrective action
Supply voltage at engine 1. Check engine governor supply voltage.
governor too low. 2. Contact Service.

119 – LOLO ECU Power Supply Voltage

ZKP-Number: 2.0140.922
TIM-ID: 0000045495 - 001

Supply voltage too low (limit value 2)

Red alarm; start cancelation
Cause Corrective action
Supply voltage at engine 1. Check Engine Control Unit supply voltage.
governor too low. 2. Contact Service.

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120 – HI ECU Power Supply Voltage
ZKP-Number: 2.0140.931
Supply voltage too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Supply voltage at engine 1. Check Engine Control Unit supply voltage.
governor too high. 2. Contact Service.

121 – HIHI ECU Power Supply Voltage

ZKP-Number: 2.0140.932
Supply voltage too high (limit value 2)
Red alarm - start cancelation of engine stop
Cause Corrective action
Supply voltage at engine 1. Check Engine Control Unit supply voltage.
governor too high. 2. Contact Service.

122 – HI T-ECU
ZKP-Number: 2.0132.921
Electronics temperature too high (limit value 1).
Yellow alarm; warning
Cause Corrective action
Electronics overheated. 1. Reduce power.
2. Improve engine room ventilation.

141 – AL Power too high

ZKP-Number: 1.1088.007
Maximum value exceeded
Yellow alarm; warning
Cause Corrective action
Power mean value has exceeded u Contact Service.
the specified maximum value in
the last 24 hours.

142 – AL MCR exceeded 1 hour

TIM-ID: 0000045495 - 001

ZKP-Number: 1.1088.006
MCR exceeded
Yellow alarm; warning
Cause Corrective action
MCR was exceeded in the last u Contact Service.
12 hours for longer than one
hour.

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176 – AL LifeData not available
ZKP-Number: 2.4000.004
No (matching) LifeData backup system available
Yellow alarm; warning
Cause Corrective action
After a wait time has elapsed u Contact Service.
after ECU reset: Backup system
has no LifeData function or CAN
bus to backup system
disconnected.

177 – AL LifeData restore incomplete

ZKP-Number: 2.4000.006
Yellow alarm; warning
Cause Corrective action
This error message is generated u Contact Service.
if a CRC is faulty during a data
upload (to the engine governor)
(indicated for each indiv.
module).

180 – AL CAN1 Node Lost

ZKP-Number: 2.0500.680
Connection to a node on CAN bus 1 failed
Yellow alarm; warning
Cause Corrective action
Connection or communication 1. Check devices connected to CAN.
with a node on CAN bus 1 has 2. Check wiring (→ Page 265).
failed. 3. Contact Service.

181 – AL CAN2 Node Lost

ZKP-Number: 2.0500.681
Connection to a node on CAN bus 2 failed
Yellow alarm; warning
Cause Corrective action
TIM-ID: 0000045495 - 001

Connection or communication 1. Check devices connected to CAN.

with a node on CAN bus 2 has 2. Check wiring (→ Page 265).
failed. 3. Contact Service.

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182 – AL CAN Wrong Parameters
ZKP-Number: 2.0500.682
Incorrect parameters on CAN
Yellow alarm; warning
Cause Corrective action
Wrong parameter value entered u Contact Service.
in data record.

183 – AL CAN No PU-Data

ZKP-Number: 2.0500.683
CAN PU data not present or available
Yellow alarm; warning
Cause Corrective action
The selected CAN mode 1. Check devices connected to CAN.
initializes communication by 2. Contact Service.
means of the application
environment data module. A
faulted occurred during an
attempt to copy a received data
module to the engine governor.

184 – AL CAN PU-Data Flash Error

ZKP-Number: 2.0500.684
CAN PU data flash error
Cause Corrective action
A program fault occurred while u Contact electronic Service.
trying to copy a received PU
data module into the flash
module.

186 – AL CAN1 Bus Off

ZKP-Number: 2.0500.686
CAN controller 1 is in "Bus-Off" status
Yellow alarm; automatic changeover to CAN 2
Cause Corrective action
TIM-ID: 0000045495 - 001

Short circuit, massive 1. Check CAN bus for short circuit, rectify short circuit as
interference or Baud rate necessary.
incompatibility. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

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187 – AL CAN1 Error Passive
ZKP-Number: 2.0500.687
CAN controller 1 error
Yellow alarm; warning
Cause Corrective action
Missing associated node, minor 1. Check CAN bus for short circuit, rectify short circuit as
disruptions or temporary bus necessary.
overload. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

188 – AL CAN2 Bus Off

ZKP-Number: 2.0500.688
CAN controller 2 is in "Bus-Off" status
Yellow alarm; automatic changeover to CAN 1
Cause Corrective action
Short circuit, massive 1. Check CAN bus for short circuit, rectify short circuit as
interference or Baud rate necessary.
incompatibility. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

189 – AL CAN2 Error Passive

ZKP-Number: 2.0500.689
CAN controller 2 error
Yellow alarm; warning
Cause Corrective action
Missing associated node, minor 1. Check CAN bus for short circuit, rectify short circuit as
disruptions or temporary bus necessary.
overload. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

190 – AL EMU Parameter Not Supported

ZKP-Number: 2.0500.690
Yellow alarm; warning
Cause Corrective action
TIM-ID: 0000045495 - 001

EMU parameters are not u Contact Service.

supported. ==> Incompatibility

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201 – SD T-Coolant
ZKP-Number: 1.8004.570
Signal error, coolant temperature sensor
Yellow alarm; warning
Cause Corrective action
Coolant temperature sensor 1. Check sensor and wiring (B6), replace as necessary
faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

202 – SD T-Fuel
ZKP-Number: 1.8004.572
Signal error, fuel temperature sensor
Yellow alarm; warning
Cause Corrective action
Fuel temperature sensor faulty. 1. Check sensor and wiring (B33), replace as necessary
Short circuit or wire break. (→ Page 265).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

203 – SD T-Charge Air

ZKP-Number: 1.8004.571
Signal error, charge-air temperature sensor
Yellow alarm; warning
Cause Corrective action
Charge air temperature sensor 1. Check sensor and wiring (B9), replace as necessary
faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted. (→ Page 77)
3. Contact Service.

204 – SD Level Lube Oil

ZKP-Number: 1.8004.602
Signal error, lube oil level sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Lube oil level sensor faulty. 1. Check sensor and wiring, replace as necessary (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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205 – SD T-Coolant Charge-Air Cooler
ZKP-Number: 1.8004.574
Signal error, coolant temperature sensor
Yellow alarm; warning
Cause Corrective action
Coolant pressure sensor of 1. Check sensor and wiring (B26), replace as necessary
charge-air cooler faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

206 – SD T-Exhaust A
ZKP-Number: 1.8004.576
Signal error, exhaust temperature sensor on A side
Yellow alarm; warning
Cause Corrective action
Exhaust temperature sensor on 1. Check sensor and wiring (B4.21), replace as necessary
A side faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

207 – SD T-Exhaust B
ZKP-Number: 1.8004.577
Signal error, exhaust temperature sensor on B side
Yellow alarm; warning
Cause Corrective action
Exhaust temperature sensor on 1. Check sensor and wiring (B4.22), replace as necessary
B-side faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

208 – SD P-Charge Air

ZKP-Number: 1.8004.566
Signal error, charge-air pressure sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Charge air pressure sensor 1. Check sensor and wiring (B10), replace as necessary
faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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211 – SD P-Lube Oil
ZKP-Number: 1.8004.563
Signal error, lube oil pressure sensor
Yellow alarm; warning
Cause Corrective action
Lube-oil pressure sensor faulty. 1. Check sensor and wiring (B5), replace as necessary
Short circuit or wire break. (→ Page 265).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

212 – SD P-Coolant
ZKP-Number: 1.8004.564
Signal error, coolant pressure sensor
Yellow alarm; warning
Cause Corrective action
Coolant pressure sensor faulty. 1. Check sensor and wiring (B16), replace as necessary
Short circuit or wire break. (→ Page 265).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

213 – SD P-Coolant Charge-Air Cooler

ZKP-Number: 1.8004.569
Charge-air cooler coolant pressure sensor faulty
Yellow alarm; warning
Cause Corrective action
Charge-air cooler coolant 1. Check sensor and wiring (B43), replace as necessary
pressure sensor faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

214 – SD P-Crankcase
ZKP-Number: 1.8004.568
Signal error, crankcase pressure sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Crankcase pressure sensor 1. Check sensor and wiring (B50), replace as necessary
faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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215 – SD P-HD
ZKP-Number: 1.8004.567
Signal error, rail pressure sensor
Yellow alarm; high-pressure regulator emergency operation
Cause Corrective action
Rail pressure sensor faulty. ==> 1. Check sensor and wiring (B48), replace as necessary
high-pressure regulator (→ Page 265).
emergency operation. 2. Fault is rectified when engine is restarted (→ Page 77).
Short circuit or wire break. 3. Contact Service.

216 – SD T-Lube Oil

ZKP-Number: 1.8004.575
Signal error, lube oil temperature sensor
Yellow alarm; warning
Cause Corrective action
Lube oil temperature sensor 1. Check sensor and wiring (B7), replace as necessary
faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

219 – SD T-Intake Air

ZKP-Number: 1.8004.573
Signal error, intake air temperature sensor
Yellow alarm; warning
Cause Corrective action
Intake air temperature sensor 1. Check sensor and cabling (B3), replace as necessary
faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

220 – SD Level Coolant Water

ZKP-Number: 1.8004.584
Signal error, coolant level sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Coolant level sensor faulty. 1. Check sensor and cabling (F33), replace as necessary
Short circuit or wire break. (→ Page 265).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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221 – SD P-Diff Lube Oil
ZKP-Number: 1.8004.585
Signal error, lube oil differential pressure sensor faulty
Yellow alarm; warning
Cause Corrective action
Lube oil differential pressure 1. Check sensor and cabling (F25), replace as necessary
sensor faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

222 – SD Level Leak-off Fuel

ZKP-Number: 1.8004.582
Signal error, leak fuel level sensor
Yellow alarm; warning
Cause Corrective action
Leak fuel level sensor faulty. 1. Check sensor and wiring (F46), replace as necessary
Short circuit or wire break. (→ Page 265).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

223 – SD Level Coolant Charge-Air Cooler

ZKP-Number: 1.8004.583
Charge-air cooler coolant level sensor faulty
Yellow alarm; warning
Cause Corrective action
Charge-air cooler coolant level 1. Check sensor and wiring (F57), replace as necessary
sensor faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

227 – SD P- Lube Oil before Filter

ZKP-Number: 1.8004.620
Signal error, lube oil pressure sensor before filter
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Lube oil pressure sensor before 1. Check sensor and wiring (B34.2), replace as necessary
filter faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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228 – SD P-Fuel before Filter
ZKP-Number: 1.8004.595
Signal error, fuel pressure sensor
Yellow alarm; warning
Cause Corrective action
Fuel pressure sensor faulty. 1. Check sensor and wiring (B5.3), replace as necessary
Short circuit or wire break. (→ Page 265).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

229 – AL Stop Camshaft Sensor Defect

ZKP-Number: 1.8004.562
Stop signal error, camshaft sensor
Red alarm; engine shutdown
Cause Corrective action
Camshaft sensor faulty (and a 1. Check sensor and wiring to connector B1, replace as necessary
fault that occurred previously in (→ Page 265).
the crankshaft sensor in the 2. Fault is rectified when engine is restarted (→ Page 77).
same operating cycle). 3. Contact Service.

230 – SD Crankshaft Speed

ZKP-Number: 1.8004.498
Signal error, crankshaft sensor
Yellow alarm; warning
Cause Corrective action
Crankshaft sensor faulty. 1. Check sensor and wiring (B13), replace as necessary
Short circuit or wire break. (→ Page 265).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

231 – SD Camshaft Speed

ZKP-Number: 1.8004.499
Signal error, camshaft sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Camshaft sensor faulty. 1. Check sensor and wiring (B1), replace as necessary
Short circuit or wire break. (→ Page 265).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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232 – SD Charger 1 Speed
ZKP-Number: 1.3011.128
Signal error, primary turbocharger speed sensor
Yellow alarm; warning
Cause Corrective action
Speed sensor of primary 1. Check sensor and wiring (B44.1), replace as necessary
turbocharger faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

233 – SD Charger 2 Speed

ZKP-Number: 1.3011.129
Signal error, secondary turbocharger speed sensor
Yellow alarm; warning
Cause Corrective action
Speed sensor of secondary 1. Check sensor and wiring (B44.2), replace as necessary
turbocharger faulty. (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

239 – SD P-Diff Fuel

ZKP-Number: 1.8004.598
Differential pressure sensor for fuel faulty (only occurs with SD alarm 'fuel before filter' or 'fuel after
filter'.
Yellow alarm; warning
Cause Corrective action
Fuel differential pressure sensor u Check for additional messages.
faulty.

240 – SD P-Fuel
ZKP-Number: 1.8004.565
Signal error, fuel pressure sensor
Yellow alarm; warning
Cause Corrective action
TIM-ID: 0000045495 - 001

Fuel pressure sensor faulty. 1. Check sensor and wiring (B34), replace as necessary
Short circuit or wire break. (→ Page 265).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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241 – SD T-Recirculation
ZKP-Number: 1.8004.581

Cause Corrective action

Recirculation sensor faulty; u Check sensor and wiring (B49), replace as necessary.
Short circuit or wire break. Fault is rectified following engine restart.

242 – SD T-Coolant (R)

ZKP-Number: 1.8004.622

Cause Corrective action

Redundant coolant pressure u Check sensor and wiring, replace as necessary.
sensor faulty; Short circuit or Fault is rectified following engine restart.
wire break.

244 – SD P-Lube Oil (R)

ZKP-Number: 1.8004.621

Cause Corrective action

Redundant lube oil pressure u Check sensor and wiring, replace as necessary.
sensor faulty; Short circuit or Fault is rectified following engine restart.
wire break.

245 – SD ECU Power Supply Voltage

ZKP-Number: 2.8006.589
Signal error, engine governor supply voltage
Yellow alarm; warning
Cause Corrective action
Internal ECU fault. Electronics 1. Replace Engine Control Unit.
faulty. 2. Contact Service.

266 – SD Speed Demand

ZKP-Number: 2.8006.586
Speed setting signal error
Red alarm; forced idle
Cause Corrective action
TIM-ID: 0000045495 - 001

Analog speed setpoint faulty. 1. Check speed setting transmitter and wiring, replace as
Short circuit or wire break. necessary (→ Page 265).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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268 – SD Spinning Value
ZKP-Number: 2.8006.591
Skid signal error
Yellow alarm; warning
Cause Corrective action
Analog skid signal faulty. 1. Check sensor and wiring, replace as necessary (→ Page 265).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

269 – SD Loadp.Analog filt.

ZKP-Number: 2.8006.588
Load pulse analog signal faulty
Yellow alarm; warning
Cause Corrective action
The filtered analog signal from 1. Check wiring, replace as necessary (→ Page 265).
the load pulse is not present. 2. Fault is rectified when engine is restarted (→ Page 77).
Short circuit or wire break. 3. Contact Service.

270 – SD Frequency Input

ZKP-Number: 2.8006.590
Signal error, frequency input
Red alarm; forced idle
Cause Corrective action
Frequency input faulty. 1. Check wiring (→ Page 265).
Short circuit or wire break. 2. Check speed demand transmitter.
3. Contact Service.

301 – AL Timing Cylinder A1

ZKP-Number: 1.8004.500
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).
TIM-ID: 0000045495 - 001

302 – AL Timing Cylinder A2

ZKP-Number: 1.8004.501
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

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303 – AL Timing Cylinder A3
ZKP-Number: 1.8004.502
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

304 – AL Timing Cylinder A4

ZKP-Number: 1.8004.503
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

305 – AL Timing Cylinder A5

ZKP-Number: 1.8004.504
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

306 – AL Timing Cylinder A6

ZKP-Number: 1.8004.505
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

307 – AL Timing Cylinder A7

ZKP-Number: 1.8004.506
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
TIM-ID: 0000045495 - 001

or extremely high. (→ Page 179).

308 – AL Timing Cylinder A8

ZKP-Number: 1.8004.507
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

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309 – AL Timing Cylinder A9
ZKP-Number: 1.8004.508
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

310 – AL Timing Cylinder A10

ZKP-Number: 1.8004.509
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

311 – AL Timing Cylinder B1

ZKP-Number: 1.8004.510
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

312 – AL Timing Cylinder B2

ZKP-Number: 1.8004.511
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

313 – AL Timing Cylinder B3

ZKP-Number: 1.8004.512
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
TIM-ID: 0000045495 - 001

or extremely high. (→ Page 179).

314 – AL Timing Cylinder B4

ZKP-Number: 1.8004.513
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

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315 – AL Timing Cylinder B5
ZKP-Number: 1.8004.514
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

316 – AL Timing Cylinder B6

ZKP-Number: 1.8004.515
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

317 – AL Timing Cylinder B7

ZKP-Number: 1.8004.516
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

318 – AL Timing Cylinder B8

ZKP-Number: 1.8004.517
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

319 – AL Timing Cylinder B9

ZKP-Number: 1.8004.518
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
TIM-ID: 0000045495 - 001

or extremely high. (→ Page 179).

320 – AL Timing Cylinder B10

ZKP-Number: 1.8004.519
Time-of-flight measuring fault of injector
Cause Corrective action
Flight time value extremely low u Replace injector if the fault message appears frequently
or extremely high. (→ Page 179).

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321 – AL Wiring Cylinder A1
ZKP-Number: 1.8004.520
Wiring fault cylinder A1
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A1. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

322 – AL Wiring Cylinder A2

ZKP-Number: 1.8004.521
Wiring fault cylinder A2
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A2. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

323 – AL Wiring Cylinder A3

ZKP-Number: 1.8004.522
Wiring fault cylinder A3
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A3. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

324 – AL Wiring Cylinder A4

ZKP-Number: 1.8004.523
Wiring fault cylinder A4
Yellow alarm; misfire
TIM-ID: 0000045495 - 001

Cause Corrective action

Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A4. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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325 – AL Wiring Cylinder A5
ZKP-Number: 1.8004.524
Wiring fault cylinder A5
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A5. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

326 – AL Wiring Cylinder A6

ZKP-Number: 1.8004.525
Wiring fault cylinder A6
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A6. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

327 – AL Wiring Cylinder A7

ZKP-Number: 1.8004.526
Wiring fault cylinder A7
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A7. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

328 – AL Wiring Cylinder A8

ZKP-Number: 1.8004.527
Wiring fault cylinder A8
Yellow alarm; misfire
TIM-ID: 0000045495 - 001

Cause Corrective action

Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A8. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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329 – AL Wiring Cylinder A9
ZKP-Number: 1.8004.528
Wiring fault cylinder A9
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A9. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

330 – AL Wiring Cylinder A10

ZKP-Number: 1.8004.529
Wiring fault cylinder A10
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder A10. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

331 – AL Wiring Cylinder B1

ZKP-Number: 1.8004.530
Wiring fault cylinder B1
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B1. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

332 – AL Wiring Cylinder B2

ZKP-Number: 1.8004.531
Wiring fault cylinder B2
Yellow alarm; misfire
TIM-ID: 0000045495 - 001

Cause Corrective action

Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B2. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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333 – AL Wiring Cylinder B3
ZKP-Number: 1.8004.532
Wiring fault cylinder B3
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B3. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

334 – AL Wiring Cylinder B4

ZKP-Number: 1.8004.533
Wiring fault cylinder B4
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B4. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

335 – AL Wiring Cylinder B5

ZKP-Number: 1.8004.534
Wiring fault cylinder B5
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B5. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

336 – AL Wiring Cylinder B6

ZKP-Number: 1.8004.535
Wiring fault cylinder B6
Yellow alarm; misfire
TIM-ID: 0000045495 - 001

Cause Corrective action

Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B6. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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337 – AL Wiring Cylinder B7
ZKP-Number: 1.8004.536
Wiring fault cylinder B7
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B7. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

338 – AL Wiring Cylinder B8

ZKP-Number: 1.8004.537
Wiring fault cylinder B8
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B8. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

339 – AL Wiring Cylinder B9

ZKP-Number: 1.8004.538
Wiring fault cylinder B9
Yellow alarm; misfire
Cause Corrective action
Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B9. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

340 – AL Wiring Cylinder B10

ZKP-Number: 1.8004.539
Wiring fault cylinder B10
Yellow alarm; misfire
TIM-ID: 0000045495 - 001

Cause Corrective action

Short circuit fault in injector 1. Check injector solenoid, replace injector if necessary
wiring cylinder B10. (→ Page 179).
2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.

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341 – AL Open Load Cylinder A1
ZKP-Number: 1.8004.540
Injector wiring fault cylinder A1
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A1. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

342 – AL Open Load Cylinder A2

ZKP-Number: 1.8004.541
Injector wiring fault cylinder A2
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A2. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

343 – AL Open Load Cylinder A3

ZKP-Number: 1.8004.542
Injector wiring fault cylinder A3
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A3. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

344 – AL Open Load Cylinder A4

ZKP-Number: 1.8004.543
Injector wiring fault cylinder A4
TIM-ID: 0000045495 - 001

Yellow alarm; misfire

Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A4. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

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345 – AL Open Load Cylinder A5
ZKP-Number: 1.8004.544
Injector wiring fault cylinder A5
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A5. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

346 – AL Open Load Cylinder A6

ZKP-Number: 1.8004.545
Injector wiring fault cylinder A6
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A6. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

347 – AL Open Load Cylinder A7

ZKP-Number: 1.8004.546
Injector wiring fault cylinder A7
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A7. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

348 – AL Open Load Cylinder A8

ZKP-Number: 1.8004.547
Injector wiring fault cylinder A8
TIM-ID: 0000045495 - 001

Yellow alarm; misfire

Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A8. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

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349 – AL Open Load Cylinder A9
ZKP-Number: 1.8004.548
Injector wiring fault cylinder A9
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A9. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

350 – AL Open Load Cylinder A10

ZKP-Number: 1.8004.549
Injector wiring fault cylinder A10
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder A10. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

351 – AL Open Load Cylinder B1

ZKP-Number: 1.8004.550
Injector wiring fault cylinder B1
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B1. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

352 – AL Open Load Cylinder B2

ZKP-Number: 1.8004.551
Injector wiring fault cylinder B2
TIM-ID: 0000045495 - 001

Yellow alarm; misfire

Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B2. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

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353 – AL Open Load Cylinder B3
ZKP-Number: 1.8004.552
Injector wiring fault cylinder B3
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B3. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

354 – AL Open Load Cylinder B4

ZKP-Number: 1.8004.553
Injector wiring fault cylinder B4
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B4. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

355 – AL Open Load Cylinder B5

ZKP-Number: 1.8004.554
Injector wiring fault cylinder B5
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B5. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

356 – AL Open Load Cylinder B6

ZKP-Number: 1.8004.555
Injector wiring fault cylinder B6
TIM-ID: 0000045495 - 001

Yellow alarm; misfire

Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B6. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

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357 – AL Open Load Cylinder B7
ZKP-Number: 1.8004.556
Injector wiring fault cylinder B7
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B7. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

358 – AL Open Load Cylinder B8

ZKP-Number: 1.8004.557
Injector wiring fault cylinder B8
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B8. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

359 – AL Open Load Cylinder B9

ZKP-Number: 1.8004.558
Injector wiring fault cylinder B9
Yellow alarm; misfire
Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B9. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

360 – AL Open Load Cylinder B10

ZKP-Number: 1.8004.559
Injector wiring fault cylinder B10
TIM-ID: 0000045495 - 001

Yellow alarm; misfire

Cause Corrective action
Disruption fault in injector wiring 1. Check injector wiring for open circuit.
cylinder B10. 2. Exclude possible injector solenoid fault, replace injector if
necessary (→ Page 179).
3. Fault rectified after each working cycle.
4. Contact Service.

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361 – AL Power Stage Low
ZKP-Number: 1.8004.496
Internal electronic fault
Red alarm; engine shutdown possible
Cause Corrective action
Electronics faulty. 1. Start ITS.
2. Replace engine governor if required.
3. Check additional messages if ITS indicates diagnosis
"Electronics OK" (e.g. wiring faulty).
4. Check solenoid valve wiring.
5. Contact Service.

362 – AL Power Stage high

ZKP-Number: 1.8004.497
Internal electronic fault.
Red alarm; engine shutdown possible
Cause Corrective action
Electronics faulty. 1. Start ITS.
2. Replace engine governor if required.
3. Check additional messages if ITS indicates diagnosis
"Electronics OK" (e.g. wiring faulty).
4. Check solenoid valve wiring.
5. Contact Service.

363 – AL Stop Power Stage

ZKP-Number: 1.8004.560
Internal electronic fault.
Red alarm; engine shutdown
Cause Corrective action
Electronics faulty. 1. Start ITS.
2. Replace engine governor.
3. Check additional messages if ITS indicates diagnosis
"Electronics OK" (e.g. wiring faulty).
4. Check solenoid valve wiring.
5. Contact Service.
TIM-ID: 0000045495 - 001

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365 – AL Stop MV-Wiring Ground
ZKP-Number: 1.8004.561
Injector wiring error
Red alarm - engine shutdown via Protection Module possible
Cause Corrective action
Short circuit of injector positive 1. Check wiring (→ Page 265).
connection to ground of one or 2. Engine restart (→ Page 77).
more injectors. 3. Replace wiring harness if necessary (→ Contact Service).
Short circuit of the negative
injector connection or of one or
more injectors to ground.

371 – AL Wiring TO 1
ZKP-Number: 1.8004.634
Line disruption
Cause Corrective action
Short circuit or wire break on 1. Check charger valve/wiring, repair as necessary.
transistor output 1 (TO 1). 2. Replace engine governor.

372 – AL Wiring TO 2
ZKP-Number: 1.8004.635
Line disruption
Cause Corrective action
Short circuit or wire break on 1. Check recirculation valve/wiring, repair as necessary.
transistor output 2 (TO 2). 2. Replace engine governor.

373 – AL Wiring TO 3
ZKP-Number: 1.8004.636
Line disruption
Cause Corrective action
Short circuit or wire break on u-
transistor output 3 (TO 3).

374 – AL Wiring TO 4
TIM-ID: 0000045495 - 001

ZKP-Number: 1.8004.637
Line disruption
Cause Corrective action
Short circuit or wire break on u-
transistor output 4 (TO 4).

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381 – AL Wiring TOP 1
ZKP-Number: 2.8006.638
Line disruption on digital input 1
Yellow alarm; warning
Cause Corrective action
Short circuit or wire break on u Check wiring to plant.
transistor output, plant-side 1
(TOP 1).

382 – AL Wiring TOP 2

ZKP-Number: 2.8006.639
Line disruption on digital input 2
Yellow alarm; warning
Cause Corrective action
Short circuit or wire break on u Check wiring to plant.
transistor output, plant-side 2
(TOP 2).

383 – AL Wiring TOP 3

ZKP-Number: 2.8006.640
Line disruption on digital input 3
Yellow alarm; warning
Cause Corrective action
Short circuit or wire break on u Check wiring to plant.
transistor output, plant-side 3
(TOP 3).

384 – AL Wiring TOP 4

ZKP-Number: 2.8006.641
Line disruption on digital input 4
Yellow alarm; warning
Cause Corrective action
Short circuit or wire break on u Check wiring to plant.
transistor output, plant-side 4
TIM-ID: 0000045495 - 001

(TOP 4).

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390 – AL MCR exceeded
ZKP-Number: 1.1085.009
Speed limiter/MCR function: the maximum continuous rate was exceeded
Yellow alarm; engine power limited to permissible continuous power
Cause Corrective action
Engine was overloaded u With a continuous alarm, contact Service.
continuously.

392 – HI T-Coolant Red

ZKP-Number: 2.0129.931
Limit value 1
Cause Corrective action
Redundant coolant temperature 1. Check wiring.
reading too high. 2. Contact Service.

393 – SS T-Coolant Red

ZKP-Number: 2.0129.932
Limit value 2
Cause Corrective action
Redundant coolant temperature 1. Check wiring and sensor.
reading too high; engine stop. 2. Contact Service.

394 – LO P-Lube Oil Red

ZKP-Number: 2.0112.921
Limit value 1
Cause Corrective action
Redundant lube oil pressure 1. Check wiring and sensor.
reading too low. 2. Contact Service.

395 – SS P-Lube Oil Red

ZKP-Number: 2.0112.922
Limit value 2
Cause Corrective action
TIM-ID: 0000045495 - 001

Redundant lube oil pressure 1. Check wiring and sensor.

reading too low. 2. Contact Service.

396 – TD T-Coolant Sensor Deviation

ZKP-Number: 1.0480.193

Cause Corrective action

Maximum coolant temperature 1. Check wiring and sensor.
deviation. 2. Contact Service.

138 | Troubleshooting | MS150068/01E 2014-01

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397 – TD P-Oil Sensor Deviation
ZKP-Number: 1.0480.293

Cause Corrective action

Maximum lube oil pressure 1. Check wiring and sensor.
deviation. 2. Contact Service.

400 – AL Open Load Digital Input 1

ZKP-Number: 2.8006.625
Line disruption on digital input 1
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 265).
No resistance over switch. 2. Check target device input.
3. Contact Service.

401 – AL Open Load Digital Input 2

ZKP-Number: 2.8006.626
Line disruption on digital input 2
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 265).
No resistance over switch. 2. Check target device input.
3. Contact Service.

402 – AL Open Load Digital Input 3

ZKP-Number: 2.8006.627
Line disruption on digital input 3
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 265).
No resistance over switch. 2. Check target device input.
3. Contact Service.

403 – AL Open Load Digital Input 4

TIM-ID: 0000045495 - 001

ZKP-Number: 2.8006.628
Line disruption on digital input 4
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 265).
No resistance over switch. 2. Check target device input.
3. Contact Service.

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404 – AL Open Load Digital Input 5
ZKP-Number: 2.8006.629
Line disruption on digital input 5
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 265).
No resistance over switch. 2. Check target device input.
3. Contact Service.

405 – AL Open Load Digital Input 6

ZKP-Number: 2.8006.630
Line disruption on digital input 6
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 265).
No resistance over switch. 2. Check target device input.
3. Contact Service.

406 – AL Open Load Digital Input 7

ZKP-Number: 2.8006.631
Line disruption on digital input 7
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 265).
No resistance over switch. 2. Check target device input.
3. Contact Service.

407 – AL Open Load Digital Input 8

ZKP-Number: 2.8006.632
Line disruption on digital input 8
Yellow alarm; warning
Cause Corrective action
Wiring faulty. 1. Check wiring (→ Page 265).
No resistance over switch. 2. Check target device input.
TIM-ID: 0000045495 - 001

3. Contact Service.

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408 – AL Open Load Emerg. Stop Input ESI
ZKP-Number: 2.8006.633
Line disruption at input for emergency stop
Yellow alarm; warning
Cause Corrective action
Wiring faulty or no resistance 1. Check wiring (→ Page 265).
over switch. 2. Check target device input.
3. Contact Service.

410 – LO U-PDU
ZKP-Number: 2.0141.921
Injector voltage too low (limit value 1)
Yellow alarm; warning
Cause Corrective action
Wiring damage or faulty current 1. Check wiring (→ Page 265).
supply. 2. Check supply.
3. Contact Service.

411 – LOLO U-PDU

ZKP-Number: 2.0141.922
Injector voltage too low (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Wiring damage or faulty current 1. Check wiring (→ Page 265).
supply. 2. Check supply.
3. Acknowledge alarm.
4. Contact Service.

412 – HI U-PDU
ZKP-Number: 2.0141.931
Injector voltage too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Wiring damage or faulty current 1. Check wiring (→ Page 265).
TIM-ID: 0000045495 - 001

supply. 2. Check supply.

3. Contact Service.

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413 – HIHI U-PDU
ZKP-Number: 2.0141.932
Injector voltage too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Wiring damage or faulty current 1. Check wiring (→ Page 265).
supply. 2. Check supply.
3. Acknowledge alarm.
4. Contact Service.

414 – HI Level Water Fuel Prefilter

ZKP-Number: 2.0156.931
Water level in fuel prefilter too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Water content in fuel too high. u Empty fuel prefilter.
Water ingress in fuel tank.

415 – LO P-Coolant Charge-Air Cooler

ZKP-Number: 2.0107.921
Coolant pressure in charge-air cooler too low (limit 1)
Yellow alarm; warning
Cause Corrective action
Leak in coolant circuit. u Top up coolant.

416 – SS P-Coolant Charge-Air Cooler

ZKP-Number: 2.0107.922
Coolant pressure in charge-air cooler too low (limit 2)
Red alarm; engine shutdown
Cause Corrective action
Leak in coolant circuit. u Top up coolant.

417 – SD Level Water Fuel Prefilter

TIM-ID: 0000045495 - 001

ZKP-Number: 1.8004.594
Signal error, fuel prefilter water level sensor
Yellow alarm; warning
Cause Corrective action
Fuel prefilter water level sensor 1. Check sensor and wiring, replace as necessary (→ Page 265).
faulty. 2. Contact Service.
Short circuit or wire break.

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419 – SD T-Coolant b.Engine
ZKP-Number: 18.004.604

Cause Corrective action

Coolant inlet temperature u Check sensor and wiring (B3), replace as necessary.
sensor faulty. Short circuit or
wire break

420 – AL L1 Aux 1
ZKP-Number: 2.0160.921
Limit value 1
Cause Corrective action
Input signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded/not attained limit
value 1, depending on
configuration.

421 – AL L2 Aux 1
ZKP-Number: 2.0160.922
Limit value 2
Cause Corrective action
Input signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded/not attained limit
value 2, depending on
configuration.

428 – AL L1 T-Aux 1
ZKP-Number: 2.0130.921
Limit value 1
Cause Corrective action
Temperature signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded / not attained limit
value 1, depending on
configuration.

434 – AL L2 P-Aux 1
TIM-ID: 0000045495 - 001

ZKP-Number: 2.0173.931
Limit value 1
Cause Corrective action
Coolant temperature too high. u Check coolant circuit.

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440 – AL L1 P-Aux 1
ZKP-Number: 2.0110.921
Limit value 1
Cause Corrective action
Pressure signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded / not attained limit
value 1, depending on
configuration.

442 – AL L2 P-Aux 1
ZKP-Number: 2.0110.931
Limit value 2
Cause Corrective action
Pressure signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded / not attained limit
value 2, depending on
configuration.

444 – SD U-PDU
ZKP-Number: 1.8004.578
Injector power stage supply voltage fault
Yellow alarm; warning
Cause Corrective action
Sensor defect of injector power u Replace Engine Control Unit.
stage, or internal fault of engine
governor.

445 – SD P-Ambient Air

ZKP-Number: 1.8004.580
Signal error, ambient air pressure sensor
Yellow alarm; warning
Cause Corrective action
Ambient air pressure sensor u Replace Engine Control Unit.
faulty.
TIM-ID: 0000045495 - 001

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446 – SD P-HD2
ZKP-Number: 1.8004.599
Signal error, rail pressure sensor
Yellow alarm; high-pressure regulator emergency operation
Cause Corrective action
Rail pressure sensor faulty. 1. Check sensor and wiring (B48), replace as necessary
Short circuit or wire break. (→ Page 265).
2. Contact Service.

448 – HI P-Charge Air

ZKP-Number: 2.0103.931
Charge-air pressure too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Fault at turbine bypass flap. u Contact Service.

449 – SS P-Charge Air

ZKP-Number: 2.0103.932
Charge-air pressure too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Fault at turbine bypass flap. u Contact Service.

450 – SD Idle/End-Torque Input [%]

ZKP-Number: 2.8006.592
Signal error, start/end torque
Yellow alarm; warning
Cause Corrective action
Input signal for start/end torque 1. Check signal transmitter and wiring, replace as necessary.
faulty. (→ Page 265)
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 77).
3. Contact Service.
TIM-ID: 0000045495 - 001

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454 – SS Power Reduction Active
ZKP-Number: 2.7000.011
Power reduction activated
Red alarm - power reduction activated
Cause Corrective action
Engine operation outside u Check for additional messages.
standard limit values.
This message has the following
possible causes: Intake
depression, exhaust back
pressure, charge-air coolant
temperature or intake air
temperature outside the limit
values

455 – AL L1 Aux1 Plant

ZKP-Number: 2.8006.650
Limit value 1
Cause Corrective action
Input signal of Aux 1 (plant side) u Determine cause of limit value violation and rectify fault.
has exceeded/not attained limit
value 1, depending on
configuration.

456 – AL L2 Aux1 Plant

ZKP-Number: 2.8006.651
Limit value 2
Cause Corrective action
Input signal of Aux 1 (plant side) u Determine cause of limit value violation and rectify fault.
has exceeded/not attained limit
value 2, depending on
configuration.

460 – HI T-Exhaust EMU

ZKP-Number: 2.8006.652
Limit value 1
TIM-ID: 0000045495 - 001

Cause Corrective action

EMU exhaust gas temperature 1. Check wiring.
value too high. 2. Contact Service.

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461 – LO T-Exhaust EMU
ZKP-Number: 2.8006.653
Limit value 1
Cause Corrective action
EMU exhaust gas temperature 1. Check wiring.
value too low. 2. Contact Service.

462 – HI T-Coolant EMU

ZKP-Number: 2.8006.654
Limit value 1
Cause Corrective action
EMU coolant temperature value u Check configuration with DiaSys.
too high / low.

464 – SD P-AUX 1
ZKP-Number: 1.8004.589

Cause Corrective action

Analog input signal for Aux 1 u Check pressure transmitter and wiring, replace as necessary.
pressure faulty; short circuit or Fault is rectified following engine restart.
wire break.

467 – AL L2 T-Aux 1
ZKP-Number: 2.0130.922
Limit value 2
Cause Corrective action
Temperature signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded / not attained limit
value 2, depending on
configuration.

468 – SD T-AUX 1
ZKP-Number: 1.8004.579
Signal error, temperature Aux 1
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Analog input for Aux 2 u-
temperature faulty.

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469 – SD AUX 1
ZKP-Number: 1.8004.590

Cause Corrective action

Analog input signal for Aux 1 u Check signal sensor and wiring, replace as necessary.
faulty; short circuit or wire Fault is rectified following engine restart.
break.

470 – SD T-ECU
ZKP-Number: 1.8004.587
Signal error, engine governor temperature
Yellow alarm; warning
Cause Corrective action
Temperature sensor for engine 1. Check sensor and wiring, replace as necessary (→ Page 265).
governor faulty. 2. Engine restart (→ Page 77).
Short circuit or wire break. 3. Contact Service.

471 – SD Coil Current

ZKP-Number: 1.8004.592
Signal error, HP fuel control block
Yellow alarm; warning
Cause Corrective action
Actuation of HP fuel control 1. Check sensor and wiring, replace as necessary (→ Page 265).
block faulty. 2. Contact Service.
Short circuit or wire break.

472 – AL Stop SD
ZKP-Number: 2.8006.593
Engine stops
Red alarm; engine shutdown
Cause Corrective action
Engine stops because 'Sensor 1. Check wiring (→ Page 265).
faulty" present at channels. 2. Contact Service.

473 – AL Wiring PWM_CM2

TIM-ID: 0000045495 - 001

ZKP-Number: 1.8004.593

Cause Corrective action

Wire break or short circuit on 1. Check wiring.
channel PWM_CM2. 2. Contact Service.

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474 – AL Wiring FO
ZKP-Number: 2.8006.655
Wiring fault on FO
Yellow alarm; warning
Cause Corrective action
Wire break or short circuit on 1. Check wiring (→ Page 265).
channel FO. 2. Contact Service.

475 – AL CR Engine Shutdown Trigger

ZKP-Number: 1.8010.009
Crash recorder was triggered by an engine shutdown.
Yellow alarm; warning
Cause Corrective action
Crash recorder was triggered by u Contact Service.
an engine shutdown.

476 – AL Crash Rec. Init. Error

ZKP-Number: 1.8010.007
Initialization error of crash recorder.
Cause Corrective action
Initialization error of crash u Contact Service.
recorder.

478 – AL Comb. Alarm Yel (Plant)

ZKP-Number: 2.8006.001
Yellow combined alarm from system
Yellow alarm; warning
Cause Corrective action
Various causes possible. u Check for additional messages.

479 – AL Comb. Alarm Red (Plant)

ZKP-Number: 2.8006.002
Red combined alarm from system
TIM-ID: 0000045495 - 001

Red alarm
Cause Corrective action
Various causes possible. u Check for additional messages.

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480 – AL Ext. Engine Protection
ZKP-Number: 2.0291.921
External engine protection function active
Yellow alarm; warning
Cause Corrective action
The external engine protection 1. Check plant signal.
function is active. 2. Contact Service.
Monitoring of plant signal by
ECU active (plant side).

482 – SD T-Exhaust C
ZKP-Number: 18.004.596

Cause Corrective action

Exhaust temperature sensor on u Check sensor and wiring (B4.23), replace as necessary.
A side faulty. Short circuit or
wire break

483 – SD T-Exhaust D
ZKP-Number: 18.004.597

Cause Corrective action

Exhaust temperature sensor on u Check sensor and wiring (B4.24), replace as necessary.
A side faulty. Short circuit or
wire break

484 – HI T-Exhaust C
ZKP-Number: 20.133.931
Limit value 1
Cause Corrective action
Exhaust gas temperature (C- 1. Reduce power.
side) too high. 2. Contact Service.

485 – SS T-Exhaust C
ZKP-Number: 20.133.932
Limit value 2
TIM-ID: 0000045495 - 001

Cause Corrective action

Exhaust gas temperature (C- 1. Reduce power.
side) too high. 2. Contact Service.

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486 – HI T-Exhaust D
ZKP-Number: 20.134.931
Limit value 1
Cause Corrective action
Exhaust gas temperature (D- 1. Reduce power.
side) too high. 2. Contact Service.

487 – SS T-Exhaust D
ZKP-Number: 20.134.932
Limit value 2
Cause Corrective action
Exhaust gas temperature (D- 1. Reduce power.
side) too high. 2. Contact Service.

488 – HI ETC3 Overspeed

ZKP-Number: 2.3014.931
Speed of 2nd secondary turbocharger too high (limit value 1)
Yellow alarm; warning
Cause Corrective action
Clogged charge-air circuit or u Reduce power.
fault in turbocharger.

489 – SS ETC3 Overspeed

ZKP-Number: 2.3014.932
Speed of 2nd secondary turbocharger too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Clogged charge-air circuit or u Reduce power.
fault in turbocharger.

490 – HI ETC4 Overspeed

ZKP-Number: 2.3015.931
Speed of the 3rd secondary turbocharger too high (limit value 1)
TIM-ID: 0000045495 - 001

Yellow alarm; warning

Cause Corrective action
Clogged charge-air circuit or u Reduce power.
fault in turbocharger.

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491 – SS ETC4 Overspeed
ZKP-Number: 2.3015.932
Speed of the 3rd secondary turbocharger too high (limit value 2)
Red alarm; engine shutdown
Cause Corrective action
Clogged charge-air circuit or u Reduce power.
fault in turbocharger.

492 – AL ETC4 Cutin Failure

ZKP-Number: 18.004.202
Yellow alarm; warning
Cause Corrective action
ETC4 failed to cut in. u Check control valve at turbocharger 4.

493 – AL ETC3 Cutin Failure

ZKP-Number: 18.004.203
Yellow alarm; warning
Cause Corrective action
ETC3 failed to cut in. u Check control valve at turbocharger 3.

500 – AL Wiring POM Starter 1

ZKP-Number: 1.4500.900
Wiring fault, connection of starter 1 at POM
Yellow alarm; warning
Cause Corrective action
Missing consumer. u Check connection between POM and starter.
Short circuit or wire break

501 – AL Wiring POM Starter 2

ZKP-Number: 1.4500.901
Wiring fault, connection of starter 2 at POM
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Missing consumer. u Check connection between POM and starter.
Short circuit or wire break

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502 – AL Open Load POM Battery-charging Generator
ZKP-Number: 1.4500.902
Power disruption, battery-charging generator connection of POM
Yellow alarm; warning
Cause Corrective action
Wiring faulty or no resistance u Check connection between POM and battery-charging
over switch. generator.

503 – AL Battery Not Charging

ZKP-Number: 1.4500.903
No battery charge
Yellow alarm; warning
Cause Corrective action
Battery is not charged by u Check battery-charging generator and wiring (→ Page 265).
battery-charging generator.

504 – AL CAN POM Node Failure

ZKP-Number: 1.4500.904
POM missing on CAN bus
Yellow alarm; warning
Cause Corrective action
If alarm 508 occurs in addition, u Check connection and POM.
the resistor in the POM wiring is
missing.

506 – AL Low Starter Voltage

ZKP-Number: 1.4500.906
The battery voltage is too low for the starting process
Yellow alarm; warning
Cause Corrective action
Wiring faulty or battery is flat. u Check starter battery and wiring (→ Page 265).

507 – AL POM Fault

TIM-ID: 0000045495 - 001

ZKP-Number: 1.4500.907
A general POM fault occurred.
Yellow alarm; warning
Cause Corrective action
Fault in POM. u Replace POM.

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508 – AL Incorrect POM ID
ZKP-Number: 1.4500.908
POM sends a different ID number than expected
Yellow alarm; warning
Cause Corrective action
If alarm 504 occurs in addition, u Check POM wiring harness.
the resistor in the POM wiring is
missing.

510 – AL Override applied

ZKP-Number: 2.7002.010
Override was activated
Yellow alarm; warning
Cause Corrective action
Override suppresses other u Deactivate Override pushbutton again.
alarms.

515 – AL Starter Not Engaged

ZKP-Number: 2.1090.926
Yellow alarm - possible start cancelation
Cause Corrective action
Starter on POM could not be 1. Repeat start.
engaged. 2. Check POM, starter and wiring (→ Page 265).
3. Contact Service.

519 – Oil Level Calibration Error

ZKP-Number: 1.0158.921
Error writing calibration value into flash or SD of level sensor.
Yellow alarm; warning
Cause Corrective action
Oil level sensor or wiring faulty. 1. Check sensor and wiring, replace as necessary (→ Page 265).
2. Contact Service.

531 – AL Wiring PWM_CM1

TIM-ID: 0000045495 - 001

ZKP-Number: 1.1044.900
Red alarm
Cause Corrective action
Wire break or short circuit on u Check wiring to TecJet throttle, replace TecJet throttle if
channel PWM_CM1. necessary.

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532 – AL Wiring PWM1
ZKP-Number: 1.1046.900
Red alarm
Cause Corrective action
Wire break or short circuit on u Check wiring to mixture throttle on A side, replace mixture
channel PWM1. throttle on A side if necessary.

533 – AL Wiring PWM2

ZKP-Number: 1.1047.900
Red alarm
Cause Corrective action
Wire break or short circuit on u Check wiring to mixture throttle on B side, replace mixture
channel PWM2. throttle on B side if necessary.

543 – AL Multiple FDH Slaves

ZKP-Number: 2.0555.005
Yellow alarm
Cause Corrective action
There is more than one device u Contact Service (configuration fault).
activated as backup medium for
FDH.

544 – AL Configuration Changed

ZKP-Number: 2.0555.003
Yellow alarm
Cause Corrective action
This alarm is activated when the u Contact Service (configuration fault).
system configuration was
changed, e.g. because the ECU
or SAM was exchanged.

549 – AL Power Disruption

ZKP-Number: 2.7001.952
Alarm from the emergency stop counter function
TIM-ID: 0000045495 - 001

Yellow alarm; warning

Cause Corrective action
Engine governor power has been u Instruct operators to switch off the power supply only after the
disconnected with the engine engine has come to a standstill.
still running. This may lead to
overpressure in the HP system
which can damage the engine.

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551 – SS Engine Overspeed Camshaft
ZKP-Number: 22.510.933
Limit value 2
Cause Corrective action
Camshaft overspeed. 1. Acknowledge alarm.
2. Attempt engine restart.

555 – AL Call MTU Field Service

ZKP-Number: 20.555.001

Cause Corrective action

This fault becomes active if a u Request activation code via Internet.
maintenance case has been
processed by the ECU Field Data
Handling (FDH) feature that
results in a change of engine
parameters.
This fault remains active even
after switching off and back on
until a valid enabling code is
entered via the SAM display and
key controls. This enabling code
can be requested via the
Internet using a special
procedure.

576 – AL ESCM Override

ZKP-Number: 1.1075.083
Engine overload
Yellow alarm; warning
Cause Corrective action
Violation of corrected MCR or u Reduce power.
DBR/MCR curve.

577 – SD T-Lube Oil Pan

ZKP-Number: 1.0137.900
Signal error, oil pan temperature sensor
Yellow alarm; warning
TIM-ID: 0000045495 - 001

Cause Corrective action

Oil pan temperature sensor u Check sensor and cabling, replace as necessary (→ Page 265).
faulty.
Short circuit or wire break.

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582 – AL Emergency Stop Failure
ZKP-Number: 1.1005.006
Emergency stop command was not executed
Flashing pre-alarm and alarm
Cause Corrective action
Engine speed does not come to u Contact Service.
a standstill within a configurable
period.

584 – AL CAN Start clearance failed

Yellow alarm; warning
Cause Corrective action
Yellow alarm; warning; CAN u Contact Service.
object Start clearance was not
received within the expected
time period.

586 – LO P-Oil Refill Pump

ZKP-Number: 2.0159.911
Oil pressure in refill pump is too low - limit value 1
Yellow alarm; warning
Cause Corrective action
Oil level in oil refill tank too low. 1. Check oil level, top up as necessary (→ Page 218).
2. Contact Service.

588 – SD P-Oil Refill Pump

ZKP-Number: 1.0159.910
Signal error, refill pump oil pressure sensor
Yellow alarm; warning
Cause Corrective action
Pressure sensor defective. 1. Check sensor and wiring, replace as necessary (→ Page 265).
Short circuit or wire break. 2. Contact Service.

593 – AL T-Lube Oil in Oil Pan too Low

TIM-ID: 0000045495 - 001

ZKP-Number: 2.1090.929
Lube oil temperature in oil pan is too low.
Cause Corrective action
Preheating time is insufficient. 1. Extend preheating period.
2. Contact Service.

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596 – AL Test Parameters
ZKP-Number: 1.8004.645
Yellow alarm; warning
Cause Corrective action
The parameter set is used for u Contact Service.
trials. The alarm remains set
until a series parameter set is
loaded.

600 – SD T-Exhaust A+B

ZKP-Number: 1.8004.646
Signal error, exhaust temperature sensor A- and B-side
Yellow alarm; warning
Cause Corrective action
Exhaust temperature sensor on 1. Check sensor and wiring, replace as necessary (→ Page 265).
A- and B-side faulty. 2. Contact Service.
Short circuit or wire break.

601 – SD ETC1+ETC2
ZKP-Number: 1.3011.227
Signal error, ETC speed sensor 1 and 2
Yellow alarm; warning
Cause Corrective action
ETC speed sensors 1 and 2 1. Check sensor and wiring, replace as necessary (→ Page 265).
faulty. 2. Contact Service.
Short circuit or wire break.

602 – AL CAN Engine Start Lock

ZKP-Number: 2.1090.930
Start interlock from plant pending
Yellow alarm; warning
Cause Corrective action
Start interlock initiated by plant. u The alarm is reset by canceling the engine start instruction or
the CAN request.
TIM-ID: 0000045495 - 001

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606 – AL Double Nodes Lost CAN 1+2
ZKP-Number: 2.0500.691
ECU does not detect a monitored CAN bus.
Red alarm; forced idle
Cause Corrective action
A node on both CANs has failed. 1. Check wiring and power supply of plant (→ Page 265).
Short circuit or wire break. 2. Acknowledge alarm.
3. Restart engine (→ Page 77).
4. Contact Service.

614 – AL L1 P-Fuel Supp. Filt. Diff.

ZKP-Number: 2.0119.001
Fuel prefilter differential pressure too high
Yellow alarm; warning
Cause Corrective action
Fuel prefilter not functioning 1. Replace fuel prefilter.
correctly. 2. Contact Service.

625 – SD P-Fuel b. Supp. Filter

ZKP-Number: 1.8004.600
Signal error, fuel pressure sensor before supplementary filter
Yellow alarm; warning
Cause Corrective action
Analog input signal for fuel 1. Check pressure transmitter and wiring, replace as necessary
pressure before supplementary (→ Page 265).
filter faulty. 2. Fault is rectified when engine is restarted (→ Page 77).
Short circuit or wire break. 3. Contact Service.

641 – AL System Restart by Watchdog

ZKP-Number: 1.8012.902
System is restarted by watchdog
Cause Corrective action
System restart by watchdog u-
detected.
TIM-ID: 0000045495 - 001

687 – SD Oil Level Switch

ZKP-Number: 1.0150.920
Level switch faulty
Cause Corrective action
Lube oil level switch is faulty. 1. Check sensor and wiring (B24), replace as necessary. Alarm is
==> Short circuit or wire break. reset when fault is eliminated (→ Page 265).
2. Contact Service.

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690 – AL Oil Level too Low
ZKP-Number: 1.0150.921

Cause Corrective action

Alarm, lube oil level is too low. u-

759 – AL L1 T-Fuel b. Engine

ZKP-Number: 2.0080.921
Fuel before engine (limit 1)
Cause Corrective action
Fuel temperature before engine u-
too high.

760 – AL L2 T-Fuel b. Engine

ZKP-Number: 2.0080.922
Fuel before engine (limit 2)
Cause Corrective action
Fuel temperature before engine u-
too high.

761 – SD T-Fuel b. Engine

ZKP-Number: 1.0080.900

Cause Corrective action

Oil pan temperature sensor 1. Check sensor and wiring (B24), replace as necessary.
faulty. (→ Page 265).
==> Short circuit or wire break. 2. Contact Service.

782 – SD P-Lube oil ETC A

ZKP-Number: 1.0222.920

Cause Corrective action

SD turbocharger lube oil u-
pressure.

788 – Cyl. cutout detects turbocharger speed error

TIM-ID: 0000045495 - 001

ZKP-Number: 1.3000.069

Cause Corrective action

The cyl. cutout system has u-
detected an invalid turbocharger
speed at turbochargers 1 or 2.

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850 – SD Alive FIP
ZKP-Number: 2.0900.002
Frequency input faulty.
Cause Corrective action
Short circuit or wire break. u-
Fault in Backup ECU, Alive signal
not transmitted

856 – SD P-Lube oil ETC B

ZKP-Number: 1.0223.920

Cause Corrective action

ETC oil pressure sensor faulty. u Check sensor and wiring, replace as necessary.

858 – AL L1 P-Lube Oil ETC B

ZKP-Number: 1.0223.921
Limit value 1
Cause Corrective action
Lube oil pressure too low. u Check ETC oil lubrication.

867 – AL L1 P-Lube Oil ETC A

ZKP-Number: 1.0222.923
Limit value 1
Cause Corrective action
Lube oil pressure too low. u Check ETC oil lubrication.

868 – AL L2 P-Lube Oil ETC A

ZKP-Number: 1.0222.924
Limit value 2
Cause Corrective action
Lube oil pressure too low. u Check ETC oil lubrication.

869 – AL L2 P-Lube Oil ETC B

TIM-ID: 0000045495 - 001

ZKP-Number: 1.0223.922
Limit value 2
Cause Corrective action
Lube oil pressure too low. u Check ETC oil lubrication.

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Barring device F6555766 1
Ratchet with extension F30006212 1

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Barring engine manually

1. Release screws (1) and remove end cov-
er (2) from flywheel housing.

TIM-ID: 0000000917 - 010

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2. Engage barring device (2) in ring gear of fly-
wheel and mount on flywheel housing.
3. Fit ratchet (1) onto barring device (2).
Note: No resistance other than compression re-
sistance must be encountered.
4. Rotate crankshaft in engine direction of ro-
tation.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
5. Barring device is removed by same proce-
dure in reverse.
TIM-ID: 0000000917 - 010

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6.1.2 Engine – Barring with starting system
Barring using the automation system
Refer to automation system operating instructions

TIM-ID: 0000017532 - 003

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6.2 Cylinder Liner
6.2.1 Cylinder liner – Endoscopic examination
Preconditions
☑Engine is stopped and starting disabled

Special tools, Material, Spare parts

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

Preparatory steps
1. Remove cylinder head cover (→ Page 176).
2. Remove injector (→ Page 180).

Positioning crankshaft at BDC

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

Cylinder liner – Endoscopic examination

Findings Task
• Thin carbon coating around circumference of carbon scraper ring No action required.
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits around circumference between top piston ring and
bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark around circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Darker areas of even or varying color intensity Further endoscopic examina-
• Beginning and end of the discoloration are not sharply defined and tion required as part of mainte-
do not cover the entire stroke area nance work.
• Dark areas in the upper section of the cooling bore, remaining cir-
cumference cannot be faulted
• Piston rings faultless
• On the entire circumference not only bright discoloration (not criti- Cylinder liner must be replaced,
cal for operation) clearly visible darker stripes that begin at the top contact Service.
piston ring
TIM-ID: 0000000015 - 016

• Heat discoloration in the direction of stroke and honing pattern

damage
• Heat discoloration of piston rings

1. Compile endoscopy report using the table.

2. Use technical terms for description of the liner surface (→ Page 167).
3. Depending on findings:
• Do not take any action or
• Carry out further endoscopic examination as part of maintenance work or
• Contact Service; cylinder liner must be replaced.

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Final steps
1. Install injector (→ Page 180).
2. Install cylinder head cover (→ Page 176).

TIM-ID: 0000000015 - 016

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6.2.2 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 ex-
amination report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Findings not critical.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Findings not critical.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Findings not critical.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Findings not critical.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
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clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.

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

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6.3 Crankcase Breather
6.3.1 Crankcase breather – Overview
For 12V engines

1 Vent pipe 5 Bracket 9 Spigot pipe

2 Plug 6 Oil line 10 Drain pipe
3 Oil separator 7 Service block 11 Bracket
4 Impactor carrier 8 Vent housing 12 Connection
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For 16V engines

1 Vent pipe 5 Service block 9 Bracket

2 Impactor carrier 6 Vent housing 10 Plug
3 Bracket 7 Spigot pipe 11 Oil separator
4 Oil line 8 Drain pipe

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6.3.2 Crankcase breather – Oil mist fine separator replacement
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil
Oil mist fine separator (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

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

Replacing oil mist fine separator

1. Remove screws (1) and take off together
with holder (2).
2. Replace oil mist fine separator (3).
3. Replace O-ring (4) if necessary.
4. Replace further oil mist fine separators in
the same way.
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6.4 Valve Drive
6.4.1 Valve gear – Lubrication
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil

Valve gear – Lubrication

1. Remove cylinder head covers
(→ Page 176).
2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjust-
ing screws with oil.
4. Install cylinder head covers (→ Page 176).

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Feeler gage Y20010128 1
Torque wrench, 60-320 Nm F30452768 1
Socket wrench, 24 mm F30039526 1
Engine oil

Preparatory steps
1. Remove cylinder head cover (→ Page 176).
2. Install barring gear (→ Page 162).
3. The OT mark (1) on the flywheel (if applica-
ble) must not be used for reference.
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4. Rotate crankshaft with barring tool in en-
gine direction of rotation until marking “OT-
A1” and pointer are aligned.

Diagram for 12V engines (two

crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve

Diagram for 16V engines (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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Checking valve clearance in 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 loaded on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance adjustment with engine cold:
• Inlet valves (long rocker arm) = 0.2 mm
• Exhaust valves (short rocker arm) = 0.5 mm
3. Check all valve clearances at two crankshaft positions (firing and overlap TDC for cylinder A1) as per
diagram.
4. Use feeler gage to determine the distance between valve bridge and rocker arm.
5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

Adjusting valve clearance

1. Release locknut (1).
2. Insert feeler gage (3) between valve bridge
and rocker arm.
3. Using Allen key, set adjusting screw (2) so
that the specified valve clearance is provid-
ed.
Note: Feeler gage must just pass through the
gap.
4. Pull feeler gage (3) between valve bridge
and rocker arm.

5. Tighten locknut (1) to the specified tightening torque, holding adjusting screw (2) firmly.
Name Size Type Lubricant Value/Standard
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 gear (→ Page 162).
2. Install cylinder head cover (→ Page 176).
3. Enable engine start.
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6.4.3 Cylinder head cover – Removal and installation
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Assembly compound (Kluthe Hakuform 30-11C/Emulgier) X00059351 1
O-ring (→ Spare Parts Catalog)

Removing cylinder head cover

1. Clean very dirty cylinder head covers (1)
prior to removal.
2. Remove screws (3, 4) with washers (2, 5).
3. Take off cylinder head cover (1) with O-
ring (6) from cylinder head (7).

Installing cylinder head cover

1. Clean mounting surface.
2. Check O-ring (6) for damage, replace as necessary.
3. Coat O-ring (6) with assembly compound.
4. Position O-ring (6) in groove of cylinder head cover (1).
5. Fit cylinder head cover (1) on cylinder head (7).
6. Install cylinder head cover (1) with screws (3, 4) and washers (2, 5).
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6.5 Injection Pump / HP Pump
6.5.1 HP pump – Filling with engine oil
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil

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

WARNING
Oils/oil vapors are combustible/explosive.
Risk of fire and explosion!
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.

NOTICE
HP fuel pump not filled with engine oil.
Damage to components, major material damage!
• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.

Filling HP pump
1. Remove plug screw (1).
2. Use pump oiler to fill HP pump with engine
oil until engine oil emerges.
3. Install plug screw (1).
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6.5.2 HP pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

HP pump – Relief bore check

1. Visually inspect relief bore (1) for fuel dis-
charge.
2. For jacketed HP lines, leakage is indicated
by the yellow combined alarm.
3. If fuel discharge is found or indicated, con-
tact Service.

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

Replacing injector
u Remove injector and install new injector (→ Page 180).
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6.6.2 Injector – Removal and installation
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Installation/removal jig F6789889 1
Milling cutter F30452739 1
Torque wrench, 0.5-5 Nm 0015384230 1
Torque wrench, 10-60 Nm F30452769 1
Ratchet adapter F30027340 1
Torque wrench, 60-320 Nm F30452768 1
Ratchet adapter F30027341 1
Assembly paste(Optimoly Paste White T) 40477 1
Assembly compound (Kluthe Hakuform 30-11C/Emulgier) X00059351 1
Engine oil
O-ring (→ Spare Parts Catalog)

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

Preparatory steps
1. Shut off fuel supply to engine.
2. Remove cylinder head cover (→ Page 176).

Removing injector
1. Disconnect connectors on injector.

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2. Remove HP fuel line 4).
Note: While the adapter is removed, the injector
is drained.
3. Remove adapter (3).
4. Remove screw (2) and take off hold-down
clamp (1).

5. Install installation/removal jig on cylinder

head.
6. Remove injector with installation/removal
jig.
7. Remove installation/removal jig.

8. Remove sealing ring (4) from injector or

use a self-made hook to take it out of the
cylinder head.
9. Remove O-rings (3), O-ring (2) and damper
ring (1) from injector.
10. Clean all mating and sealing surfaces.
11. Cover all connections and bores, or seal
with suitable plugs.
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Installing injector
1. Remove plug before installing the injec-
tor. (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 retaining nut.
3. Fit new sealing ring (included in the scope
of delivery of the injector) with assembly
compound on injector, observe installation
position of sealing ring.

4. Fit new O-rings (3) (included in the scope

of delivery of the injector), O-ring (2) and
damping ring (1) onto the injector and coat
with assembly compound (Kluthe Hakuform
30-11C/Emulgier).
5. Remove oil carbon from sealing face on cyl-
inder head and protective sleeve with mill-
ing cutter.
6. Insert injector into cylinder head, ensuring
that the HP line adapter is correctly
aligned.

7. Press in injector with installation/removal

jig.
8. Remove installation/removal jig.
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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.
Name Size Type Lubricant Value/Standard
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
Note: Ensure special cleanness.
11. Coat thread and sealing cone of adapter (3) with engine oil.
12. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
Name Size Type Lubricant Value/Standard
Adapter Preload torque (Engine oil) 5 Nm to 10 Nm
13. Tighten screw (2) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M12 Tightening torque 100 Nm + 10 Nm
14. Tighten adapter (3) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Adapter Tightening torque 100 Nm + 10 Nm
Note: Ensure special cleanness.
15. Coat thread and sealing cone of HP line (5) with engine oil.
16. Mount jacketed HP line (5) and use torque wrench to tighten to the specified torque. Tightening se-
quence:
1 Adapter (4)
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2 Rail (6)
Name Size Type Lubricant Value/Standard
Union nut / thrust Tightening torque 40 Nm + 5 Nm
screw

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17. Fit connectors on injector.
Note: Failure to reset drift compensation (CDC)
will void the emissions certification.
18. Reset drift compensation (CDC) with Dia-
Sys® (→ E531920/...). If DiaSys® is not
available, contact Service.

Final steps
1. Install cylinder head cover (→ Page 176).
2. Open fuel supply to engine.

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6.7 Fuel Filter
6.7.1 Supplementary fuel filter – Overview

1 Storage tank 3 Passive standard prefilter 5 Supplementary fuel filter

2 Day tank with water separator 6 Main engine filter
4 LP pump
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6.7.2 Additional fuel filter – Replacement
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104 1
Diesel fuel
Easy-change filter (→ Spare Parts Catalog)
Synthetic ring (→ Spare Parts Catalog)

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

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

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.

Additional fuel filter – Replacement

1. Replace additional fuel filter with the engine stopped (→ Page 187).
2. Replace additional fuel filter with the engine running (→ Page 187).
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6.7.3 Fuel filter – Replacement
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104 1
Diesel fuel
Easy-change filter (→ Spare Parts Catalog)
Synthetic ring (→ Spare Parts Catalog)

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

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

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Replacing fuel filter with the en-

gine stopped
1. Cut out the filter to be replaced (1):
B Left filter cut out
C Right filter cut out
2. Remove the cut-out oil filter (1) using an oil
filter wrench.
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3. Clean sealing surface on filter head.

4. Check sealing ring of new filter (1) and coat
with fuel.
5. Screw on filter (1) and tighten manually.
6. Turn three-way cock into position (A) where
both filters are operational.
7. Replace other fuel filters in the same way.
8. Venting fuel system (→ Page 189)

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Replacing fuel filter with the en-
gine running
1. Cut out the filter to be replaced (1):
B Left filter cut out
C Right filter cut out
2. Remove the cut-out oil filter (1) using an oil
filter wrench.
3. Clean sealing surface on filter head.
4. Check sealing ring of new filter (1) and coat
with fuel.
5. Screw on filter (1) and tighten manually.
6. Turn three-way cock into position (A) where
both filters are operational.
7. Replace other fuel filters in the same way.

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6.7.4 Fuel system – Venting
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel

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

Venting LP fuel system

1. Turn three-way cock (3) into position (C)
where both filters are operational.
2. Open threaded vent plugs (1).
3. Unlock fuel priming pump (2), screw out
handle by turning it counterclockwise.
4. Operate fuel priming pump (2) until bubble-
free fuel emerges from the threaded vent
plugs (1).
5. Close threaded vent plugs (1).
6. Screw in handle by turning it clockwise.
7. Verify that fuel priming pump (2) is locked:
Handle must be tightened.
8. Put filters back into operation:
A Right filter in operation
B Left filter in operation
Result: During operation, one filter is cut in.
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6.7.5 Fuel prefilter – Differential pressure check and adjustment of gauge
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Setting adjustable pointer of dif-

ferential pressure gauge
1. After installation of a new filter element,
align adjustable 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 193).

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6.7.6 Fuel prefilter – Draining
Preconditions
☑Engine is stopped and starting disabled.

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

Draining fuel prefilter

1. Cut out the filter to be replaced (A or B).
1 Filter A cut out
2 Filter B cut out

2. Open vent plug (1) of filter to be drained.

3. Open drain valve (2).
4. Drain water and contaminants from filter
until pure fuel emerges.
5. Close drain cock (2).
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6. Connect filling pump to filling connection
(1) on the suction side of the filter.
7. Open vent valve (2) and fill with fuel until
fuel emerges from the vent pipe (3).
8. Close vent valve (2).
9. Open rotary slide valve (4) a little (by ap-
prox. 30°) and open vent valve(s) (2), until
fuel emerges from the vent pipe (3).
10. Close vent valve(s) (2).
11. Turn rotary slide valve (4) back to locked
position.

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6.7.7 Fuel prefilter – Flushing
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Diesel fuel

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

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

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Flushing fuel prefilter

1. Cut out dirty filter.
1 Filter A cut out
2 Filter B cut out
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2. Open vent plug (1) of filter to be flushed.
3. Open drain valve (2) and drain fuel.
Result: Fuel flows from filtered side back to the un-
filtered side, flushing the filter deposits
downwards out of the filter.
4. Close vent plug (1) and drain valve (2).

Fuel prefilter – Filling with fuel

1. Stop engine (→ Page 86) and disable engine start.
2. Connect filling pump to filling connection
(1) on the suction side of the filter.
3. Open vent valve (2) and fill with fuel until
fuel emerges from the vent pipe (3).
4. Close vent valve (2).
5. Open rotary slide valve (4) a little (by ap-
prox. 30°) and open vent valve(s) (2), until
fuel emerges from the vent pipe (3).
6. Close vent valve(s) (2).
7. Turn rotary slide valve (4) back to locked
position.
8. Check differential pressure (→ Page 190).
Result: Replace filter element in fuel prefilter
(→ Page 195) if flushing did not improve dif-
ferential pressure.

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6.7.8 Fuel prefilter with water separator – Filter element replacement
Preconditions
☑Engine is stopped and starting disabled.
☑System is at atmospheric pressure.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30452769 1
Ratchet adapter F30027340 1
Filter element (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

WARNING
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
• Open tank slowly.
• Wear goggles or safety mask.

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

WARNING
Component is hot.
Risk of burning!
• Wear protective gloves.

Fuel prefilter with water separa-

tor – Filter element replacement
1. Cut out the filter to be replaced (A or B):
1 Filter A cut out
2 Filter B cut out
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2. Open vent valve (1) of the filter to be re-
placed.
3. Open drain valve (5) and drain fuel.
4. Loosen screws (3) and screw out filter
housing (A or B).
5. Remove filter element (4).
6. Insert new filter element in filter housing.
7. Fit O-ring.
8. Reinstall filter housing (A or B) with filter el-
ement (4).

9. Tighten screws (6 or 3) with torque wrench to the specified tightening torque (maximum half a turn per
screw).
Name Size Type Lubricant Value/Standard
Screw Tightening torque 40 Nm
10. Connect filling pump to filling connection
(1) on the suction side of the filter.
11. Open vent valve (2) and fill with fuel until
fuel emerges from the vent pipe (3).
12. Close vent valve (2).
13. Open rotary slide valve (4) a little (by ap-
prox. 30°) and open vent valve(s) (2), until
fuel emerges from the vent pipe (3).
14. Close vent valve(s) (2).
15. Turn rotary slide valve (4) back to locked
position.

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6.7.9 Fuel prefilter with water separator – O-ring replacement in rotary slide valve
Preconditions
☑Engine is stopped and starting disabled.
☑System is at atmospheric pressure.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
O-ring (→ Spare Parts Catalog)

WARNING
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
• Open tank slowly.
• Wear goggles or safety mask.

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

Fuel prefilter with water separa-

tor – O-ring replacement in rota-
ry slide valve
1. Open vent valves (1) carefully to make sure
that the system is not pressurized.
2. Open drain valves (6) and drain fuel.
3. Remove rotary slide valve retainer (4) with
handle (5).
4. Remove rotary slide valve (3) with O-rings
(2).
5. Replace O-rings (2).
6. For assembly, follow the reverse sequence
of working steps as described for disas-
sembly.
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6.8 Exhaust Turbocharger
6.8.1 Overview of turbocharger
Turbocharger

1 Impeller housing, left 6 Bearing bush 11 Bolt

2 Impeller housing, right 7 Shaft 12 Turbine housing, right
3 Washer 8 Sprung pin 13 Turbine housing, left
4 Nut 9 Sealing ring
5 Shaft 10 Sealing flange

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Turbine housing, left turbocharger

1 R-ring 10 Circlip 19 Dished washer

2 Turbine housing 11 Circlip 20 Dished washer
3 Turbine 12 Washer 21 Stud bolt
4 Piston ring 13 Bearing bush 22 Bolt
5 Heat shield 14 O-ring 23 Washer
6 Housing cover 15 Bearing housing 24 Blanking plate
7 Washer 16 Bolt 25 Blanking plate
8 Bearing bush 17 Nut 26 Washer
9 Washer 18 Dished washer 27 Bolt
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Impeller housing, left

1 O-ring 10 O-ring 19 Sealing ring

2 Bearing body 11 Retaining ring 20 Plug bolt
3 O-ring 12 Impeller 21 Clamping piece
4 Washer 13 Magnetic nut 22 Washer
5 Thrust bearing 14 Grooved pin 23 Bolt
6 Washer 15 Identification plate 24 Bolt
7 Piston ring 16 Impeller housing 25 Washer
8 Piston ring 17 Plug bolt
9 Ring retainer 18 Sealing ring

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Turbine housing, right turbocharger

1 R-ring 11 Circlip 21 Stud bolt

2 Turbine housing 12 Washer 22 Bolt
3 Turbine 13 Bearing bush 23 Washer
4 Piston ring 14 O-ring 24 Bush
5 Heat shield 15 Bearing housing 25 Pin
6 Housing cover 16 Bolt 26 Wastegate
7 Washer 17 Nut 27 Bolt
8 Bearing bush 18 Dished washer 28 Washer
9 Washer 19 Dished washer 29 Bush
10 Circlip 20 Dished washer
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Impeller housing, right turbocharger

1 O-ring 10 O-ring 19 Sealing ring

2 Bearing body 11 Retaining ring 20 Identification plate
3 O-ring 12 Impeller 21 Grooved pin
4 Washer 13 Magnetic nut 22 Plug bolt
5 Thrust bearing 14 Bolt 23 Sealing ring
6 Washer 15 Washer 24 Bolt
7 Piston ring 16 Clamping piece 25 Washer
8 Piston ring 17 Impeller housing
9 Ring retainer 18 Plug bolt

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Impeller housing

1 Impeller housing 2 Plug bolt 3 Sealing ring

Bearing housing
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1 Bearing housing 2 Sprung pin

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Thrust bearing

1 Ball 2 Thrust bearing

Magnetic nut

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1 Magnetic nut 2 Magnet

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6.8.2 Compressor wheel – Cleaning
Preconditions
☑Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30452769 1
Ratchet adapter F30027340 1
Cleaner 40377 1
Engine oil
Engine coolant
Sealing rings (→ Spare Parts Catalog) 3
Sealing rings (→ Spare Parts Catalog) 4

WARNING
Chemical substances.
Risk of irritation and chemical burns!
• Observe the instructions of the cleaning agent manufacturer.

NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Preparatory steps – Horizontal air intake

1. Drain engine coolant (→ Page 236).
2. Remove air filter (→ Page 215).
3. Seal all openings with suitable covers.
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4. Remove charge-air pipework (1) from ex-
haust turbocharger to intercooler.
5. Remove oil lines (2).

6. Loosen clamp (1).

7. Remove intake housing (3) with actuating
cylinder (2).

8. Remove coolant lines (1) from compressor

housing (3).
9. Remove coolant ventilation line (2) from
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10. Undo screws (1).
11. Remove compressor housing (2).

Cleaning compressor wheel

Note: Do not use wire brushes, scrapers or simi-
lar tools for cleaning!
1. Clean compressor housing with a smooth
paint brush or brush.
2. Clean compressor wheel (2) and bearing
housing (1).
3. Thoroughly remove cleaner from all compo-
nents.
4. Fit new sealing rings between bearing
housing/compressor housing and plug-in
sleeves if necessary.

Final steps – Horizontal air in-

take
1. Install compressor housing (2).
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2. Tighten screws (1) to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm
3. Install coolant ventilation line and coolant lines on compressor housing.
4. Install intake housing (3) with actuating cyl-
inder (2).

5. Align clamp (1) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 15 Nm + 2 Nm

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6. Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm +4 Nm
A
7. Install charge-air pipework (1) between exhaust turbocharger and intercooler.
8. Install air filter (→ Page 215).
9. Fill with engine coolant (→ Page 239).

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Preparatory steps – Vertical air intake
1. Drain engine coolant (→ Page 236).
2. Remove air filter (→ Page 215).
3. Seal all openings with suitable covers.
4. Remove charge-air pipework (1) from ex-
haust turbocharger to intercooler.
5. Remove oil lines (2).

6. Loosen clamp (1).

7. Remove intake housing (3) with actuating
cylinder (2).
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8. Remove coolant lines (1) from compressor
housing (3).
9. Remove coolant ventilation line (2) from
compressor housing (3).

10. Undo screws (1).

11. Remove compressor housing (2).

Cleaning compressor wheel

4. Fit new sealing rings between bearing

housing/compressor housing and plug-in
sleeves if necessary.

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Final steps – Vertical air intake
1. Install compressor casing (2).

2. Tighten screws (1) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm
3. Install coolant ventilation line and coolant lines on compressor housing.
4. Install intake housing (3) with actuating cyl-
inder (2).

5. Align clamp (1) and tighten to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Clamp Tightening torque 15 Nm + 2 Nm
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6. Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm +4 Nm
A
7. Install charge-air pipework (1) between exhaust turbocharger and intercooler.
8. Install air filter (→ Page 215).
9. Fill with engine coolant (→ Page 239).

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6.9 Charge-Air Cooling
6.9.1 Intercooler – Checking condensate drain for water discharge and obstruction
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Intercooler – Checking conden-

sate drain for water discharge
and obstruction
1. With the engine running, check if air
emerges from drain bore(s) on the left and
right sides on engine driving end.
Result: If no air emerges:
• Clean condensate drain bore(s).
• Blow out with compressed air.
2. If a large amount of coolant is continuously
discharged, the intercooler is leaking. Con-
tact Service.

Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 180).
2. Bar engine manually (→ Page 162).
3. Bar engine with starting system to blow out combustion chambers (→ Page 162).
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4. Install injectors (→ Page 180).

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

Replacing the air filter

1. Remove old air filter and install new air filter (→ Page 215).
2. Reset signal ring of contamination indicator (→ Page 216).

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6.10.2 Air filter – Removal and installation
Preconditions
☑Engine is stopped and starting disabled.

Air filter
1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from
connecting flange of housing (3).
3. Verify that there are no objects in the
flange of the intake housing (3) and clean
it.
4. Attach air filter (1) with clamp (2) onto in-
take housing (3).
5. Tighten clamp (2).

Air filter with intake silencer

1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from in-
take silencer (3).
3. Clean intake silencer (3) and check for ob-
structions.
4. Attach air filter (1) with clamp (2) onto in-
take silencer (1).
5. Tighten clamp (2).
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6.11 Air Intake
6.11.1 Service indicator – Signal ring position check (optional)
Preconditions
☑Engine is stopped and starting disabled.

Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 214).
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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6.12 Starting Equipment
6.12.1 Starter – Condition check
Preconditions
☑Engine is stopped and starting disabled.

Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 265).
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6.13 Lube Oil System, Lube Oil Circuit
6.13.1 Engine oil – Level check
Preconditions
☑Engine is stopped and starting disabled.

Oil level check prior to engine

start
1. 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
be up to 2 cm above mark (1). This may be
caused e.g. by oil from oil filters and heat
exchanger flowing back into 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 219).
5. Insert dipstick into guide tube up to the
stop.

Oil level check 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 219).
5. Insert dipstick into guide tube up to the stop.

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

Special tools, Material, Spare parts

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

Oil change without semirotary hand pump: Draining oil via drain plug(s) on oil
pan
1. Provide a suitable container to collect the oil.
2. Remove drain plug(s) and drain oil.
3. Install drain plug(s) with new sealing ring.

Oil change with semirotary hand pump: Oil extraction

1. Provide a suitable container to collect the oil.
2. Draw all oil from oil pan using the semirotary hand pump.

Draining residual oil at gearcase

1. Provide a suitable container to collect the
oil.
2. Remove drain plugs (1) and (2) and drain
oil:
• Approx. 12 liters at (1)
• Approx. 5 liters at (2)
3. Install drain plug(s) with new sealing ring.
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4. Tighten drain plugs (1) and (2) to specified torque using a torque wrench:
Name Size Type Lubricant Value/Standard
Screw M26x1.5 Tightening torque (Engine oil) 100 Nm+10 Nm

Filling with new oil

1. Open cap on filler neck.
2. Pour oil in at filler neck up to 'max.' mark
at oil dipstick.
3. Close cap on filler neck.
4. Check engine oil level (→ Page 218).
5. Turn engine with starting system after oil
change (→ Page 164).

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6.13.3 Engine oil – Sample extraction and analysis
Preconditions
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
MTU test kit 5605892099/00 1

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Engine oil – Sample extraction

and analysis
1. With the engine running at operating tem-
perature, open screw on centrifugal oil fil-
ter carrier by 1 to 2 rotations.
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 in the
MTU test kit, analyze the engine oil for:
• Dispersion capability (spot test);
• Water content;
• Dilution by fuel.
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Engine oil – Sample extraction
and analysis (engines with
switchable oil filter)
1. With the engine running at operating tem-
perature, open screw on flange of centrifu-
gal oil filter by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw.
5. Using the equipment and chemicals in the
MTU test kit, analyze the engine oil for:
• Dispersion capability (spot test);
• Water content;
• Dilution by fuel.

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6.14 Oil Filtration / Cooling
6.14.1 Engine oil filter ‒ Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Filter wrench F30379104
Engine oil
Oil filter (→ Spare Parts Catalog)

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Engine oil filter ‒ Replacement

1. Stop engine (→ Page 86) and disable en-
gine start.
2. Unscrew oil filter using filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing
ring and moisten it with oil.
5. Screw on and tighten new oil filter by hand.
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6. Replace other oil filters in the same way.

7. Turn engine with starting system after ev-
ery oil change and filter replacement
(→ Page 164).
8. Check oil level (→ Page 218).

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Oil filter with diverter (option):
Oil filter replacement with the
engine stopped
1. Stop engine (→ Page 86) and disable en-
gine start.
2. Unscrew oil filter using oil filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing
ring and moisten it with oil.
5. Fit SOLAS shield (→ Page 16).
6. Screw on and tighten new oil filter by hand.
7. Replace other oil filters in the same way.
8. Turn engine with starting system after ev-
ery oil change and filter replacement
(→ Page 164).
9. Check oil level (→ Page 218).

Oil filter with diverter (option):

Oil filter replacement with the
engine running
1. To cut out the filter to be replaced, set the
three-way cock to the corresponding posi-
tion.
• Position A: Lower filters cut out
• Position B: Both filters cut in (normal op-
erating position)
• Position C: Upper filters cut out.

2. Unscrew oil filter using oil filter wrench.

3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing
ring and moisten it with oil.
5. Fit SOLAS shield (→ Page 16).
6. Screw on and tighten new oil filter by hand.
7. Replace other oil filters in the same way.
8. Check oil level (→ Page 218).
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6.14.2 Oil indicator filter – Cleaning and check
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Cleaning agent (Snow-White 11-0) 40460 1
Cleaning agent (Hakupur 312) 30390 1
Engine oil
Strainer (→ Spare Parts Catalog)
Square-section ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.

Removing strainer
1. Clean oil indicator filter before disassem-
bling it.
2. Remove screws (1).
3. Take off cover (2) with O-ring (3).
4. Take strainer (5) from filter housing.
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Checking strainer
Item Findings Action
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Contact Service
Strainer Damaged Fit new part
Square-section ring Damaged Fit new part
O-ring Damaged Fit new part

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 O-ring (3) with engine oil and fit in filter housing.
3. Fit cover (2) and secure with screws (1) and washers.

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6.14.3 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 6-50 Nm F30027336 1
Filter wrench F30379104 1
Cleaner Hakutex 60
Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1
Filter sleeve (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)

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Centrifugal oil filter – Cleaning
and filter sleeve replacement
1. Remove clamp (14).
2. Release Tommy nut (2) and take off cov-
er (1).
3. Carefully lift rotor (11), allow oil to drain
and remove from housing.
4. Holding the rotor (11) firmly, release rotor
cover nut (3).
5. Take off rotor cover (4).
6. Remove filter sleeve (6).
7. Measure layer thickness of oil residues on
filter sleeve (6).
Result: If the oil residues exceed the maximum lay-
er thickness of 45 mm, shorten the mainte-
nance interval.
8. Disassemble rotor tube (7), conical disk (8)
and rotor base (10).
9. Wash rotor cover (4), rotor tube (7), conical
disk (8) and rotor base (10) with cold
cleaner.
10. Blow out with compressed air.
11. Check sealing ring (9), fit new one if neces-
sary.
12. Assemble rotor tube (7), conical disk (8)
and rotor base (10) with sealing ring (9).
13. Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the
outer wall.
14. Check sealing ring (5), fit new one if neces-
sary.
15. Mount rotor cover (4) with sealing ring (5).
16. Tighten rotor cover nut (3) with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
Nut Tightening torque 35 Nm to 45 Nm
17. Place rotor (11) in housing (12) and check for ease of movement.
18. Check sealing ring (13), fit new one if necessary.
19. Fit sealing ring (13) on housing (12).
20. Fit hood (1).
21. Tighten Tommy nut (2) by hand.
22. Install clamp (14) and tighten with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
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Clamp Tightening torque 8 Nm to 10 Nm

23. Tighten cover nut (2) with torque wrench to the specified torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 5 Nm to 7 Nm

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Cleaning centrifugal oil filter
and replacing filter sleeve (en-
gines with switchable oil filter)
1. Undo and remove screw (1).
2. Remove clamp (3) and take off hood (2).
3. Carefully remove rotor (5) from housing.
4. Hold rotor assembly (5) firmly in position
with filter wrench and undo knurled nut (7).
5. Take off rotor cap (8).
6. Remove filter sleeve (9), stiffener plate (10)
and sealing ring (11).
7. Measure thickness of oil residues on filter
sleeve.
8. If maximum layer thickness of oil residues
exceeds 30 mm, shorten maintenance in-
terval.
9. Remove standpipe (12) from lower rotor
section (13).
10. Wash hood (2), rotor cap (8), stiffener
plate (10), standpipe (12), lower rotor sec-
tion (13) and nozzles (14) with cleaner and
blow out with compressed air. Do not use
sharp objects for cleaning.
11. Check nozzles (14) for obstructions.
12. Push standpipe (12) onto rotor lower sec-
tion (13).
13. Insert new filter sleeve (9) with stiffener
plate (10) into rotor cap (8), ensuring that
the smooth surface of the filter sleeve (9)
faces the rotor cap (8).
14. Check sealing ring (11), replace if necessa-
ry. Coat sealing ring with grease and insert
in groove of rotor cap (8).
15. Place rotor cap (8) onto standpipe (12).
16. Hold rotor assembly (5) firmly in position
with filter wrench and tighten knurled
nut (7).
17. Lubricate bearings of rotor (5), insert in
housing (6) and check for ease of move-
ment.
18. Check sealing ring (4), replace if necessary.
Fit sealing ring on housing (6).
19. Fit hood (2).
20. Tighten screw (1) by hand.
21. Install clamp (3) and tighten to specified torque using a torque wrench:
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Name Size Type Lubricant Value/Standard

Clamp Tightening torque 6 Nm + 1 Nm
22. Tighten screw (1) to specified torque using a torque wrench:
Name Size Type Lubricant Value/Standard
Screw Tightening torque 6 Nm + 1 Nm

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6.15 Coolant Circuit, General, High-Temperature Circuit
6.15.1 Drain and vent points
Coolant lines on ETC
1 Vent point

Coolant line to intercooler

1 Vent point

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1 Vent point

Coolant line to raw water cooler

1 Vent point
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Vent line – Distribution cross
1 Vent point

Coolant drain point, engine driving end

1 Drain point

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Coolant drain point, engine free end
1 Drain point
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6.15.2 Engine coolant level – Check
Preconditions
☑Engine is stopped and starting disabled.
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

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

Checking engine coolant level at filler neck:

1. Turn breather valve on coolant expansion tank (for engines with remote heat exchanger: the expansion
tank is part of the remote cooling system) counterclockwise up 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 bottom edge of the cast-in eye in the filler neck).

Checking engine coolant level at

external cooler:
1. Check coolant level (coolant must be visi-
ble at marker plate).
2. Top up with treated coolant as necessary
(→ Page 239).
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.
2. Top up with treated coolant as necessary (→ Page 239).
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6.15.3 Engine coolant – Change
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Coolant

Engine coolant change

1. Drain engine coolant (→ Page 236).
2. Fill with engine coolant (→ Page 239).
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6.15.4 Engine coolant – Draining
Preconditions
☑Engine is stopped and starting disabled.

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

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

Engine coolant – Draining

1. Turn breather valve on expansion tank (for engines with remote heat exchanger: the expansion tank is
part of the remote cooling system) counterclockwise up to the 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 vent valves on carrier housing (1).

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5. Open vent valve on exhaust pipework (driv-
ing end) (1).

6. Open vent valve on seawater cooler (1) (or

remote heat exchanger).

7. Open drain plug (1) and drain coolant at

crankcase.
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8. Open drain screw (1) and drain coolant on
coolant pump elbow.

Final steps
1. Seal all open vent and drain points.
2. Set breather valve onto filler neck and close it.

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

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine coolant

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

NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.

Preparatory steps
1. Turn breather valve on expansion tank (for
engines with remote heat exchanger: the
expansion tank is part of the remote cool-
ing system) counterclockwise up to the
first stop and allow pressure to escape.
2. Continue to turn breather valve counter-
clockwise and remove.
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Filling coolant through filler
neck
1. Open vent points on charge-air cooler, ex-
haust turbochargers and on plate-core heat
exchanger (arrows).
2. Fill coolant through the filler neck of the
expansion tank (for engines with remote
heat exchanger: the expansion tank is part
of the remote cooling system) until the
coolant level at the top edge of the filler
neck remains constant.
3. When coolant emerges from the vent
points, close vent points one by one, pro-
ceeding from the lowest point upwards.
4. Check proper condition of breather valve
and clean sealing faces if required.
5. Set breather valve onto filler neck and turn
until the first stop.
6. Start engine (→ Page 77).
7. After 10 seconds of running the engine
without load, shut down the engine
(→ Page 86).
8. Turn breather valve counterclockwise and
remove.
9. Check coolant level (→ Page 234) and top
up engine coolant as required:
a) Repeat the steps from starting the en-
gine (→ Step 6) until no coolant needs
to be topped up any more.
b) Check proper condition of breather
valve and clean sealing faces if re-
quired.
c) Set breather valve onto filler neck and
close it.

Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 234) and top up engine coolant as required.
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6.15.6 HT coolant pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

HT coolant pump – Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
2. Stop engine (→ Operating instructions elec-
tronic system) and disable engine start.
3. Clean the relief bore with a wire if it is
dirty.
• Permissible engine coolant discharge:
up to 10 drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits,
contact Service.
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6.15.7 Engine coolant – Sample extraction and analysis
Preconditions
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
MTU test kit 5605892099/00 1

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

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

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Engine coolant – Sample extrac-

tion and analysis
1. Open drain valve (arrow) with the engine
running.
2. Flush sampling point by draining approx. 1
liter coolant.
3. Drain approx. 1 liter of engine coolant into
a clean container.
4. Close drain valve (arrow).
5. Use the equipment and chemicals of the
MTU test kit to check the coolant for:
• Antifreeze concentration
• Corrosion inhibitor concentration
• pH value
6. Engine coolant change intervals (→ MTU
Fluids and Lubricants Specifications).
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6.15.8 Engine coolant filter – Replacement
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104 1
Engine oil
Engine coolant filter (→ Spare Parts Catalog)

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

Engine coolant filter – Replace-

ment
1. Remove locking device (1).
2. Close shut-off cock (3).
3. Remove engine coolant filter (2) with filter
wrench.
4. Clean sealing surface on connecting piece.
5. Coat seal on new engine coolant filter (2)
with engine oil.
6. Screw on engine coolant filter (2) and tight-
en hand-tight.
7. Open shut-off cock (3).
8. Install locking device (1).
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6.15.9 Preheating unit
Hotstart preheating unit

1 Plastic cap (drain) 4 Shutoff valve 7 Thermostat

2 On/Off switch 5 Continuous flow heater 8 Circulation pump
3 Plastic cap (supply line) 6 Vent valve
Cylinders Nominal voltage / frequency Heating power kW
12 V 230 V / 50 Hz 9
400 V / 50 Hz 9
230 V / 60 Hz 9
440 V / 60 Hz 9
16 V 230 V / 50 Hz 12
400 V / 50 Hz 12
230 V / 60 Hz 12
440 V / 60 Hz 12

Function
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The preheating unit is intended to warm up the engine coolant. The circulating pump (8) ensures the
circulation of the preheated engine coolant through the engine.
The continuous flow heater (5) comprises a heating element. The thermostat (7) switches off the pre-
heating unit via contactors when the engine coolant temperature has reached the setting of the thermo-
stat (7).
In the event of excessive coolant temperature, the temperature limiter of the thermostat (7) opens the
control loop. The preheating unit is switched off.
The unit must be reset manually after the fault has been rectified.

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Hilzinger preheating unit

1 On/Off switch
Cylinders Nominal voltage / frequency Heating power kW
12 V and 16 V 230 V / 50 Hz 9
400 V / 50 Hz 9
230 V / 60 Hz 9
440 V / 60 Hz 9
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Hilzinger preheating unit, side view

1 Flange (supply and return) 3 Non-return flap 5 Thermostat

2 Junction box 4 Continuous flow heater 6 Circulation pump

Function
The preheating unit is intended to warm up the engine coolant. The circulation pump (6) ensures the
circulation of the preheated coolant through the engine.
The continuous flow heater (4) comprises a heating element. A non-return flap (3) prevents coolant
from flowing through the preheating unit when the engine is running.
When the coolant temperature has reached the value of the thermostat setting (5), the thermostat (5)
switches off the preheating unit via contactors.
In the event of excessive coolant temperature, the temperature limiter of the thermostat (5) opens the
control loop. The preheater is switched off.
The unit must be reset manually after the fault has been rectified.
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6.15.10 Preheater – Overhaul
Preconditions
☑Engine is stopped and starting disabled.

DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!

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

Overhauling preheater
1. Disconnect power supply to heating element.
2. Close shut-off valve in coolant line before and after preheater.
3. Drain coolant at drain valve into a clean container.
4. Clean and flush coolant circuit.
5. Check hoses for cracks and other damage. Replace as necessary.
6. Check wiring for damage and overheating.
7. Remove heating element.
8. Clean heating element and tank.
9. Remove pump from volute (if applicable) and check for residues in impeller and lines.
10. Install heating element.
11. Connect heating element to power supply.
12. Connect hoses and open shut-off valves.
13. Check preheater for leakage and correct operation (→ Page 248).
14. Check coolant level (→ Page 234).
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6.15.11 Preheater – Function and leak-tightness check
Preconditions
☑Preheater is switched on.

WARNING
Coolant is hot and highly pressurized.
Risk of injury! Risk of scalding!
• Allow engine to cool down.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Checking operation
Note: The coolant temperature must correlate to the control range of the thermostat when the preheater is
ready for operation.
1. Check coolant preheating temperature.
2. Set the thermostat accordingly if the temperatures are not in the control range.

Checking for leaks

1. Check leak-tightness at coolant inlet and outlet.
2. Tighten any leaking unions.

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6.16 Raw Water Pump with Connections
6.16.1 Raw water pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Raw water pump – Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
2. Stop engine (→ Page 86) and disable en-
gine start.
3. Clean the relief bore with a wire if it is
dirty.
• Permissible engine coolant discharge:
up to 10 drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits,
contact Service.
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6.17 Engine Mounting / Support
6.17.1 Engine mounting – Check

Engine mounting – Check

Item Findings Action
Visually inspect mounts. • Damage Replace (contact Service).
• Brittleness
• Deformation
• Crack formation
• Swelling
visible

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6.18 Battery-Charging Generator
6.18.1 Battery-charging generator drive – Coupling condition check
Preconditions
☑Engine is stopped and starting disabled.

Battery-charging generator drive

– Coupling condition check
1. Remove screws (1).
2. Remove protective cover (2).
3. Check resilient coupling (3) for cracks and
plastic deformation.
4. If there is serious deformation or crack for-
mation, contact Service.
5. Install protective cover (2) with screws (1).
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6.19 Auxiliary PTO
6.19.1 Bilge pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Bilge pump – Relief bore check

1. Check relief bores for oil and water dis-
charge.
2. Stop engine (→ Page 86) and disable en-
gine start.
3. Clean relief bores with a wire if dirty.
• Permissible water discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour
4. If discharge exceeds the specified limits:
Contact Service.

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6.20 Fuel Supply System
6.20.1 Water drain valve – Check

Water drain valve – Check

1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.
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6.20.2 Differential pressure gauge – Check
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Checking differential pressure gauge

1. Switch on fuel treatment system (→ Page 84).
2. Set the alarm points at the differential pressure gauge to zero.
Result: Alarm is initiated with preset delay.
3. Reset the alarm points at the differential pressure gauge to the specified values.

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6.20.3 Water level probe (3-in-1 rod electrode) – Check
Preconditions
☑System is put out of operation and emptied.

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

Checking water level probe (3-in-1 rod electrode)

1. Disconnect connector from water level probe.
2. Unscrew water level probe.
3. Disconnect connector from water level probe.
4. Immerse water level probe into a tank filled with water until water level reaches the thread.
5. Switch system on.
Result: Water drain valve opens.
6. Leave water level probe in tank.
Result: Alarm must be triggered with the preset delay.
7. Switch off the system.
8. Disconnect connector from water level probe.
9. Remove water level probe from tank.
10. Screw in water level probe.
11. Connect connector for water level probe.
12. Fill and vent the system then put it into operation.
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6.20.4 Pump capacity – Check
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Pump capacity – Check

1. Install suitable pressure gauge at the neck of the intake side of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system (→ Page 84).
Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflow-
ing fuel and can be disregarded.
b) Close ball valve at the outlet of the fuel treatment system.
c) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
3. Check pump pressure with reduced suction.
a) Reduce suction pressure of pump to -0.8 bar with the shutoff valve at the pump intake side.
b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
c) Open ball valve at inlet and outlet of fuel treatment system.
4. Calculate wear limit.
Example:
Measured value (normal condition). 3 bar
Measured value (reduced suction condition). 2.6 bar
If the measured value (reduced suction condition) is 10% lower than the measured value (normal condition),
the wear limit is reached. Repair pump (contact Service).

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6.20.5 Coalescer filter element – Replacement
Preconditions
☑System is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 6-50 Nm F30027336 1
Ratchet F30027339 1
Diesel fuel
Engine oil
Coalescer filter element (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)

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

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

Coalescer filter element – Re-

placement
1. Close ball valve at the inlet and outlet of
the fuel treatment system.
2. Open drain valve.
3. Drain fuel.
4. Close drain valve.
5. Remove nuts (9) and washers (2).
6. Remove screws (1).
7. Remove cover with gasket (10).
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8. Remove nut (3), washer (8) and end

plate (4).
9. Remove coalescer filter element (5).
10. Catch fuel as it runs out.
11. Clean housing with a non-linting cloth,
rinse with fuel if required.
12. Check housing for corrosion.
13. Clean housing sealing surfaces.
14. Install coalescer filter element (5).
15. Install end plate (4), washer (8) and nut (3).

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16. Tighten nut (3) to specified tightening torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm
17. Fit gasket (10).
18. Install cover.
19. Install screws (1), washers (2) and nuts (9).
20. Tighten nuts (9).
21. Open ball valve at the inlet and outlet of the fuel treatment system.
Result: The fuel treatment system is ready for operation.

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6.21 Wiring (General) for Engine/Gearbox/Unit
6.21.1 Engine wiring harness – Overview
Engine wiring harnesses – Terminal assignment
Description Terminal assignment
Sensors B1 Camshaft speed
B3 Intake air temperature
B4.21 Exhaust temperature, A side
B4.22 Exhaust temperature, B-side
B5.1 Oil pressure downstream of filter
B5.3 Oil pressure upstream of filter
B6 Coolant temperature
B7 Oil temperature
B9 Charge-air temperature
B10 Charge-air pressure
B13 Crankshaft speed
B16 Coolant pressure
B33 Fuel temperature
B34.1 Fuel pressure downstream of filter
B34.2 Fuel pressure upstream of filter
B34.3 Fuel pressure upstream of external filter
B44.1 Rotation speed, exhaust turbocharger A
B44.2 Rotation speed, exhaust turbocharger B
B48 HP fuel pressure
B49 Charge air before recirculation
B50 Crankcase pressure
B54 Replenishment pump pressure
Level monitor F33 Coolant level
XF33 Coolant level adaptation
XXF33 Coolant level, hull-mounted cooling system
F46 Fuel overflow level
Pump M8 Fuel pump
Limit switch S37.1 Start interlock A
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S37.2 Start interlock B

Adaptation X2 ECU-7 governor
X4 ECU-7 governor
X37 Cranking start interlock
XG03 Battery-charging generator
Valves Y26 Charge-air recirculation
Y27 Exhaust turbocharger

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Description Terminal assignment
Injectors Y39A1 to Y39AX Engine A side
Y39B1 to Y39BX Engine B side

Engine wiring harness for sensors, 12V engine

1 M8 13 B4.22 25 B4.21
2 B1 14 B9 26 B10
3 B6 15 S37.1 27 B13
4 X2 16 B34.3 28 S37.2
5 X37 17 B34.2 29 B7
6 XXF33 18 B34.1 30 B5.1
7 F33 19 B50 31 B48
8 B16 20 B49 32 B33
9 XF33 21 B44.1 33 F46
10 B54 22 Y26 34 XG03
11 B44.2 23 B5.3
12 Y27 24 B3
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Engine wiring harness for sensors, 16V engine

1 M8 13 B4.22 25 B4.21
2 B1 14 B9 26 B10
3 B6 15 S37.1 27 B13
4 X2 16 B34.3 28 S37.2
5 Y27 17 B34.2 29 B7
6 B44.2 18 B34.1 30 B5.1
7 X37 19 B50 31 B48
8 XF33 20 B49 32 B33
9 B54 21 B44.1 33 F46
10 B16 22 Y26 34 XG03
11 XXF33 23 B5.3
12 F33 24 B3
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Engine wiring harness for injectors, 12V engine

1 Y39A1 6 Y39A6 11 Y39B3

2 Y39A2 7 X4 12 Y39B2
3 Y39A3 8 Y39B6 13 Y39B1
4 Y39A4 9 Y39B5
5 Y39A5 10 Y39B4

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Engine wiring harness for injectors, 16V engine

1 Y39A1 7 Y39A7 13 Y39B5

2 Y39A2 8 Y39A8 14 Y39B4
3 Y39A3 9 X4 15 Y39B3
4 Y39A4 10 Y39B8 16 Y39B2
5 Y39A5 11 Y39B7 17 Y39B1
6 Y39A6 12 Y39B6
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Engine wiring harness for electric starter

1 Connection terminals, EIM 2 Fuse F1 3 Connection terminals,

starter

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6.21.2 Engine wiring – Check
Preconditions
☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

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

Engine wiring – Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Verify that all cable clips are closed and in proper condition.
4. Replace cable clips if defective.
5. Check that cable clamps are firm, tighten loose cable clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical line components for damage:
• Connector housing
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
8. Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
9. Ensure that all sensor connectors are securely engaged.
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6.22 Accessories for (Electronic) Engine Governor / Control System
6.22.1 CDC parameters – Reset
Preconditions
☑Engine is stopped and starting disabled.

Note: Failure to reset drift compensation (CDC parameters) will void the emissions certification.

Resetting CDC parameters with DiaSys®

u (→ Dialog system DiaSys® E531920/..).

Resetting CDC parameters without DiaSys®

u If no DiaSys® is available, contact Service.

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6.22.2 Limit switch for start interlock ‒ Check
Preconditions
☑Engine is stopped and starting disabled.

Note: In the OFF position, the limit switch initiates a start interlock, i.e. the engine cannot be started.
Checking limit switch for start
interlock
1. Check whether switches (3) and guard
plate (1) with engine support (4) are instal-
led on both sides of flywheel housing (2).
2. Check whether both switches (3) are actu-
ated.
3. If switches (3) and/or guard plate (1) with
engine support (4) is/are not installed:
• Screw on guard plate (1) with engine
support (4).
• Then screw on switch (3), ensuring that
the switch (3) is actuated by the guard
plate (1).
4. If switch (3) and guard plate (1) are instal-
led, but switch (3) is in the OFF position:
• Make certain that the guard plate (1) at
the side of the switch (3) is not distort-
ed.
• Release guard plate (1) and screw on
such that the switch (3) is actuated.
TIM-ID: 0000016782 - 006

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6.22.3 Engine Control Unit ECU 7 – Checking plug connections
Preconditions
☑Engine is stopped and starting disabled.

Check plug connections on ECU

7
1. Check all connectors on ECU for firm seat-
ing. Ensure that the clips (1) are engaged.
2. Check screws (2) of cable clamps on ECU
for firm seating. Ensure that cable clamps
are not faulty.

TIM-ID: 0000016847 - 006

268 | Task Description | MS150068/01E 2014-01

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6.22.4 Engine Monitoring Unit EMU 7 – Plug connection check
Preconditions
☑Engine is stopped and starting disabled.

Checking EMU plug connections

1. Check both connectors on EMU (2) for firm
seating. Ensure that the clips (1) are engag-
ed.
2. Check screws (3) of cable clamps on
EMU (2) for firm seating. Ensure that cable
clamps are not faulty.
TIM-ID: 0000035355 - 002

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6.22.5 Interface module EIM plug connections – Check
Preconditions
☑Engine is stopped and starting disabled.

Checking EIM plug connections

1. Check both Tyco plugs (62-pole) (2) on EIM
for firm seating. Ensure that clips (3) are
engaged.
2. Check screws (1) of cable clamps on EIM
for firm seating. Ensure that cable clamps
are not faulty.

TIM-ID: 0000017034 - 004

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6.22.6 Engine Control Unit ECU 7 – Removal and installation
Preconditions
☑Engine is stopped and starting disabled.

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

Removing Engine Control Unit

from engine
1. Note or mark assignment of cables and
connectors.
2. Remove all screws (3).
3. Undo clips (2) on connectors.
4. Remove all male connectors.
5. Remove screws (1).
6. Take off Engine Control Unit.

Installing Engine Control Unit on engine

1. Install in reverse order. Ensure correct assignment of connectors and sockets.
2. Check resilient mount before installing.
Result: If resilient mount is porous or defective then replace it.
TIM-ID: 0000000049 - 008

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6.22.7 EMU 7 – Removal and installation
Preconditions
☑Engine is stopped and starting disabled.

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

Removing ECU with EMU from

engine
1. Note or mark assignment of cables and
connectors.
2. Remove all screws (2).
3. Undo latches (3) of the connectors.
4. Disconnect all connectors.
5. Remove screws (1).
6. Remove ECU (5) with EMU (4).

Removing EMU
1. Unscrew screws on base of EMU (4).
2. Remove EMU (4) from ECU (5).

Installing EMU
1. Place EMU (4) on ECU (5).
2. Screw in and tighten screws on base of EMU (4).

Installing ECU with EMU on engine

1. Install in reverse order. Ensure correct assignment of connectors and sockets in so doing.
2. Check resilient mount before installing.
Result: Replace resilient mount if porous or defective.
TIM-ID: 0000016799 - 007

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6.22.8 Engine Interface Module EIM – Removal and installation
Preconditions
☑Engine is stopped and starting disabled.

Removing EIM from the engine

1. Note or mark assignment of cables and
connectors.
2. Unscrew all screws (1).
3. Undo clips (2) on connectors.
4. Disconnect all connectors.
5. Unscrew power and starter cable.
6. Remove screws (3).
7. Take off EIM.

Installing EIM on the engine

1. Install in reverse order. When doing so, observe correct assignment between cables and plugs.
2. Check seal before installing.
Result: Replace seal if porous or defective.

Downloading software
1. The new EIM still does not have appropriate FSW and parameter/descriptor module (the diagnostic
lamp (DILA) indicates flashing code 4 when the power supply is connected, (→ Page 274)).
2. The FSW and the parameter/descriptor module must first be downloaded from the central database
(CDB) based on the relevant engine number using the DiaSys software tool, and then loaded in the EIM.
TIM-ID: 0000017035 - 005

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6.22.9 Diagnostic features of EIM
Diagnostic lamp (DILA)
A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM).
It indicates the operating status of the EIM.
Functions of diagnostic lamp DILA
DILA lights Engine Interface Module (EIM) is OK.
DILA dark EIM supply voltage missing or diagnostic lamp activation is faulty.
DILA flashes Hardware or software fault in the Engine Interface Module.

The diagnostic lamp (DILA) signals the following states:

1 Time in seconds 4 Application loader active 7 No firmware

2 Timing: 1/8 s 5 External RAM faulty 8 Application crashed
3 Ready for operation 6 External FLASH faulty

Fuse lamp (SILA)

A second indicator is the fuse lamp.
TIM-ID: 0000038009 - 003

This is also integrated in the housing of the Engine Interface Module. It indicates the status of the fuses.
An orange LED is provided to allow diagnosis of a “tripped fuse” fault directly at the unit as it is often
difficult to pinpoint a fault in the field without cabling diagrams.
This LED is activated by the controller.
Functions of fuse lamp SILA
SILA dark Norma operating state.
SILA flashes orange One or more fuses have tripped.

The fuse lamp (SILA) signals the following states:

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1 Preamble 6 VSP current path failed 11 ES pushbutton current
2 ECU current path failed (S5) path failed – 24V external
(S1) 7 SLD current path failed (S10)
3 MCS current path failed (S6) 12 Key switch current path
(S2) 8 DDV current path failed failed (S11)
4 EMU current path failed (S7) 13 SDAF 1+2 current path
(S3) 9 Gear monitoring current failed (S12)
5 Starter voltage: Terminal path failed (S8) 14 PIM current path failed
30, 31 not connected and 10 Emergency stop current (S13)
PR 10.0600.001 has value path failed – 24V internal 15 Spare current path failed
1 or 2 (S4) (S9) (S14)
The failed current paths are signaled consecutively following the preamble (LED on for 4 seconds (1)).
There is a pause lasting 4 seconds in between.
TIM-ID: 0000038009 - 003

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Sample flashing sequences

A Fuse S5 failure (1/2 sec- B Fuse S1 and fuse S4 fail-

ond steps) ure (1/2 second steps)
Note:
These bit sequences are transmitted constantly.

Information about the status of the current paths of the EIM is also provided in the CAN message “Sta-
tus internal power supply”.

TIM-ID: 0000038009 - 003

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7 Appendix A
7.1 Abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine governor
AL Alarm Alarm (general)
ANSI American National Standards Institute Governing body for US American standards
ETC Exhaust turbocharger
BR Baureihe (Series)
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Setting for drift correction with DiaSys in engine gov-
ernor
CPP Controllable Pitch Propeller
DILA Diagnostic lamp on EIM
DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards ("Deutsche In-
dustrie-Norm")
DIS Display unit Display panel
DL Default Lost Alarm: Default CAN bus failure
ECS Engine Control System Engine management system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EIM Engine Interface Module Interface to engine monitoring system
EMU Engine Monitoring Unit
SPC Spare Parts Catalog
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
HAT Harbor Acceptance Test
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
TIM-ID: 0000002050 - 005

ICFN ISO - Continuous rating - Fuel stop Power specification in accordance with DIN-ISO
power - Net 3046-7
IDM Interface Data Module Memory module for interface data
IIG Initial Injector Equalization Entering of injector code with DiaSys in engine gover-
nor
IMO International Maritime Organization
ISO International Organization for Stand- International umbrella organization for all national
ardization standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204

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Abbrevia- Meaning Explanation
tion
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing Microprocessor (unit)
Unit
TDC Top Dead Center
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Operating panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency-air shutoff flap(s)
SILA Fuse lamp on EIM
SOLAS International Convention for the Safety
of Life at Sea
SS Safety System Indicated alarm is initiated by the safety system
SSK Emergency-air shutoff flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Sensor comparison fault
BDC Bottom Dead Center
VS Voith Schneider Voith-Schneider drive
WJ Water Jet Water jet drive
TIM-ID: 0000002050 - 005

TC Tool Catalog
ZKP Zugehörigkeit-Kategorie-Parameter Numbering plan for ADEC ECU signals

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7.2 MTU contact persons/service partners
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 person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000

Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015

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8 Appendix B
8.1 Special Tools
Barring device
Part No.: F6555766
Qty.: 1
Used in: 6.1.1 Engine – Barring manually (→ Page 162)

Feeler gage
Part No.: Y20010128
Qty.: 1
Used in: 6.4.2 Valve clearance – Check and adjustment
(→ Page 173)

Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 6.7.2 Additional fuel filter – Replacement (→ Page 186)
Qty.: 1
Used in: 6.7.3 Fuel filter – Replacement (→ Page 187)
Qty.:
Used in: 6.14.1 Engine oil filter ‒ Replacement (→ Page 223)
Qty.: 1
Used in: 6.14.3 Centrifugal oil filter – Cleaning and filter sleeve
replacement (→ Page 227)
Qty.: 1
DCL-ID: 0000005758 - 004

Used in: 6.15.8 Engine coolant filter – Replacement

(→ Page 243)

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Installation/removal jig
Part No.: F6789889
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 180)

Milling cutter
Part No.: F30452739
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 180)

MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 6.13.3 Engine oil – Sample extraction and analysis
(→ Page 221)
Qty.: 1
Used in: 6.15.7 Engine coolant – Sample extraction and analysis
(→ Page 242)

Ratchet
Part No.: F30027339
Qty.: 1
Used in: 6.20.5 Coalescer filter element – Replacement
(→ Page 257)
DCL-ID: 0000005758 - 004

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Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 180)
Qty.: 1
Used in: 6.7.8 Fuel prefilter with water separator – Filter ele-
ment replacement (→ Page 195)
Qty.: 1
Used in: 6.8.2 Compressor wheel – Cleaning (→ Page 205)

Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 180)
Qty.: 1
Used in: 6.13.2 Engine oil – Change (→ Page 219)

Ratchet with extension

Part No.: F30006212
Qty.: 1
Used in: 6.1.1 Engine – Barring manually (→ Page 162)

Rigid endoscope
Part No.: Y20097353
Qty.: 1
Used in: 6.2.1 Cylinder liner – Endoscopic examination
(→ Page 165)
DCL-ID: 0000005758 - 004

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Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
Used in: 6.4.2 Valve clearance – Check and adjustment
(→ Page 173)

Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 3.14 Plant – Cleaning (→ Page 89)

Torque wrench, 0.5-5 Nm

Part No.: 0015384230
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 180)

Torque wrench, 10-60 Nm

Part No.: F30452769
Qty.: 1
Used in: 6.6.2 Injector – Removal and installation (→ Page 180)
Qty.: 1
Used in: 6.7.8 Fuel prefilter with water separator – Filter ele-
ment replacement (→ Page 195)
Qty.: 1
Used in: 6.8.2 Compressor wheel – Cleaning (→ Page 205)
DCL-ID: 0000005758 - 004

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Torque wrench, 40-200 Nm
Part No.: F30027337
Qty.: 1
Used in: 6.13.2 Engine oil – Change (→ Page 219)

Torque wrench, 6-50 Nm

Part No.: F30027336
Qty.: 1
Used in: 6.14.3 Centrifugal oil filter – Cleaning and filter sleeve
replacement (→ Page 227)

Torque wrench, 6-50 Nm

Part No.: F30027336
Qty.: 1
Used in: 6.20.5 Coalescer filter element – Replacement
(→ Page 257)

Torque wrench, 60-320 Nm

Part No.: F30452768
Qty.: 1
Used in: 6.4.2 Valve clearance – Check and adjustment
(→ Page 173)
Qty.: 1
DCL-ID: 0000005758 - 004

Used in: 6.6.2 Injector – Removal and installation (→ Page 180)

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8.2 Index
Preheating unit 244 Crankcase breather system
– Overview 169
Numerics Cylinder
12V 4000 M23F engine data, RheinSchUO, stage II, IMO – Designation 52
Tier II 56 Cylinder head cover
12V 4000 M23S engine data, IMO Tier II, EPA Tier 2 62 – Installation 176
12V 4000 M23S engine data, RheinSchUO, stage II, IMO – Removal 176
Tier II 59 Cylinder liner
16V 4000 M23F engine data, RheinSchUO, stage II, IMO – Endoscopic examination 165
Tier II 65 – Instructions and comments on endoscopic and visual
16V 4000 M23S engine data, IMO Tier II, EPA Tier 2 71 examination 167
16V 4000 M23S engine data, RheinSchUO, stage II, IMO
D
Tier II 68
Designations
A – Engine sides and cylinders 52
Abbreviations 277 Differential pressure gauge
Actuators – Check 254
– Overview 32 Drain and vent points 230
Additional fuel filter Drift compensation
– Replacement 186 – Reset 266
ADEC (ECU 7)
E
– Fault codes 97
– Fault messages 96 ECU 7
After stopping the engine 88 – Installation 271
Air filter – Removal 271
– Removal and installation 215 EMU 7
– Replacement 214 – Installation 272
– Plug connection check 269
B – Removal 272
Battery-charging generator drive Engine
– Coupling condition check 251 – Barring manually 162
Bilge pump – Barring with starting system 164
– Relief bore check 252 – Emergency stop 87
– Main dimensions 53
C – Start 77
CDC parameters – Stopping 86
– Reset 266 – Wiring check 265
Centrifugal oil filter Engine Control Unit ECU 7
– Cleaning 227 – Checking plug connections 268
Checks – Installation 271
– Prior to start-up 80 – Removal 271
Coalescer filter element Engine coolant
– Replacement 257 – Change 235
Compressor wheel – Draining 236
– Cleaning 205 – Filter replacement 243
DCL-ID: 0000005758 - 004

Contact persons 279 – Sample analysis 242

Controls 74 – Sample extraction 242
Coolant Engine coolant level
– Change 235 – Check 234
Cooler Engine coolant – Filling 239
– Charge-air Engine governor ADEC (ECU 7)
– Checking condensate drain for water discharge and – Fault codes 97
obstruction 213 – Fault messages 96
Crankcase breather Engine Interface Module EIM
– Oil mist fine separator – Removal and installation 273
– Replacement 171 Engine layout 28

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Engine Monitoring Unit EMU 7 H
– Plug connection check 269 Hotline 279
Engine mounting HP pump
– Check 250 – Filling with engine oil 177
Engine oil – Relief bore check 178
– Sample extraction and analysis 221 HT coolant pump
Engine oil – Relief bore check 241
– Change 219
Engine oil filter I
– Replacement 223 Injector
Engine oil level – Installation 180
– Check 218 – Removal 180
Engine sides – Replacement 179
– Designation 52 Intercooler
Engine wiring – Checking condensate drain for water discharge and
– Check 265 obstruction 213
Engine wiring harness Interface module EIM
– Overview 259 – Check 270

F L
Fault codes Limit switch for start interlock
– Engine governor ADEC (ECU 7) 97 – Check 267
Fault messages
– Engine governor ADEC (ECU 7) 96 M
Filter Maintenance schedule
– Coalescer element – Maintenance task reference table [QL1] 90
– Replacement 257 MTU contact persons 279
– Engine coolant
– Replacement 243 O
Filter sleeve Oil indicator filter
– Replacement 227 – Check 225
Firing order 55 – Cleaning 225
Fuel Operational checks 78
– Treatment system
– Switching on 84 P
– Troubleshooting 95 Plant
– treatment system – Cleaning 89
– Shutdown 85 Plug connections
Fuel filter – Check 270
– Replacement 187 Preheater
Fuel prefilter – Overhaul 247
– Flushing 193 – Function and leak-tightness
Fuel prefilter – check 248
– Draining 191 Product description 16
Fuel prefilter with water separator Pump capacity
– Filter element replacement 195 – Check 256
Fuel prefilter with water separator – Rotary slide valve O- Putting the engine into operation after extended out-of-
DCL-ID: 0000005758 - 004

rings service periods (>3 months) 75

– Replacement 197 Putting the engine into operation after scheduled out-of-
Fuel prefilter – Differential pressure gauge service-period 76
– Adjustment 190
– Check 190 R
Fuel system Raw water pump
– Venting 189 – Relief bore check 249
Fuel treatment system
– Putting into operation 81 S
– Shutdown 85 Safety notices, standards 15
– Switching on 84

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Safety regulations
– Auxiliary materials 13
– Environmental protection 13
– Fire prevention 13
– Fluids and lubricants 13
– Important provisions 7
– Maintenance work 10
– Organizational requirements 8
– Personnel requirements 8
– Repair work 10
– Safety notices, standards 15
Sensors
– Overview 32
Service indicator
– Signal ring position check 216
Service partners 279
Spare parts service 279
Starter
– Condition check 217
Supplementary fuel filter
– Overview 185

T
Tasks
– After extended out-of-service periods 79
Tasks after extended out-of-service periods (>3 weeks) 79
transport 9
Troubleshooting 92
– Fuel treatment system 95
Turbocharger
– Overview 198

V
Valve clearance
– Adjustment 173
– Check 173
Valve gear
– Lubrication 172

W
Water drain valve
– Check 253
Water level probe (3-in-1 rod electrode)
– Check 255
DCL-ID: 0000005758 - 004

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