MTU 12V4000M*3 series Operating Instructions Manual
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MTU 12V4000M*3 series Operating Instructions Manual

MTU 12V4000M*3 series Operating Instructions Manual

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Operating Instructions
Diesel engine
12V/16V4000Mx3x
MS15036/00E

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Summary of Contents for MTU 12V4000M*3 series

  • Page 1 Operating Instructions Diesel engine 12V/16V4000Mx3x MS15036/00E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 5: Table Of Contents

    Table of Contents 1 Safety 4.7 Engine data 16V4000M43S, IMO Tier II, EPA Tier 2 1.1 Important provisions for all products 4.8 Engine data 12V4000M23F, RheinSchUO, 1.2 Correct use of all products stage II, IMO Tier II 1.3 Personnel and organizational requirements 4.9 Engine data 12V4000M23S, RheinSchUO, 1.4 Initial start-up and operation –...
  • Page 6 7.5 Engine Control Unit ADEC (ECU 7) – Fault 8.10.1 Intercooler – Checking condensate drain for water discharge and obstruction codes 8.11 Air Filter 8 Task Description 8.11.1 Air filter – Replacement 8.11.2 Air filter – Removal and installation 8.1 SOLAS 8.12 Air Intake 8.1.1 SOLAS shielding as per MTN 5233 –...
  • Page 7 9 Appendix A connections 8.23.3 Engine Monitoring Unit EMU 7 – Plug 9.1 List of abbreviations connection check 9.2 MTU Contact/Service Partners 8.23.4 Engine Monitoring Unit EMU 7 – Plug connection check 8.23.5 Interface module EIM plug connections – 10 Appendix B Check 10.1 Special Tools...

  • Page 8: Safety

    Nameplates, model designation or serial number can be found on the product. All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv- ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system is not visible without the removal of components, the system integrator must install the second nameplate in a clearly visible area on the vehicle/system.
  • Page 9 Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life. Exception: Engines used exclusively in land-based, military applications other than by US government agen- cies.

  • Page 10: Correct Use Of All Products

    • With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al- so applies to engine control/parameters) •...

  • Page 11: Personnel And Organizational Requirements

    1.3 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.

  • Page 12: Initial Start-Up And Operation - Safety Regulations

    1.4 Initial start-up and operation – Safety regulations Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 13 Do not inhale the exhaust gases of the product. The following requirements must be fulfilled before the product is started: • Wear ear protectors. • Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent. Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live.

  • Page 14: Assembly, Maintenance, And Repair Work - Safety Regulations

    1.5 Assembly, maintenance, and repair work – Safety regulations Safety regulations for work prior to assembly, maintenance, and repair Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants, risk of burning).
  • Page 15 When working high on the equipment, always use suitable ladders and work platforms. Special instructions for outdoor areas: There must be no risk of slipping e.g. due to icing. Removing, installing and cleanliness Pay particular attention to cleanliness at all times. Completely wipe up escaped fluids and lubricants due to the risk of slipping.
  • Page 16 Welding work Welding operations on the product or mounted units are not permitted. Cover the product when welding in its vicinity. Before starting welding work: • Switch off the power supply master switch. • Disconnect the battery cables or actuate the battery isolating switch. •...
  • Page 17 Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur- ing operation by: • Contact with sharp edges • Chafing on components • Contact with hot surfaces. Do not secure cables on lines carrying fluids. Do not use cable ties to secure lines.

  • Page 18: Fire And Environmental Protection, Fluids And Lubricants

    Process materials can also be or contain hazardous or toxic substances. When using process materials and other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi- cations must be used.
  • Page 19 Particularly hazardous substances used with our products are named in a list: www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products Compressed air • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion.

  • Page 20: Fire Prevention And Environmental

    1.7 Fire prevention and environmental protection, fluids and lubricants, auxiliary materials, specific information for gaseous fuel supply in gaseous-fuel or dual-fuel applications General notes on gas Observe the information contained in the safety data sheet of the gas used. Consult with gas supplier/utility. The gas used must comply with the (→...

  • Page 21: Standards For Warning Notices In The Text And Highlighted Information

    1.8 Standards for warning notices in the text and highlighted information 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! •...

  • Page 22: Transport

    Setting the engine down after transport • Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. • Never set an engine/genset/system down on the oil pan unless expressively authorized to do so by MTU on a case-to-case basis.

  • Page 23: General Information

    3 General Information 3.1 Engine – Overview Engines with remote raw water cooler and horizontal air intake The following overviews also apply to 12V4000Mx3. 1 Engine management and 10 Recirculation line 19 Battery-charging generator monitoring 11 Exhaust manifold 20 HP fuel pump 2 Oil cooler 12 Engine mounting 21 Oil filter...
  • Page 24 Engines with installed raw water cooler and horizontal air intake 1 Raw-water outlet 10 Exhaust outlet 19 Cylinder head 2 Engine management and 11 Air pipe to charge-air cooler 20 Crankcase monitoring 12 Recirculation line 21 Fuel filter 3 Plate-core heat exchanger 13 Exhaust manifold 22 Battery-charging generator 4 Oil cooler...
  • Page 25 Engines with remote raw water cooler 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 charge-air cooler 21 Oil filter cooling system 13 Charge-air cooler...
  • Page 26 Engines with installed raw water cooler 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 charge-air cooler 22 Oil filter 4 Plate-core heat exchanger 14 Charge-air cooler...

  • Page 27: Product Description

    3.2 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.
  • Page 28 • 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.
  • Page 29 2 Cleaning cycle 3 ditto MTU marine engine Series 4000M53R to …M93L may be operated in low-load operation. State-of-the-art de- sign and equipment features, e.g. TE coolant circuit, sequential turbocharging, jacketed, coolant-cooled ex- haust lines, Common Rail fuel injection and cylinder cutout allow engine operation at low load.
  • Page 30 100 operating hours in low-load operation, at the lat- est. 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. 28 | General Information | MS15036/00E 2018-08...
  • Page 31 1 SOLAS clip on the fuel line: after LP pump 1 SOLAS clip on the fuel line: on fuel fil- ter head retainer 1 SOLAS clip on the fuel line: on HP pump 2 SOLAS clip on the fuel line: after fuel filter head MS15036/00E 2018-08 | General Information | 29...
  • Page 32 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. 30 | General Information | MS15036/00E 2018-08...
  • Page 33 1 SOLAS clips on exhaust flap switching cylinder ETC B1 1 SOLAS clips on air flap switching cylin- der ETC B1 2 SOLAS clips on flap control T adapter ETC B1 1 SOLAS clips on distributor element 2 SOLAS clips on oil return MS15036/00E 2018-08 | General Information | 31...
  • Page 34 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 recirculation valve 4 SOLAS clips on oil line from main gal- lery 1 SOLAS clips on recirculation valve 32 | General Information | MS15036/00E 2018-08...
  • Page 35 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 MS15036/00E 2018-08 | General Information | 33...
  • Page 36 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 confirmed as being SOLAS-compliant by GL and DNV. 34 | General Information | MS15036/00E 2018-08...
  • Page 37 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 pres- sure.
  • Page 38 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...

  • Page 39: Tightening Specifications For Screws, Nuts And Bolts

    3.3 Tightening specifications for screws, nuts and bolts Tightening torques for setscrew and connections as per MTN 5008 standard This standard applies to setscrews not subject to dynamic loads and the associated nuts according to: • MMN 384 • ISO 4762 (DIN 912) •...
  • Page 40 Hand-tightening Machine-tightening Thread 8.8 M (Nm) 10.9 M (Nm) 8.8 M (Nm) 10.9 M (Nm) M20 x 1.5 M22 x 1.5 M24 x 1.5 M24 x 2 1250 1175 M27 x 2 1350 1275 1200 1700 1100 1600 M30 x 2 1350 1900 1250...
  • Page 41 Tightening torque for self-locking hex nuts (Nm) Thread Lubricants 7.5 +1 – 17 +2 – 35 +4 – 59 +6 – 100 +10 – 140 +14 – 290 +29 – = tightening torques Tightening torque for stress bolt connections as per MTN 5007 standard This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of strength class 10.9 as well as to the associated nuts.
  • Page 42 Not torsion-protected M (Nm) Torsion-protected M (Nm) Thread 1250 1575 *Protect screw shaft from torsion when tightening. = tightening torques. Tightening torques for plug screws as per MTN 5183-1 standard This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852 Form A (sealed with sealing ring to DIN 7603-Cu).
  • Page 43 Tightening torques M are given for screw plugs made of steel (St) with surface protected by a phosphate coating and oiled or galvanized. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
  • Page 44 screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M64 x 2 = tightening torques Tightening torque for plug screws DIN 7604C (with long screwed end) screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M8 x 1 M22 x 1.5...
  • Page 45 The stated tightening torques M apply to steel (St) banjo screws with a phosphatized surface and oiled or galvanized and for copper-aluminum alloy. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
  • Page 46 Tightening torques for male connectors as per MTN 5183-3 standard This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by sealing ring to DIN 7603-Cu). Tightening torques M are given for male unions made of steel (St) with phosphatized surface coating and oiled, or galvanized.
  • Page 47 Tightening torques for union nuts as per DIN 3859-2 1 Union nut 2 Screw fixture 3 O-ring 4 Linear ball bearing Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase in force), it should be tightened another 1/4 turn (90°) past this point. Tightening torques for spigot unions with O-ring to ISO 6149-2 Thread Torque (Nm) +10%...
  • Page 48 Thread Torque (Nm) +10% M27 x 2 M33 x 2 M42 x 2 M48 x 2 M60 x 2 Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789) Tightening torques for screwed plugs with O-ring as per ISO 6149-3 Thread Torque (Nm) +10% M8 x 1...
  • Page 49 Tightening torques for plug screw joints as per MTN 5183-6 screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M10 x 1 10 +2 M12 x 1.5 14 +2 M14 x 1.5 15 +3 M16 x 1.5 18 +3 M18 x 1.5 23 +3...
  • Page 50 Sealing head/sealing cone with metric union nut Metric thread Pipe outer dia. Torque (Nm) M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5 M26 x 1.5 M30 x 2 M36 x 2 M42 x 2 M45 x 2 M52 x 2 Sealing head with BSP union nut...
  • Page 51 ORFS – flat sealing with union nut UNF thread Size Torque (Nm) 9/16–18 –4 14 +2 11/16–16 –6 24 +3 13/16–16 –8 43 +4 1–14 –10 60 +8 1.3/16–12 –12 90 +5 1.3/16–12 –14 90 +5 1.7/16–12 –16 125 +10 1.11/16–12 –20 170 +20...

  • Page 52: Engine Side And Cylinder Designations

    3.4 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite) Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

  • Page 53: Sensors, Actuators And Injectors On 12V Engines - Overview

    3.5 Sensors, actuators and injectors on 12V engines – Overview Engines with remote raw water cooler and horizontal air intake Left engine side 12V4000Mx3 1 B50 (P-Crankcase) 4 B10 (P-Charge air) 7 B34.1 (P-Fuel after filter) 2 B3 (T-Intake air) 5 B34.3 (fuel pressure before 8 F46 (leak fuel level) 3 B44.1 (N-Turbocharger A)
  • Page 54 Free end 12V4000Mx3 1 B33 (fuel temperature in 5 B5.1 (P-Lube oil after filter) 9 B6.2 (coolant temperature) common rail) 6 B48 (P-Fuel in common rail) (optional) 2 B7 (T-Lube oil) 7 B1 (N-Camshaft) 10 B6 (T-Coolant) 3 B5.2 (lube oil pressure after 8 B54 (oil refill pump pres- 11 XD1 connector (dialog unit) filter) (optional)
  • Page 55 Right engine side 12V4000Mx3 1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant) 2 Y27 (turbocharger control 4 B9 (T-Charge Air) valve) MS15036/00E 2018-08 | General Information | 53...
  • Page 56 Driving end 12V4000Mx3 1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch) 2 B4.22 (T-Exhaust, B bank) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft speed) (optional) 54 | General Information | MS15036/00E 2018-08...
  • Page 57 Plan view 12V4000Mx3 1 B5.8 (P-Lube before exhaust 3 B4 (T-Individual exhaust turbocharger A) temperature A1-A6, B1-B6) 2 B49/Y26 (T-Charge-air be- (optional) fore recirculation valve/ 4 B5.9 (P-Lube oil before tur- recirculation valve A) bocharger B) MS15036/00E 2018-08 | General Information | 55...
  • Page 58 Engines with installed raw water cooler and horizontal air intake Left engine side 12V4000Mx3 1 B50 (P-Crankcase) 5 B10 (P-Charge air) 9 F46 (leak fuel level) 2 B49/Y26 (charge-air tem- 6 B34.3 (fuel pressure before 10 B33 (fuel temperature in perature before recircula- filter) (only if supplementary common rail)
  • Page 59 Free end 12V4000Mx3 1 B48 (P-Fuel in common rail) 5 B5.3 (P-Lube oil before fil- 9 B6 (T-Coolant) 2 B7 (T-Lube oil) ter) 10 XD1 connector (dialog unit) 3 B5.2 (P-Lube oil after filter) 6 B1 (N-Camshaft) (optional) 7 B54 (P-Oil refill pump) (op- 4 B5.1 (P-Lube oil after filter) tional) 8 B6.2 (T-Coolant tempera-...
  • Page 60 Right engine side 12V4000Mx3 1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant) 5 B9 (T-Charge Air) 2 Y27 (turbocharger control 4 B21 (raw-water pressure) valve) (optional) 58 | General Information | MS15036/00E 2018-08...
  • Page 61 Driving end 12V4000Mx3 1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch) 2 B4.22 (T-Exhaust, B bank) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft) (op- tional) MS15036/00E 2018-08 | General Information | 59...
  • Page 62 Plan view 12V4000Mx3 1 B5.8 (P-Lube before exhaust 3 F33 (H-Coolant) turbocharger A) 4 B5.9 (P-Lube oil before tur- 2 B4 (cylinder exhaust tem- bocharger B) perature A1-A6, B1-B6) (op- tional) 60 | General Information | MS15036/00E 2018-08...

  • Page 63: Sensors, Actuators And Injectors On 16V Engines - Overview

    3.6 Sensors, actuators and injectors on 16V engines – Overview Engines with remote raw water cooler and horizontal air intake Left engine side 16V4000Mx3 1 B50 (P-Crankcase) 4 B10 (P-Charge air) 7 B34.1 (P-Fuel after filter) 2 B3 (T-Intake air) 5 B34.3 (fuel pressure before 8 F46 (leak fuel level) 3 B44.1 (N-Turbocharger A)
  • Page 64 Free end 16V4000Mx3 1 B33 (T-Fuel in common rail) 5 B5.1 (P-Lube oil after filter) 9 B6.2 (T-Coolant) (optional) 2 B7 (T-Lube oil) 6 B48 (P-Fuel in common rail) 10 B6 (T-Coolant) 3 B5.2 (P-Lube oil after filter) 7 B1 (N-Camshaft) 11 XD1 connector (dialog unit) (optional) 8 B54 (P-Oil refill pump) (op-...
  • Page 65 Right engine side 16V4000Mx3 1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant) 2 Y27 (turbocharger control 4 B9 (T-Charge Air) valve) MS15036/00E 2018-08 | General Information | 63...
  • Page 66 Driving end 16V4000Mx3 1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch) 2 B4.22 (T-Exhaust, B bank) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft) (op- tional) 64 | General Information | MS15036/00E 2018-08...
  • Page 67 Plan view 16V4000Mx3 1 B5.8 (P-Lube before exhaust 3 B4 (cylinder exhaust tem- turbocharger A) perature A1-A6, B1-B6) (op- 2 B49/Y26 (T-Charge-air be- tional) fore recirculation valve/ 4 B5.9 (P-Lube oil before tur- recirculation valve A) bocharger B) MS15036/00E 2018-08 | General Information | 65...
  • Page 68 Engines with installed raw water cooler and horizontal air intake Left engine side 16V4000Mx3 1 B50 (P-Crankcase) 5 B10 (P-Charge air) 9 F46 (leak fuel level) 2 B49/Y26 (charge-air tem- 6 B34.3 (fuel pressure before 10 B33 (T-Fuel in common rail) perature before recircula- filter) (only if supplementary tion valve/recirculation...
  • Page 69 Free end 16V4000Mx3 1 B48 (P-Fuel in common rail) 5 B5.3 (P-Lube oil before fil- 9 B6 (T-Coolant) 2 B7 (T-Lube oil) ter) 10 XD1 connector (dialog unit) 3 B5.2 (P-Lube oil after filter) 6 B1 (N-Camshaft) (optional) 7 B54 (P-Oil refill pump) (op- 4 B5.1 (P-Lube oil after filter) tional) 8 B6.2 (T-Coolant) (optional)
  • Page 70 Right engine side 16V4000Mx3 1 B44.2 (N-Turbocharger B) 3 B16 (P-Coolant) 5 B9 (T-Charge Air) 2 Y27 (turbocharger control 4 B21 (raw-water pressure) valve) (optional) 68 | General Information | MS15036/00E 2018-08...
  • Page 71 Driving end 16V4000Mx3 1 B4.21 (T-Exhaust, A side) 3 B13 (N-Crankshaft) 5 S37.1 (S-Safety switch) 2 B4.22 (T-Exhaust, B side) 4 S37.2 (S-Safety switch) 6 B13.2 (N-Crankshaft) (op- tional) MS15036/00E 2018-08 | General Information | 69...
  • Page 72 Plan view 16V4000Mx3 1 B5.8 (P-Lube before exhaust 3 F33 (H-Coolant) turbocharger A) 4 B5.9 (P-Lube oil before tur- 2 B4 (cylinder exhaust tem- bocharger B) perature A1-A6, B1-B6) (op- tional) 70 | General Information | MS15036/00E 2018-08...

  • Page 73: Firing Order

    3.7 Firing order Cylinders Firing order A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 MS15036/00E 2018-08 | General Information | 71...

  • Page 74: Main Engine Dimensions

    3.8 Main engine 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 M53R/ approx. 3108 mm approx. 1690 mm approx. 1850 mm approx.
  • Page 75 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/3 12V 4000 M53R/ 53/63 16V 4000 approx.

  • Page 76: Technical Data

    4 Technical Data 4.1 ENGINE DATA 12V4000M33F, RheinSchUO Stage II, IMO Tier 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 setting) N Not yet defined value - Not applicable X Applicable...
  • Page 77 Heat exchanger Heat exchanger installed separate Cylinder displacement Liters 4.77 4.77 4.77 4.77 Displacement, total Liters 57.2 57.2 57.2 57.2 Inlet valves per cylinder Exhaust valves per cylinder RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate Raw water pump: Inlet pressure, min. -0.4 -0.4 Raw water pump: inlet pressure, max.
  • Page 78 STARTER (electric) Heat exchanger Heat exchanger installed separate Rated starter voltage (standard design) STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling...

  • Page 79: Engine Data 12V4000M33S, Rheinschuo Stage Ii, Imo Tier

    4.2 ENGINE DATA 12V4000M33S, RheinSchUO Stage II, IMO Tier 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 setting) N Not yet defined value - Not applicable X Applicable...
  • Page 80 Heat exchanger Heat exchanger installed separate Inlet valves per cylinder Exhaust valves per cylinder RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate Raw water pump: inlet pressure, min. -0.4 -0.4 Raw water pump: inlet pressure, max. Pressure loss in engine-external raw water system, max.
  • Page 81 STARTER (electric) Heat exchanger Heat exchanger installed separate Rated starter voltage (standard design) STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling...

  • Page 82: Engine Data 12V4000M33S, Imo Tier Ii, Epa Tier

    4.3 ENGINE DATA 12V4000M33S, 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 setting) N Not yet defined value - Not applicable X Applicable...

  • Page 83: Starter (Electric)

    RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate Raw water pump: Inlet pressure, min. -0.4 -0.4 Raw water pump: inlet pressure, max. Pressure loss in engine-external raw water system, max. LUBE OIL SYSTEM Heat exchanger Heat exchanger installed separate Lube oil operating temperature before en-...

  • Page 84: Starting (With Compressed Air/Hydraulic Starter)

    STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling Liters system) Total engine oil capacity at initial filling Liters (standard oil system) (option: max.

  • Page 85: Engine Data 16V4000M33F, Rheinschuo Stage Ii, Imo Tier

    4.4 ENGINE DATA 16V4000M33F, RheinSchUO Stage II, IMO Tier 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 setting) N Not yet defined value - Not applicable X Applicable...
  • Page 86 Heat exchanger Heat exchanger installed separate Inlet valves per cylinder Exhaust valves per cylinder RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate Raw water pump: inlet pressure, min. -0.4 -0.4 Raw water pump: inlet pressure, max. Pressure loss in engine-external raw water system, max.

  • Page 87: Starting-Air Pressure Before Starter Motor, Min

    STARTER (electric) Heat exchanger Heat exchanger installed separate Rated starter voltage (standard design) STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling...

  • Page 88: Engine Data 16V4000M33S, Rheinschuo Stage Ii, Imo Tier

    4.5 ENGINE DATA 16V4000M33S, RheinSchUO Stage II, IMO Tier 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 setting) N Not yet defined value - Not applicable X Applicable...
  • Page 89 Heat exchanger Heat exchanger installed separate Inlet valves per cylinder Exhaust valves per cylinder RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate Raw water pump: inlet pressure, min. -0.4 -0.4 Raw water pump: inlet pressure, max. Pressure loss in engine-external raw water system, max.

  • Page 90: Oil Pan Capacity At Dipstick Mark "Max

    STARTER (electric) Heat exchanger Heat exchanger installed separate Rated starter voltage (standard design) STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling...

  • Page 91: Engine Data 16V4000M33S, Imo Tier Ii, Epa Tier

    4.6 ENGINE DATA 16V4000M33S, 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 setting) N Not yet defined value - Not applicable X Applicable...
  • Page 92 RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger installed separate Raw water pump: inlet pressure, min. -0.4 -0.4 Raw water pump: inlet pressure, max. Pressure loss in engine-external raw water system, max. LUBE OIL SYSTEM Heat exchanger Heat exchanger installed separate Lube oil operating temperature before en-...
  • Page 93 STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger installed separate Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger installed separate Engine coolant, engine side (with cooling Liters system) Total engine oil capacity at initial filling Liters (standard oil system) (option: max.

  • Page 94: Engine Data 16V4000M43S, Imo Tier Ii, Epa Tier

    4.7 Engine data 16V4000M43S, IMO Tier II, EPA Tier 2 Explanation: DL Reference value: Continuous power (CP) BL Reference value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value up to which the engine can be operated without change, e.g. of power setting. N Not yet defined value - Not applicable X Applicable...
  • Page 95 RAW WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger engine-mounted remote Raw water pump: Inlet pressure, min. -0.4 -0.4 Raw water pump: Inlet pressure, max. Pressure loss in off-engine raw water sys- tem, max. LUBE OIL SYSTEM Heat exchanger Heat exchanger engine-mounted remote Lube oil operating temperature before en-...
  • Page 96 STARTER (compressed air/hydraulic starter motor) Heat exchanger Heat exchanger engine-mounted remote Starting-air pressure before starter motor, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger engine-mounted remote Engine coolant, engine side (with cooling Liters system) Engine oil on initial filling (standard oil sys- Liters tem) (option: max.

  • Page 97: Engine Data 12V4000M23F, Rheinschuo, Stage Ii, Imo Tier

    4.8 Engine data 12V4000M23F, 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...
  • Page 98 RAW-WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger mounted separate Raw-water pump: Inlet pressure, min. -0.4 -0.4 Raw-water pump: Inlet pressure, max. Pressure loss in engine-external raw-water system, max. LUBE-OIL SYSTEM Heat exchanger Heat exchanger mounted separate Lube-oil operating temperature before en- °C gine, from Lube-oil operating temperature before en-...
  • Page 99 STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger mounted separate Starting-air pressure before starter, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger mounted separate Engine coolant, engine-side (with cooling Liters system) Engine oil, total, for initial filling (standard Liters oil system) (option: max.

  • Page 100: Engine Data 12V4000M23S, Rheinschuo, Stage Ii, Imo Tier

    4.9 Engine data 12V4000M23S, 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...
  • Page 101 RAW-WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger mounted separate Raw-water pump: Inlet pressure, min. -0.4 -0.4 Raw-water pump: Inlet pressure, max. Pressure loss in engine-external raw-water system, max. LUBE-OIL SYSTEM Heat exchanger Heat exchanger mounted separate Lube-oil operating temperature before en- °C gine, from Lube-oil operating temperature before en-...
  • Page 102 STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger mounted separate Starting-air pressure before starter, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger mounted separate Engine coolant, engine-side (with cooling Liters system) Engine oil, total, for initial filling (standard Liters oil system) (option: max.

  • Page 103: Engine Data 12V4000M23S, Imo Tier Ii, Epa Tier

    4.10 Engine data 12V4000M23S, 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...
  • Page 104 RAW-WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger mounted separate Raw-water pump: Inlet pressure, min. -0.4 -0.4 Raw-water pump: Inlet pressure, max. Pressure loss in engine-external raw-water system, max. LUBE-OIL SYSTEM Heat exchanger Heat exchanger mounted separate Lube-oil operating temperature before en- °C gine, from Lube-oil operating temperature before en-...
  • Page 105 STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger mounted separate Starting-air pressure before starter, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger mounted separate Engine coolant, engine-side (with cooling Liters system) Engine oil, total, for initial filling (standard Liters oil system) (option: max.

  • Page 106: Engine Data 16V4000M23F, Rheinschuo, Stage Ii, Imo Tier

    4.11 Engine data 16V4000M23F, 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...
  • Page 107 RAW-WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger mounted separate Raw-water pump: Inlet pressure, min. -0.4 -0.4 Raw-water pump: Inlet pressure, max. Pressure loss in engine-external raw-water system, max. LUBE-OIL SYSTEM Heat exchanger Heat exchanger mounted separate Lube-oil operating temperature before en- °C gine, from Lube-oil operating temperature before en-...
  • Page 108 STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger mounted separate Starting-air pressure before starter, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger mounted separate Engine coolant, engine-side (with cooling Liters system) Engine oil, total, for initial filling (standard Liters oil system) (option: max.

  • Page 109: Engine Data 16V4000M23S, Rheinschuo, Stage Ii, Imo Tier

    4.12 Engine data 16V4000M23S, 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...
  • Page 110 RAW-WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger mounted separate Raw-water pump: Inlet pressure, min. -0.4 -0.4 Raw-water pump: Inlet pressure, max. Pressure loss in engine-external raw-water system, max. LUBE-OIL SYSTEM Heat exchanger Heat exchanger mounted separate Lube-oil operating temperature before en- °C gine, from Lube-oil operating temperature before en-...
  • Page 111 STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger mounted separate Starting-air pressure before starter, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger mounted separate Engine coolant, engine-side (with cooling Liters system) Engine oil, total, for initial filling (standard Liters oil system) (option: max.

  • Page 112: Engine Data 16V4000M23S, Imo Tier Ii, Epa Tier

    4.13 Engine data 16V4000M23S, 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...
  • Page 113 RAW-WATER CIRCUIT (open circuit) Heat exchanger Heat exchanger mounted separate Raw-water pump: Inlet pressure, min. -0.4 -0.4 Raw-water pump: Inlet pressure, max. Pressure loss in engine-external raw-water system, max. LUBE-OIL SYSTEM Heat exchanger Heat exchanger mounted separate Lube-oil operating temperature before en- °C gine, from Lube-oil operating temperature before en-...
  • Page 114 STARTING (with compressed air/hydraulic starter) Heat exchanger Heat exchanger mounted separate Starting-air pressure before starter, min. Starting-air pressure before starter, max. CAPACITIES Heat exchanger Heat exchanger mounted separate Engine coolant, engine-side (with cooling Liters system) Engine oil, total, for initial filling (standard Liters oil system) (option: max.

  • Page 115: Operation

    5 Operation 5.1 Controls Automation system controls Refer to automation system operating instructions MS15036/00E 2018-08 | Operation | 113...

  • Page 116: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

    5.2 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...

  • Page 117: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    5.3 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 297); Preheat engine oil if required. Coolant system Check coolant level (→...

  • Page 118: Starting The Engine

    5.4 Starting the engine Start the engine via the automation system Refer to automation system operating instructions 116 | Operation | MS15036/00E 2018-08...

  • Page 119: Re-Starting The Engine Following An Automatic Safety Shutdown

    5.5 Re-starting the engine following an automatic safety shutdown NOTICE Re-starting the engine following an automatic safety shutdown. Risk of severe engine damage! • Before starting the engine, make sure the root cause of the safety shutdown was eliminated. • If the root cause cannot be identified or eliminated, contact Service. Note: •...

  • Page 120: Operational Checks

    5.6 Operational checks DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 121: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    5.7 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. Start up fuel treatment system (→ Page 121). Shut down fuel treatment system (→ Page 125). MS15036/00E 2018-08 | Operation | 119...

  • Page 122: Checks Prior To Start-Up

    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/..). Close drain valves on housing. Open all supply and discharge valves.

  • Page 123: Fuel Treatment System - Initial Start-Up

    5.9 Fuel treatment system – Initial start-up 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 tank...
  • Page 124 Initial start-up: HAT Replace fuel filter on engine (→ Page 266). Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump. Install pressure gage in fuel supply line from Yard fuel system to engine. Switch on fuel treatment system and operate it for some minutes (→ Page 124). Result: Fuel is drawn from the tank (24).
  • Page 125 Simulating power failure (emergency): SAT Switch on fuel treatment system (→ Page 124). Start engine (→ Page 116). Run engine at idling speed. Switch off pump (21) at switchgear cabinet (20). Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24). Check suction pressure at the engine-mounted fuel delivery pump.

  • Page 126: Fuel Treatment System - Switching On

    5.10 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. •...

  • Page 127: Fuel Treatment System - Shutdown

    5.11 Fuel treatment system – Shutdown Shutting down fuel treatment system Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet stops. Switch off fuel treatment system. Close ball valve at the inlet to the fuel treatment system. Close ball valve at the outlet of the fuel treatment system.

  • Page 128: Stopping The Engine

    5.12 Stopping the engine Stopping the engine via the automation system Refer to automation system operating instructions 126 | Operation | MS15036/00E 2018-08...

  • Page 129: Emergency Engine Stop

    5.13 Emergency engine stop NOTICE An emergency stop subjects the engine system to an extremely high load. Risk of overheating, damage to components! • Trigger an emergency stop only in emergency situations. Emergency stop Refer to automation system operating instructions. Follow instructions.

  • Page 130: After Shutdown

    Switch off. Air intake and exhaust sys- Out-of-service-period > 1 week • Seal engine on air and exhaust sides. Out-of-service-period > 1 month • Carry out engine preservation (→ MTU Preservation and Represervation Specifications A001070/..). 128 | Operation | MS15036/00E 2018-08...

  • Page 131: Plant - Cleaning

    5.15 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaner (→ Tools Catalog) Cleaner (Hakupur 50/136) X00056700 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 132: Maintenance

    6 Maintenance 6.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte- nance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
  • Page 133 Task Maintenance tasks W1713 Injector: reset drift compensation parameters (CDC). (→ Page 358) W1864 Check and clean oil indicator filter. (→ Page 304) Table 2: Maintenance task reference table [QL1] MS15036/00E 2018-08 | Maintenance | 131...

  • Page 134: Troubleshooting

    7 Troubleshooting 7.1 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 faulty u Check firm seating of cable connections (see separate documentation). u Check firm seating of cable connections, contact Service.
  • Page 135 Speed transmitter faulty u Contact Service. Engine Control Unit faulty Charge-air temperature too high Cause Corrective action u Check (MTU test kit). Incorrect coolant concentration u Contact Service. Intercooler dirty Engine room: Air-intake u Check fans and air supply/ventilation ducts.
  • Page 136 White exhaust gas Cause Corrective action u Run engine to reach operating temperature. Engine is not at operating temperature Intercooler leaking u Contact Service. 134 | Troubleshooting | MS15036/00E 2018-08...

  • Page 137: Control Cabinet Of Fuel Treatment System - Troubleshooting

    7.2 Control cabinet of fuel treatment system – Troubleshooting Water alarm Cause Corrective action When the maximum water level is 1. Press illuminated pushbutton 'Water alarm' for acknowledgment. reached, the water level electrode 2. In addition to the automatic water drain function, water can also be opens the water drain valve and drained manually: Press illuminated pushbutton 'Water drain'.

  • Page 138: Engine Governor Adec (Ecu 7) Fault Messages For Series 4000 Engines, Marine Application

    7.3 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 139: Adec Engine Governor - Fault Codes

    7.4 ADEC engine governor – Fault codes 29 – HI ETC Idle Speed too High ZKP-Number: 1.8004.206 Cause Corrective action Idle speed of one of the u Contact Service. secondary turbochargers is too high. 38 – AL ETC Speed Deviation ZKP-Number: 1.8004.205 Cause Corrective action...
  • Page 140 141 – AL Power too high ZKP-Number: 1.1088.007 Cause Corrective action This alarm occurs if the average u Reduce power. value of power over the last 24 hours exceeded the maximum value specified in PR1.1088.001. 142 – AL MCR exceeded 1 hour ZKP-Number: 1.1088.006 Cause Corrective action...
  • Page 141 205 – SD T-Coolant Intercooler ZKP-Number: 1.8004.574 Cause Corrective action Charge-air cooler coolant u Check sensor and cabling (B26), replace as necessary. temperature sensor faulty; Short circuit or wire break 206 – SD T-Exhaust A ZKP-Number: 1.8004.576 Cause Corrective action u Check sensor and cabling (B4.21), replace as necessary.
  • Page 142 213 – SD P-Coolant charge-air cooler ZKP-Number: 1.8004.569 Cause Corrective action Charge-air cooler coolant 1. Check sensor and cabling (B43), replace as necessary. pressure sensor faulty; Short 2. Error cleared after restarting the engine. circuit or wire break 214 – SD P-CrankCase ZKP-Number: 1.8004.568 Cause Corrective action...
  • Page 143 221 – SD P-Diff-Lube Oil ZKP-Number: 1.8004.585 Cause Corrective action Lube oil differential pressure 1. Check sensor and cabling (F25), replace as necessary. sensor faulty; Short circuit or wire 2. Error cleared after restarting the engine. break 222 – SD Level Leakage Fuel ZKP-Number: 1.8004.582 Cause Corrective action...
  • Page 144 230 – SD Crankshaft Speed ZKP-Number: 1.8004.498 Cause Corrective action Crankshaft sensor faulty; Short 1. Check sensor and cabling (B13), replace as necessary. circuit or wire break 2. Error cleared after restarting the engine. 231 – SD Camshaft Speed ZKP-Number: 1.8004.499 Cause Corrective action Camshaft sensor faulty;...
  • Page 145 241 – SD T-Circulating air ZKP-Number: 1.8004.581 Cause Corrective action Recirculation temperature sensor 1. Check sensor and cabling (B49), replace as necessary. faulty; Short circuit or wire break 2. Error cleared after restarting the engine. 242 – SD T-Coolant (R) ZKP-Number: 1.8004.622 Cause Corrective action...
  • Page 146 304 – AL Timing Cylinder A4 ZKP-Number: 1.8004.503 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector in cylinder A4: Time-of flight measured value extremely low or extremely high. 305 – AL Timing Cylinder A5 ZKP-Number: 1.8004.504 Cause Corrective action...
  • Page 147 309 – AL Timing Cylinder A9 ZKP-Number: 1.8004.508 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector in cylinder A9: Time-of flight measured value extremely low or extremely high. 310 – AL Timing Cylinder A10 ZKP-Number: 1.8004.509 Cause Corrective action...
  • Page 148 314 – AL Timing Cylinder B4 ZKP-Number: 1.8004.513 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector B4: Time-of flight measured value extremely low or extremely high. 315 – AL Timing Cylinder B5 ZKP-Number: 1.8004.514 Cause Corrective action...
  • Page 149 319 – AL Timing Cylinder B9 ZKP-Number: 1.8004.518 Cause Corrective action Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector injector B9: Time-of flight measured value extremely low or extremely high. 320 – AL Timing Cylinder B10 ZKP-Number: 1.8004.519 Cause Corrective action...
  • Page 150 325 – AL Wiring Cylinder A5 ZKP-Number: 1.8004.524 Cause Corrective action Short-circuit in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative) cylinder A5. Result: Misfiring (e.g. by exchanging injectors). 2. Error cleared after restarting the engine. 326 –...
  • Page 151 331 – AL Wiring Cylinder B1 ZKP-Number: 1.8004.530 Cause Corrective action Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative) cylinder B1. Result: Misfiring (e.g. by exchanging injectors). 2. Error cleared after restarting the engine. 332 –...
  • Page 152 337 – AL Wiring Cylinder B7 ZKP-Number: 1.8004.536 Cause Corrective action Cabling fault in injector cabling to 1. Rectify injector solenoid valve short circuit (positive to negative) cylinder B7. Result: Misfiring (e.g. by exchanging injectors). 2. Error cleared after restarting the engine. 338 –...
  • Page 153 343 – AL Open Load Cylinder A3 ZKP-Number: 1.8004.542 Cause Corrective action Disruption fault in injector cabling 1. Check continuity of injector cabling or exclude open load in to cylinder A3. Result: Misfiring solenoid valve circuit (e.g. by injector replacement) 2.
  • Page 154 349 – AL Open Load Cylinder A9 ZKP-Number: 1.8004.548 Cause Corrective action Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in to cylinder A9. Result: Misfiring the solenoid valve (e.g. by replacing the injector) 2.
  • Page 155 355 – AL Open Load Cylinder B5 ZKP-Number: 1.8004.554 Cause Corrective action Disruption fault in injector cabling 1. Check injector wiring for disruption or rule out any discontinuity in to cylinder B5. Result: Misfiring the solenoid valve (e.g. by replacing the injector) 2.
  • Page 156 361 – AL Power Stage Low ZKP-Number: 1.8004.496 Cause Corrective action Internal electronic fault u Start ITS. If the ITS diagnosis result is "electronics OK", note (electronics possibly faulty). If bit further fault messages (e.g. cabling faults). "1.1020.021" (Power Stage Failure: Stop Engine) is set, engine will be shut down as additional measure.
  • Page 157 371 – AL Wiring TO 1 ZKP-Number: 1.8004.634 Cause Corrective action Short circuit or wire break on 1. Check charger valve/cabling, repair as necessary. transistor output 1 (TO 1). 2. Replace engine governor 372 – AL Wiring TO 2 ZKP-Number: 1.8004.635 Cause Corrective action Short circuit or wire break on...
  • Page 158 397 – TD P-Lube Oil ZKP-Number: 1.8004.625 Cause Corrective action Maximum deviation of lube oil 1. Check sensor and cabling, replace as necessary. pressure values from sensors 2. Contact Service. 417 – SD Level Water Fuel Prefilter ZKP-Number: 1.8004.594 Cause Corrective action Water level sensor in fuel prefilter u Check sensor and cabling, replace as necessary.
  • Page 159 468 – SD T-AUX 1 ZKP-Number: 1.8004.579 Cause Corrective action Analog input signal for Aux 1 1. Check signal transmitter and cabling, replace as necessary. temperature faulty;. 2. Replace engine governor. 469 – SD AUX 1 ZKP-Number: 1.8004.590 Cause Corrective action Analog input signal for Aux 1 u Check signal transmitter and cabling, replace as necessary.
  • Page 160 476 – AL Crash Rec. Init. Error ZKP-Number: 1.8010.007 Cause Corrective action Crash recorder initialization error. 1. Check setting with DiaSys. 2. Contact Service. 482 – SD T-Exhaust C ZKP-Number: 1.8004.596 Cause Corrective action Exhaust temperature sensor on A- u Check sensor and cabling (B4.23), replace as necessary. side faulty;...
  • Page 161 501 – AL Wiring POM Starter 2 ZKP-Number: 1.4500.901 Cause Corrective action A wiring fault was detected in the u Check connection between POM and starter. connection between starter 2 and POM. This may be a missing consumer, a wire break, or a short circuit.
  • Page 162 508 – AL Wrong POM-ID ZKP-Number: 1.4500.908 Cause Corrective action POM transmits an unexpected ID u Check POM wiring harness. number. If alarm occurs in combination with alarm 504, the resistor in the POM cabling is missing. 519 – Oillevel Calibration Error ZKP-Number: 1.0158.921 Cause Corrective action...
  • Page 163 576 – AL ESCM Override ZKP-Number: 1.1075.083 Cause Corrective action Violation of corrected MCR or u Reduce power. DBR/MCR curve. Engine overload! 577 – SD T-Lube Oil Pan ZKP-Number: 1.0137.900 Cause Corrective action Temperature sensor in oil pan u Check sensor and cabling, replace as necessary. defective;...
  • Page 164 601 – SD ETC1+ETC2 ZKP-Number: 1.3011.227 Cause Corrective action SD ETC1 and ETC2 u Check sensor and cabling, replace as necessary. 625 – SD P-Fuel before Prefilter ZKP-Number: 1.8004.600 Cause Corrective action Analog input signal for pressure 1. Check pressure sensor and cabling, replace as necessary. before prefilter faulty;...

  • Page 165: Engine Control Unit Adec (Ecu 7) - Fault Codes

    7.5 Engine Control Unit 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 heat. 1. Reduce power. 2. Contact Service. 4 –...
  • Page 166 9 – HI T-Coolant Intercooler ZKP-Number: 2.0124.931 Coolant temperature in intercooler too high (limit value 1) Yellow alarm; warning Cause Corrective action Coolant circuit for charge-air 1. Reduce power. faulty. 2. Check intercooler and coolant cooler. 3. Contact Service. 10 – SS T-Coolant Intercooler ZKP-Number: 2.0124.932 Coolant temperature in intercooler too high (limit value 2) Red alarm;...
  • Page 167 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 346). 2. Contact Service. 20 – SS T-Exhaust A ZKP-Number: 2.0126.932 Exhaust temperature too high, A side (limit value 2) Red alarm;...
  • Page 168 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 out of order. u Replace oil filter (→ Page 302). 26 – HI P-Diff. Lube Oil ZKP-Number: 2.0154.932 Differential oil pressure at oil filter too high (limit value 2) Red alarm;...
  • Page 169 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 fault 1. Reduce power. 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;...
  • Page 170 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 fault u Contact Service. in turbocharger. 38 – AL ETC Speed Deviation ZKP-Number: 1.8004.205 Yellow alarm;...
  • Page 171 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 297). 2. Contact Service. 57 – LO P-Coolant ZKP-Number: 2.0101.921 Coolant pressure too low (limit value 1) Yellow alarm;...
  • Page 172 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 out of order (e.g. 1. Activate fan emergency operating mode as necessary. damage, leaks, low coolant level). 2.
  • Page 173 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.
  • Page 174 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 block 1. Check wiring (→ Page 346). jamming or HP fuel control block 2.
  • Page 175 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;...
  • Page 176 95 – AL Prelubrication Fault ZKP-Number: 2.1090.920 Oil priming fault Yellow alarm; warning Cause Corrective action Priming oil pressure not reached. 1. Check priming system. 2. Contact Service. 102 – AL Fuel Cons. Counter Defect ZKP-Number: 1.8004.624 Error in fuel consumption checksum Yellow alarm;...
  • Page 177 120 – 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 Control 1. Check Engine Control Unit supply voltage. Unit too high. 2. Contact Service. 121 –...
  • Page 178 176 – 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 after u Contact Service. ECU reset: Backup system has no LifeData function or CAN bus to backup system disconnected.
  • Page 179 182 – AL CAN Wrong Parameters ZKP-Number: 2.0500.682 Incorrect parameters on CAN Yellow alarm; warning Cause Corrective action Wrong parameter value entered in u Contact Service. data record. 183 – AL CAN No PU-Data ZKP-Number: 2.0500.683 CAN PU data not present or available Yellow alarm;...
  • Page 180 187 – 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 necessary. disruptions or temporary bus 2. Check shielding, improve shielding as necessary. overload.
  • Page 181 202 – 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 (→ Page 346). Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 116). 3.
  • Page 182 206 – 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 A 1. Check sensor and wiring (B4.21), replace as necessary side faulty. (→ Page 346). Short circuit or wire break.
  • Page 183 212 – 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 (→ Page 346). Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 116). 3.
  • Page 184 216 – 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 (→ Page 346). faulty. 2. Fault is rectified when engine is restarted (→ Page 116). Short circuit or wire break.
  • Page 185 222 – 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 (→ Page 346). Short circuit or wire break. 2.
  • Page 186 229 – 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 187 233 – 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 346). Short circuit or wire break. 2.
  • Page 188 244 – 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 wire Fault is rectified when engine is restarted. break. 245 – SD ECU Power Supply Voltage ZKP-Number: 2.8006.589 Signal error, Engine Control Unit supply voltage Yellow alarm;...
  • Page 189 270 – 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 346). Short circuit or wire break. 2. Check speed demand transmitter. 3. Contact Service. 301 –...
  • Page 190 305 – AL Timing Cylinder A5 ZKP-Number: 1.8004.504 Flight time measuring fault of injector Cause Corrective action Flight time value extremely low or u Replace injector if the fault message appears frequently extremely high. (→ Page 256). 306 – AL Timing Cylinder A6 ZKP-Number: 1.8004.505 Flight time measuring fault of injector Cause...
  • Page 191 311 – AL Timing Cylinder B1 ZKP-Number: 1.8004.510 Flight time measuring fault of injector Cause Corrective action Flight time value extremely low or u Replace injector if the fault message appears frequently extremely high. (→ Page 256). 312 – AL Timing Cylinder B2 ZKP-Number: 1.8004.511 Flight time measuring fault of injector Cause...
  • Page 192 317 – AL Timing Cylinder B7 ZKP-Number: 1.8004.516 Flight time measuring fault of injector Cause Corrective action Flight time value extremely low or u Replace injector if the fault message appears frequently extremely high. (→ Page 256). 318 – AL Timing Cylinder B8 ZKP-Number: 1.8004.517 Flight time measuring fault of injector Cause...
  • Page 193 322 – 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 as necessary wiring cylinder A2. (→ Page 256). 2. Fault is rectified when engine is restarted (→ Page 116). 3.
  • Page 194 326 – 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 as necessary wiring cylinder A6. (→ Page 256). 2. Fault is rectified when engine is restarted (→ Page 116). 3.
  • Page 195 330 – 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 as necessary wiring cylinder A10. (→ Page 256). 2. Fault is rectified when engine is restarted (→ Page 116). 3.
  • Page 196 334 – 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 as necessary wiring cylinder B4. (→ Page 256). 2. Fault is rectified when engine is restarted (→ Page 116). 3.
  • Page 197 338 – 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 as necessary wiring cylinder B8. (→ Page 256). 2. Fault is rectified when engine is restarted (→ Page 116). 3.
  • Page 198 342 – AL Open Load Cylinder A2 ZKP-Number: 1.8004.541 Injector wiring fault cylinder A2 Yellow alarm; misfire Cause Corrective action Disruption in injector wiring 1. Check injector wiring for disruption. cylinder A2. 2. Exclude possible injector solenoid fault, replace injector as necessary (→...
  • Page 199 346 – AL Open Load Cylinder A6 ZKP-Number: 1.8004.545 Injector wiring fault cylinder A6 Yellow alarm; misfire Cause Corrective action Disruption in injector wiring 1. Check injector wiring for disruption. cylinder A6. 2. Exclude possible injector solenoid fault, replace injector as necessary (→...
  • Page 200 350 – AL Open Load Cylinder A10 ZKP-Number: 1.8004.549 Injector wiring fault cylinder A10 Yellow alarm; misfire Cause Corrective action Disruption in injector wiring 1. Check injector wiring for disruption. cylinder A10. 2. Exclude possible injector solenoid fault, replace injector as necessary (→...
  • Page 201 354 – AL Open Load Cylinder B4 ZKP-Number: 1.8004.553 Injector wiring fault cylinder B4 Yellow alarm; misfire Cause Corrective action Disruption in injector wiring 1. Check injector wiring for disruption. cylinder B4. 2. Exclude possible injector solenoid fault, replace injector as necessary (→...
  • Page 202 358 – AL Open Load Cylinder B8 ZKP-Number: 1.8004.557 Injector wiring fault cylinder B8 Yellow alarm; misfire Cause Corrective action Disruption in injector wiring 1. Check injector wiring for disruption. cylinder B8. 2. Exclude possible injector solenoid fault, replace injector as necessary (→...
  • Page 203 362 – 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 Control Unit as necessary. 3. Check additional messages if ITS indicates diagnosis “Electronics OK”...
  • Page 204 372 – 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 Control Unit. 373 – AL Wiring TO 3 ZKP-Number: 1.8004.636 Line disruption Cause...
  • Page 205 383 – 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;...
  • Page 206 394 – 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 Redundant lube oil pressure...
  • Page 207 401 – 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 346). No resistance over switch. 2. Check target device input. 3. Contact Service. 402 –...
  • Page 208 405 – 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 346). No resistance over switch. 2. Check target device input. 3. Contact Service. 406 –...
  • Page 209 410 – 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 power 1. Check wiring (→ Page 346). 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;...
  • Page 210 414 – 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 –...
  • Page 211 420 – 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...
  • Page 212 442 – 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 –...
  • Page 213 449 – 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;...
  • Page 214 456 – 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 –...
  • Page 215 467 – 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 –...
  • Page 216 472 – 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 346). faulty" present at channels. 2. Contact Service. 473 – AL Wiring PWM_CM2 ZKP-Number: 1.8004.593 Cause Corrective action Wire break or short circuit on...
  • Page 217 478 – 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 Red alarm Cause Corrective action...
  • Page 218 484 – HI T-Exhaust C ZKP-Number: 20.133.931 Limit value 1 Cause Corrective action Exhaust gas temperature (C-side) 1. Reduce power. too high. 2. Contact Service. 485 – SS T-Exhaust C ZKP-Number: 20.133.932 Limit value 2 Cause Corrective action Exhaust gas temperature (C-side) 1.
  • Page 219 489 – 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 fault u Reduce power. in turbocharger. 490 – HI ETC4 Overspeed ZKP-Number: 2.3015.931 Speed of the 3rd secondary turbocharger too high (limit value 1) Yellow alarm;...
  • Page 220 500 – 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;...
  • Page 221 506 – 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 346). 507 – AL POM Fault ZKP-Number: 1.4500.907 A general POM fault occurred Yellow alarm;...
  • Page 222 519 – 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 346). 2.
  • Page 223 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 u Request activation code via Internet. This fault becomes active if a maintenance case has been...
  • Page 224 576 – 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 Cause Corrective action Oil pan temperature sensor faulty.
  • Page 225 588 – 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 faulty. 1. Check sensor and wiring, replace as necessary (→ Page 346). Short circuit or wire break. 2.
  • Page 226 602 – 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. 606 –...
  • Page 227 687 – 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 346). 2.
  • Page 228 788 – Cyl. cutout detects turbocharger speed error ZKP-Number: 1.3000.069 Cause Corrective action The cyl. cutout system has detected an invalid turbocharger speed at turbochargers 1 or 2. 850 – SD Alive FIP ZKP-Number: 2.0900.002 Frequency input faulty. Cause Corrective action Short circuit or wire break.
  • Page 229 869 – AL L2 P-Lube Oil ETC B ZKP-Number: 1.0223.922 Limit value 2 Cause Corrective action Lube oil pressure too low. u Check ETC oil lubrication. MS15036/00E 2018-08 | Troubleshooting | 227...

  • Page 230: Task Description

    8 Task Description 8.1 SOLAS 8.1.1 SOLAS shielding as per MTN 5233 – Installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Shield A4 735233000100 Shield A5 735233000101 Shield A6 735233000102 Shield A7 735233000103...

  • Page 231: Solas Shielding - Installation

    8.1.2 SOLAS shielding – Installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter shield X00040625 Shield for switchable oil filter X00040625 Installing SOLAS shield Pinpoint installation location.

  • Page 232: Installation Locations For Solas Shielding

    8.1.3 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 228). Shield unions with adhesive tape if SOLAS shielding as per MTN 5233 is not possible (→ Page 237). When affixing adhesive connections ensure that escaping fluid can flow out without pressure (→ Page 237). Fuel system, fuel lines with fuel pressures exceeding >1.8 bar Item Type of shielding...
  • Page 233 Item Type of shielding Installation location Shield A8 Fuel filter head holder * This shield must be installed on the assembly line. This location is no longer accessible, or only with great difficulty, following assembly of the air pipework and/or fuel filters. Item Type of shielding Installation location...
  • Page 234 Item Type of shielding Installation location 2 x shielding B6 Fuel line at fuel filter head * This shield must be installed on the assembly line. This location is no longer accessible, or only with great difficulty, following assembly of the air pipework. Lube oil system, oil lines with oil pressures exceeding 1.8 bar Item Type of shielding...
  • Page 235 Item Type of shielding Installation location 2 x shielding A5 Actuating cylinder exhaust flap turbocharger A1 2 x shielding A5 Actuating cylinder air flap turbocharger A1 4 x shielding A5 4/2-way directional control valve Item Type of shielding Installation location 2 x shielding A5 Air recirculation valve 2 x shielding A5...
  • Page 236 Item Type of shielding Installation location Shield A4 ETC oil supply 2 x shielding A5 ETC oil supply Item Type of shielding Installation location Shield A4 ETC oil supply 234 | SOLAS | MS15036/00E 2018-08...
  • Page 237 Item Type of shielding Installation location Shield A6 Oil supply line to HP pump: To HP pump Item Type of shielding Installation location Shield B4 Oil supply line to HP pump: On equipment carrier MS15036/00E 2018-08 | SOLAS | 235...
  • Page 238 Item Type of shielding Installation location Shield B2 Oil line on equipment carrier Shield B2 Oil line on pressure reducing valve Item Type of shielding Installation location Cover Oil/easy-change fuel filter 236 | SOLAS | MS15036/00E 2018-08...

  • Page 239: Adhesive Tape For Solas Shielding - Application

    8.1.4 Adhesive tape for SOLAS shielding – Application Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Adhesive tape Applying adhesive tape – gener- al information Note: Use the cable clamp to make a drainage channel.

  • Page 240: Engine

    8.2 Engine 8.2.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6555766 Ratchet with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 241 Note: Use barring device F6555766. Engage barring device (2) in ring gear of fly- wheel and install it on flywheel housing. Fit ratchet (1) onto barring device (2). Note: No resistance other than compression resist- ance must be encountered. Rotate crankshaft in engine direction of rota- tion.

  • Page 242: Barring Engine With Starting System

    8.2.2 Barring engine with starting system Barring using the automation system Refer to automation system operating instructions 240 | Engine | MS15036/00E 2018-08...

  • Page 243: Cylinder Liner

    8.3 Cylinder Liner 8.3.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 252). Remove injector (→...
  • Page 244 Final steps Install injector (→ Page 257). Install cylinder head cover (→ Page 252). 242 | Cylinder Liner | MS15036/00E 2018-08...

  • Page 245: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    8.3.2 Cylinder liner – Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina- tion 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).
  • Page 246 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and burn marks 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.

  • Page 247: Crankcase Breather

    8.4 Crankcase Breather 8.4.1 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 MS15036/00E 2018-08 | Crankcase Breather | 245...
  • Page 248 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 246 | Crankcase Breather | MS15036/00E 2018-08...

  • Page 249: Crankcase Breather - Oil Mist Separator Replacement

    8.4.2 Crankcase breather – Oil mist separator replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Oil mist separator (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) WARNING Oil is hot.

  • Page 250: Valve Drive

    8.5 Valve Drive 8.5.1 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 Remove cylinder head covers (→ Page 252). Fill oil chambers of valve bridges with oil.

  • Page 251: Valve Clearance - Check And Adjustment

    8.5.2 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 Valve setting gage Y4349603...
  • Page 252 Note: Danger of confusion: Additional marking OT/A1 (1) on outer circumference, if applica- ble. Additional OT/A1 (1) marking on the outer circumference of flywheel must not be used. Diagram for 12V engines (two crankshaft positions) Diagram for 16V engines (two crankshaft positions) 250 | Valve Drive | MS15036/00E 2018-08...
  • Page 253 Checking valve clearance in two crankshaft positions 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. Check valve clearance adjustment with engine cold: •...

  • Page 254: Cylinder Head Cover - Removal And Installation

    8.5.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Gasket (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (3) prior to removal.

  • Page 255: Injection Pump / Hp Pump

    8.6 Injection Pump / HP Pump 8.6.1 HP fuel pump – Filling with engine oil Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Fuel suction device F30378207 Engine oil WARNING...
  • Page 256 Preparatory steps Loosen nut (2) and remove oil line (1) from HP pump. HP pump – Filling Remove union (1). Note: Excess engine oil runs into gear box. Use fuel suction device to fill HP pump with 2 liters of clean engine oil. Screw in union (1) and use torque wrench to tighten to specified tightening torque.

  • Page 257: Hp Fuel Pump - Relief Bore Check

    8.6.2 HP fuel pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 258: Injection Valve / Injector

    8.7 Injection Valve / Injector 8.7.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 257). 256 | Injection Valve / Injector | MS15036/00E 2018-08...

  • Page 259: Injector - Removal And Installation (Jacketed Fuel System)

    8.7.2 Injector – Removal and installation (jacketed fuel system) Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal jig F6789889 Milling cutter F30452739 Torque wrench, 10–60 Nm F30452769 Ratchet bit F30027340 Torque wrench, 60–320 Nm F30452768...
  • Page 260 WARNING Internal load and residual pressure in the HP fuel system. Parts may be expelled at high speed on re- lease. Fuel may spurt out. Risk of injury by flying parts and sprayed fuel! • Only use specified tools and devices. •...
  • Page 261 Note: Observe system pressure. Slowly loosen union on HP line (4). Remove HP line (4). Note: The fuel stored in the injector drains out when the adapter (3) is unscrewed. Unscrew adapter (3). Note: Components are sensitive. Protect contact surfaces of HP line (4) and adapter (3) on cylinder head and the HP line (4) itself against damage.
  • Page 262 Installing injector Note: • The new sealing ring is included in the scope of supply of the injector (new part). • Use a multi-purpose grease without solids content. Install new sealing ring (1) with multi-purpose grease and ensure that the installation posi- tion is correct.
  • Page 263 Press in injector with installation/removal jig. Remove installation/removal jig. Coat screw mating face (2) and thread with engine oil. Fit hold-down clamp (1) in correct position, fit screw (2) and tighten by hand. Note: Make sure parts are perfectly clean. Apply engine oil to thread, sealing taper and thrust ring of adapter (3).
  • Page 264 Use torque wrench to tighten jacketed HP line (5) according to tightening sequence to specified tightening torque. Tightening sequence: 1 Adapter (4) 2 Rail (6) Name Size Type Lubricant Value/Standard Union nut / thrust Tightening torque (Engine oil) 40 Nm +5 Nm screw Note: Do not hold in place by hand.
  • Page 265 Fit cable connector on injector. For new assembly: CDC parameters – Reset Note: Failure to reset drift compensation (CDC) will void the emissions certification of the engine. Reset drift compensation (CDC) with DiaSys® (→ Dialog system DiaSys® E531920/..). If DiaSys® is not available, contact Service.

  • Page 266: Fuel Filter

    8.8 Fuel Filter 8.8.1 Additional fuel filter – Overview 1 Storage tank 3 Passive fuel prefilter with 5 Additional fuel filter, switch- 2 Day tank water separator able 4 LP pump 6 Main engine filter, switcha- 264 | Fuel Filter | MS15036/00E 2018-08...

  • Page 267: Additional Fuel Filter - Replacement

    8.8.2 Additional fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Synthetic ring (→ Spare Parts Catalog) DANGER Components are moving or rotating.

  • Page 268: Fuel Filter - Replacement

    8.8.3 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Synthetic ring (→ Spare Parts Catalog) DANGER Components are moving or rotating.
  • Page 269 Cut out the filter to be replaced. Unscrew cut-out easy-change filter with oil filter wrench. Clean sealing surface on filter head. Check sealing ring of the new easy-change filter and moisten it with fuel. Fit SOLAS shield (→ Page 25). Screw on easy-change filter and tighten by hand.

  • Page 270: Fuel Prefilter - Differential Pressure Gage Check And Adjustment

    8.8.4 Fuel prefilter – Differential pressure gage check and adjustment DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 271: Fuel Prefilter - Draining

    8.8.5 Fuel prefilter – Draining DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Liquid or gaseous media, e.g.
  • Page 272 Open vent valves (1) of filter to be drained. Open drain valve (2). Drain water and contamination from filter un- til clean fuel emerges. Close drain valve (2). Open rotary slide valve (2) a little (turning to approx. 30°) to introduce fuel into the filter housing with the new filter element.

  • Page 273: Fuel Prefilter - Flushing

    8.8.6 Fuel prefilter – Flushing Preconditions ☑ Positive pressure at the prefilter inlet. DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Liquid or gaseous media, e.g.
  • Page 274 Open threaded vent plug (1) of the filter to be flushed. Remove drain valve (2) and drain fuel. Result: Fuel flows from filtered side back to the unfil- tered side, flushing the filter deposits down- wards out of the filter. Close threaded vent plug (1) and drain valve (2).

  • Page 275: Fuel Prefilter With Water Separator - Filter Element Replacement

    8.8.7 Fuel prefilter with water separator – Filter element replacement Preconditions ☑ Positive pressure at the prefilter inlet Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340 Filter element (→ Spare Parts Catalog) O-ring (→...
  • Page 276 Fuel prefilter with water separa- tor – Filter element replacement Cut out the filter to be replaced (A or B): 1 Filter A cut out 2 Filter B cut out Open vent valve (3) of the filter to be re- placed.
  • Page 277 Open rotary slide valve (2) a little (turning to approx. 30°) to introduce fuel into the filter housing with the new filter element. Close vent valve (1) as soon as fuel emerges from vent pipe (4). Turn the rotary slide valve to the upright posi- tion (3) until it engages.

  • Page 278: Fuel Prefilter With Water Separator - O-Ring Replacement In Rotary Slide Valve

    8.8.8 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.

  • Page 279: Exhaust Turbocharger

    8.9 Exhaust Turbocharger 8.9.1 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 MS15036/00E 2018-08 | Exhaust Turbocharger | 277...
  • Page 280 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...
  • Page 281 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...
  • Page 282 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...
  • Page 283 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...
  • Page 284 Impeller housing 1 Impeller housing 2 Plug bolt 3 Sealing ring Bearing housing 1 Bearing housing 2 Sprung pin 282 | Exhaust Turbocharger | MS15036/00E 2018-08...
  • Page 285 Thrust bearing 1 Ball 2 Thrust bearing Magnetic nut 1 Magnetic nut 2 Magnet MS15036/00E 2018-08 | Exhaust Turbocharger | 283...

  • Page 286: Compressor Wheel - Cleaning

    8.9.2 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 Ratchet adapter F30027340 Cleaner 40377 Engine oil Engine coolant Sealing rings (→...
  • Page 287 Remove charge-air pipework (1) from exhaust turbocharger to intercooler. Remove oil lines (2). Loosen clamp (1). Remove intake housing (3) with actuating cyl- inder (2). Remove coolant lines (1) from compressor housing (3). Remove coolant ventilation line (2) from com- pressor housing (3).
  • Page 288 Undo screws (1). Remove compressor housing (2). Cleaning compressor wheel Note: Do not use wire brushes, scrapers or similar tools for cleaning! Clean compressor housing with a smooth paint brush or brush. Clean compressor wheel (2) and bearing housing (1). Thoroughly remove cleaner from all compo- nents.
  • Page 289 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 Install coolant ventilation line and coolant lines on compressor housing. Install intake housing (3) with actuating cylin- der (2).
  • Page 290 Preparatory steps – Vertical air intake Drain engine coolant (→ Page 315). Remove air filter (→ Page 294). Seal all openings with suitable covers. Remove charge-air pipework (1) from exhaust turbocharger to intercooler. Remove oil lines (2). Loosen clamp (1). Remove intake housing (3) with actuating cyl- inder (2).
  • Page 291 Remove coolant lines (1) from compressor housing (3). Remove coolant ventilation line (2) from com- pressor housing (3). Undo screws (1). Remove compressor housing (2). Cleaning compressor wheel Note: Do not use wire brushes, scrapers or similar tools for cleaning! Clean compressor housing with a smooth paint brush or brush.
  • Page 292 Final steps – Vertical air intake Install compressor casing (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 Install coolant ventilation line and coolant lines on compressor housing. Install intake housing (3) with actuating cylin- der (2).
  • Page 293 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 Install charge-air pipework (1) between exhaust turbocharger and intercooler. Install air filter (→...

  • Page 294: Charge-Air Cooling

    8.10 Charge-Air Cooling 8.10.1 Intercooler – Checking condensate drain for water discharge and obstruction DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 295: Air Filter

    8.11 Air Filter 8.11.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing air filter Remove old air filter and install new air filter (→ Page 294). Reset signal ring of contamination indicator (→...

  • Page 296: Air Filter - Removal And Installation

    8.11.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Air filter Loosen clamp (2). Remove air filter (1) and clamp (2) from con- necting flange of housing (3).

  • Page 297: Air Intake

    8.12 Air Intake 8.12.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. WARNING The engine draws in large volumes of ambient air for combustion. This air intake results in a strong vac- uum. Risk of injury if body parts are drawn in! There is also a danger if opening of the entrance door can be prevented! •...

  • Page 298: Starting Equipment

    8.13 Starting Equipment 8.13.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Starter – Condition check Check securing screws of starter and nut on cable connection for secure seating and tighten if required. Check cabling (→ Page 346). 296 | Starting Equipment | MS15036/00E 2018-08...

  • Page 299: Lube Oil System, Lube Oil Circuit

    8.14 Lube Oil System, Lube Oil Circuit 8.14.1 Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Oil is hot. Oil can contain residue/substances which are harmful to health. Risk of injury and poisoning! • Allow the product to cool to below 50 °C before beginning work. •...

  • Page 300: Engine Oil - Change

    8.14.2 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...
  • Page 301 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 engine oil Open cap (1) on filler neck. Pour oil in at filler neck up to “max.” mark on oil dipstick.

  • Page 302: Engine Oil - Sample Extraction And Analysis

    8.14.3 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 DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 303 Drain approx. 1 liter engine oil into a clean container. Close screw. Using the equipment and chemicals in the MTU test kit, analyze the engine oil for: • Dispersion capability (spot test) • Proportion of water • Fuel dilution Engine oil, sample extraction...

  • Page 304: Oil Filtration / Cooling

    8.15 Oil Filtration / Cooling 8.15.1 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 Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 305 Engine oil filter with diverter (option) – Oil filter replacement with engine at standstill Stop engine (→ Page 126) and disable engine start. Unscrew engine oil filter using filter wrench. Clean sealing surface on connecting piece. Check condition of the new engine oil filter sealing ring and coat it with engine oil.

  • Page 306: Oil Indicator Filter - Cleaning And Check

    8.15.2 Oil indicator filter – Cleaning and check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner (Snow-White 11-0) X00054118 Cleaner (Hakupur 50/136) X00056700 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
  • Page 307 Removing strainer Clean oil indicator filter before disassembling Remove screws (1). Take off cover (2) with O-ring (3). Extract spring (4) and strainer (6) from filter housing. Checking strainer Item Findings Measure Strainer Metallic residues • Clean • Monitor engine operation •...

  • Page 308: Centrifugal Oil Filter - Cleaning And Filter Sleeve Replacement

    8.15.3 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, 4–20 Nm F30044239 Torque wrench, 20–100 Nm F30026582 Ratchet bit F30027340 Cold cleaner (Hakutex 60) X00056750...
  • Page 309 Centrifugal oil filter – Cleaning and filter sleeve replacement Remove clamp (14). Loosen Tommy nut (2) and take off hood (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, loosen rotor cover nut (3).
  • Page 310 Cleaning centrifugal oil filter and replacing filter sleeve (oil filters with diverter) Undo screw (1) and remove. Remove clamp (3) and take off hood (2). Carefully remove rotor assembly (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and undo knurled nut (7).

  • Page 311: Coolant Circuit, General, High-Temperature Circuit

    8.16 Coolant Circuit, General, High-Temperature Circuit 8.16.1 Drain and vent points Coolant lines on ETC 1 Vent point Coolant line to intercooler 1 Vent point MS15036/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 309...
  • Page 312 1 Vent point Coolant line to raw water cooler 1 Vent point 310 | Coolant Circuit, General, High-Temperature Circuit | MS15036/00E 2018-08...
  • Page 313 Vent line – Distribution cross 1 Vent point Coolant drain point, engine driving end 1 Drain point MS15036/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 311...
  • Page 314 Coolant drain point, engine free end 1 Drain point 312 | Coolant Circuit, General, High-Temperature Circuit | MS15036/00E 2018-08...

  • Page 315: Engine Coolant Level - Check

    8.16.2 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.

  • Page 316: Engine Coolant Change

    8.16.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 315). Fill with engine coolant (→ Page 318). 314 | Coolant Circuit, General, High-Temperature Circuit | MS15036/00E 2018-08...

  • Page 317: Engine Coolant - Draining

    8.16.4 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 Provide an appropriate container to drain the coolant into.
  • Page 318 Open vent valve on exhaust pipework (driving end) (1). Open vent valve on seawater cooler (1) (or re- mote heat exchanger). Open drain plug (1) and drain coolant at crankcase. 316 | Coolant Circuit, General, High-Temperature Circuit | MS15036/00E 2018-08...
  • Page 319 Open drain screw (1) and drain coolant on coolant pump elbow. Final steps Seal all open vent and drain points. Set breather valve onto filler neck and close it. MS15036/00E 2018-08 | Coolant Circuit, General, High-Temperature Circuit | 317...

  • Page 320: Engine Coolant - Filling

    8.16.5 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.
  • Page 321 Filling coolant through filler neck Open vent points on charge-air cooler, ex- haust turbochargers and on plate-core heat exchanger (arrows). Note: On engines with a separate heat exchanger, the expansion tank is connected separately from the engine to the external cooling sys- tem.

  • Page 322: Ht Coolant Pump - Relief Bore Check

    8.16.6 HT coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 323: Engine Coolant - Sample Extraction And Analysis

    Spindle 11a/f Tightening torque 12 Nm Using the equipment and chemicals of the MTU test kit, examine engine coolant for: • antifreeze concentration • concentration of corrosion protection oil • pH value For engine coolant change intervals, see (→ MTU Fluids and Lubricants Specifications).

  • Page 324: Engine Coolant Filter - Replacement

    8.16.8 Engine coolant filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Engine coolant filter (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 325: Preheating Unit

    8.16.9 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 Rated voltage / frequency Heating power kW 230 V / 50 Hz 400 V / 50 Hz 230 V / 60 Hz...
  • Page 326 Hilzinger preheating unit 1 On/Off switch Cylinders Rated voltage / frequency Heating power kW 12V and 16V 230 V / 50 Hz 400 V / 50 Hz 230 V / 60 Hz 440 V / 60 Hz 324 | Coolant Circuit, General, High-Temperature Circuit | MS15036/00E 2018-08...
  • Page 327 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 circula- tion of the preheated coolant through the engine.

  • Page 328: Preheater - Function And Leak-Tightness Check

    8.16.10 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...

  • Page 329: Preheater - Overhaul

    8.16.11 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.

  • Page 330: Raw Water Pump With Connections

    8.17 Raw Water Pump with Connections 8.17.1 Raw water pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 331: Battery-Charging Generator

    8.18 Battery-Charging Generator 8.18.1 Battery-charging generator drive – Coupling condition check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Endoscope Y20097353 Battery-charging generator drive, coupling condition check Install barring tool (→ Page 238). Guide endoscope optics between guard plate (1) and battery-charging generator car- rier (2) (arrow).

  • Page 332: Engine Mounting / Support

    8.19 Engine Mounting / Support 8.19.1 Engine mounting – Checking resilient element NOTICE Contamination of engine mounts made of natural rubber with fuel or oil. Engine mounts swell. Risk of shorter service life or destruction of the mounts! • Cover engine mounts when working with fuel or oil. •...

  • Page 333: Auxiliary Pto

    8.20 Auxiliary PTO 8.20.1 Bilge pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.

  • Page 334: Fuel Supply System

    8.21 Fuel Supply System 8.21.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. 332 | Fuel Supply System | MS15036/00E 2018-08...

  • Page 335: Differential Pressure Gage - Alarm Function Check

    8.21.2 Differential pressure gage – Alarm function check WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking differential pressure gage alarm function Switch on fuel treatment system (→...

  • Page 336: Water Level Probe (3-In-1 Rod Electrode)

    8.21.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of service and emptied. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. •...

  • Page 337: Pump Capacity - Check

    8.21.4 Pump capacity – Check WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking pump capacity Install suitable pressure gauge in the intake connection of the pump.

  • Page 338: Coalescer Filter Element - Replacement

    8.21.5 Coalescer filter element ‒ Replacement Preconditions ☑ System is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ratchet adapter F30027340 Fuel Engine oil Coalescer filter element (→ Spare Parts Catalog) Gasket (→...
  • Page 339 Tighten nut (3) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Tightening torque (Engine oil) 30 Nm +3 Nm Fit seal (10). Install cover. Install screws (1), washers (2) and nuts (9). Tighten nuts (9). Open ball valve at the inlet and outlet of the fuel treatment system. Result: The fuel treatment system is ready for operation.

  • Page 340: Engine Wiring Harness – Overview

    8.22 Wiring (General) for Engine/Gearbox/Unit 8.22.1 Engine wiring harness – Overview Engine wiring harnesses – Terminal assignment Description Terminal assignment Sensors Camshaft speed 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 B5.8...
  • Page 341 Description Terminal assignment Adaptation ECU-7 governor ECU Power ECU-7 governor Cranking start interlock EIM engine box XB19 Starting air pressure Dialog XG03 Battery-charging generator Starting system Valves Charge-air recirculation Exhaust turbocharger Injectors Y39A1 to Y39AX Engine A side Y39B1 to Y39BX Engine B side MS15036/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 339...
  • Page 342 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 XF33 17 B34.2 29 B7 6 X37 18 B34.1 30 B5.1 7 B54 19 B50...
  • Page 343 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 XF33 17 B34.2 29 B7 6 X37 18 B34.1 30 B5.1 7 B54 19 B50...
  • Page 344 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 342 | Wiring (General) for Engine/Gearbox/Unit | MS15036/00E 2018-08...
  • Page 345 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 MS15036/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 343...
  • Page 346 Engine wiring harness for EIM 1 XD1 4 X52 7 XB19 2 X1 5 XY1 8 X37 3 X3 6 X11 344 | Wiring (General) for Engine/Gearbox/Unit | MS15036/00E 2018-08...
  • Page 347 Engine wiring harness for electric starter 1 Connection terminals, EIM 2 Fuse F1 3 Connection terminals, start- MS15036/00E 2018-08 | Wiring (General) for Engine/Gearbox/Unit | 345...

  • Page 348: Engine Cabling – Check

    8.22.2 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.

  • Page 349: Accessories For (Electronic) Engine Governor / Control System

    8.23 Accessories for (Electronic) Engine Governor / Control System 8.23.1 Limit switch for start interlock – Check Preconditions ☑ Engine is stopped and starting disabled. Note: In the OFF position, the limit switch activates a start interlock, i.e. the engine cannot be started. Limit switch for start interlock –...

  • Page 350: Engine Control Unit Ecu 7 – Checking Plug Connections

    8.23.2 Engine Control Unit ECU 7 – Checking plug connections Preconditions ☑ Engine is stopped and starting disabled. Check plug connections on ECU Check all connectors on ECU for firm seating. Ensure that the clips (1) are engaged. Check screws (2) of cable clamps on ECU for firm seating.

  • Page 351: Engine Monitoring Unit Emu 7 – Plug Connection Check

    8.23.3 Engine Monitoring Unit EMU 7 – Plug connection check Preconditions ☑ Engine is stopped and starting disabled. Checking EMU plug connections Check both connectors on EMU (2) for firm seating. Ensure that the clips (1) are engag- Check screws (3) of cable clamps on EMU (2) for firm seating.

  • Page 352: Engine Monitoring Unit Emu 7 – Plug Connection Check

    8.23.4 Engine Monitoring Unit EMU 7 – Plug connection check Preconditions ☑ Engine is stopped and starting disabled. Checking EMU plug connections Check both connectors on EMU (2) for firm seating. Make sure that frames (3) are engag- Check screws (1) of cable clamps on EMU (2) for firm seating.

  • Page 353: Interface Module Eim Plug Connections Check

    8.23.5 Interface module EIM plug connections – Check Preconditions ☑ Engine is stopped and starting disabled. Checking EIM plug connections Check both Tyco plugs (62-pole) (2) on EIM for firm seating. Ensure that clips (3) are en- gaged. Check screws (1) of cable clamps on EIM for firm seating.

  • Page 354: Installation

    8.23.6 Engine governor ECU 7 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine electronics is powered off. 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.
  • Page 355 8.23.7 EMU 7 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine electronics is powered off. 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.
  • Page 356 8.23.8 Engine Interface Module EIM 2 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Removing Engine Interface Mod- ule from engine Note or mark assignment of cables and con- nectors. Unscrew all screws (1). Undo clips (2) on connectors. Disconnect all connectors.
  • Page 357 8.23.9 Engine Interface Module EIM 2 – Diagnostic features Diagnostic lamp (DILA) A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM 2). It indicates the operating status of the EIM 2. Functions of diagnostic lamp DILA DILA glows Engine Interface Module (EIM 2) is OK.
  • Page 358 1 Preamble 6 VSP current path failed (S5) 11 ES pushbutton current path 2 Engine Control Unit current 7 SLD current path failed (S6) failed – 24 V external (S10) path failed (S1) 8 DDV current path failed (S7) 12 Key switch current path 3 MCS current path failed 9 Gear monitoring current failed (S11)
  • Page 359 Sample flashing sequences A Fuse S5 failure (1/2 second B Fuse S1 and fuse S4 failure steps) (1/2 second steps) Note: These bit patterns are continuously transmitted. The CAN message “Status of internal power supply” also contains information on the current path states of the EIM 2.
  • Page 360 8.23.10 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® (→ Dialog system DiaSys® E531920/..). Resetting CDC parameters without DiaSys® If no DiaSys®...
  • Page 361 Abgasturbolader Exhaust turbocharger Backup Data Module Date backup module Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU publica- tion no. A00106... C&I Commercial and Industrial Controller Area Network Data bus system, bus standard CaPoS Capacitor Power System Capacitor-based starting system Calibration Drift Compensation Resetting the drift correction with DiaSys®...
  • Page 362 Abbre- Meaning Explanation viation EPDM Ethylen-Propylen-Dien, M-Gruppe Synthetic rubber Electrostatic Discharge Protection against static discharge Emergency Stop Input Emergency stop input channel of the engine gover- Ersatzteilkatalog Spare parts catalog European Union Europäische Wirtschaftsgemeinschaft European Economic Community (EEC) Frequency Output Function software Ground Hochdruck...
  • Page 363 Explanation viation Safety Integrity Level Safety System Safety system alarm Time Before Overhaul Technical Evolution Network Technical data for MTU products T-xyz Temperature-xyz Temperature measuring point xyz Union Internationale des Chemins de Fer International railway association Unterer Totpunkt Bottom dead center (BDC)
  • Page 364 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 high flexibility, we're your contact around the clock: during each operating phase, preventive maintenance and corrective operations in case of a malfunction, for information on changes in conditions of use and for supplying spare parts.
  • Page 365 10 Appendix B 10.1 Special Tools Barring tool Part No.: F6555766 Qty.: Used in: 8.2.1 Engine – Barring manually (→ Page 238) Endoscope Part No.: Y20097353 Qty.: Used in: 8.18.1 Battery-charging generator drive – Coupling condi- tion check (→ Page 329) Feeler gage Part No.: Y20010128...
  • Page 366 Filter wrench Part No.: F30379104 Qty.: Used in: 8.8.2 Additional fuel filter – Replacement (→ Page 265) Qty.: Used in: 8.8.3 Fuel filter – Replacement (→ Page 266) Qty.: Used in: 8.15.1 Engine oil filter – Replacement (→ Page 302) Qty.: Used in: 8.16.8 Engine coolant filter –...
  • Page 367 Milling cutter Part No.: F30452739 Qty.: Used in: 8.7.2 Injector – Removal and installation (jacketed fuel system) (→ Page 257) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 8.14.3 Engine oil – Sample extraction and analysis (→ Page 300) MTU test kit Part No.:...
  • Page 368 Ratchet bit Part No.: F30027340 Qty.: Used in: 8.7.2 Injector – Removal and installation (jacketed fuel system) (→ Page 257) Qty.: Used in: 8.15.3 Centrifugal oil filter – Cleaning and filter sleeve re- placement (→ Page 306) Ratchet bit Part No.: F30027342 Qty.: Used in:...
  • Page 369 Rigid endoscope Part No.: Y20097353 Qty.: Used in: 8.3.1 Cylinder liner – Endoscopic examination (→ Page 241) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 8.5.2 Valve clearance – Check and adjustment (→ Page 249) Torque wrench, 10–60 Nm Part No.: F30452769 Qty.:...
  • Page 370 Torque wrench, 40–200 Nm Part No.: F30027337 Qty.: Used in: 8.14.2 Engine oil – Change (→ Page 298) Torque wrench, 4–20 Nm Part No.: F30044239 Qty.: Used in: 8.15.3 Centrifugal oil filter – Cleaning and filter sleeve re- placement (→ Page 306) Torque wrench, 60–320 Nm Part No.: F30452768...
  • Page 371 Valve setting gage Part No.: Y4349603 Qty.: Used in: 8.5.2 Valve clearance – Check and adjustment (→ Page 249) MS15036/00E 2018-08 | Special Tools | 369...
  • Page 372 10.2 Index Coolant  Preheating unit 323 – Change  314 Numerics Cooler  – Charge-air   12V4000M23F engine data, RheinSchUO, stage II, IMO – Checking condensate drain for water discharge and Tier II 95 obstruction  292 12V4000M23S engine data, IMO Tier II, EPA Tier 2 101 Coupling ...
  • Page 373 Engine  Engine – Overview 21 – Barring   – Manually  238 Fault codes  – With starting system  240 – Engine Control Unit ADEC (ECU 7)  163 – Emergency stop  127 Fault messages  – Main dimensions  72 – Engine governor ADEC (ECU 7)  136 –...
  • Page 374  16 Maintenance Schedule  – Environmental protection, specific information for dual – Maintenance task reference table [QL1]  130 fuel applications  18 MTU contact persons 362 – Environmental protection, specific information for gas- eous fuel supply applications  18 – Fire prevention  16 Oil indicator filter ...
  • Page 375 Valve clearance  – Adjustment  249 – Check  249 Valve gear  – Lubrication  248 Warning notices, standards 19 Water drain valve  – Check  332 Water level probe (3-in-1 rod electrode)  – Check  334 MS15036/00E 2018-08 | Index | 373...

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