Mtu Diesel Engine MS150068 - 01e

Operating Instructions
Diesel engine
12 V 4000 M23F
12 V 4000 M23S
16 V 4000 M23F
16 V 4000 M23S
MS150068/01E
Printed in Germany
2014 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Commissioning Note
Table of Contents
1 Safety
1.1
1.2
1.3
1.4
Important provisions for all products

Personnel and organizational requirements
Transport
Safety regulations for maintenance and
repair work
1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials
1.6 Standards for safety notices in the text
7
8
9
10
13
15
3.8 Fuel treatment system Putting into

operation
3.9 Fuel treatment system Switching on
3.10 Fuel treatment system Shutdown
3.11 Stopping the engine
3.12 Emergency engine stop
3.13 After stopping the engine
3.14 Plant Cleaning
81
84
85
86
87
88
89
4 Maintenance
4.1 Maintenance task reference table [QL1]
90
2 Product Summary
2.1 Engine Layout
16
2.1.1 Product description

2.1.2 Engine layout
2.1.3 Overview of sensors and actuators
16
28
32
2.2 Engine Side and Cylinder Designations
52
53
5.1 Troubleshooting
5.2 Fuel treatment system Troubleshooting
5.3 Engine governor ADEC (ECU 7) fault
messages for Series 4000 engines, marine
application
5.4 Engine governor ADEC (ECU 7) Fault
codes
2.4 Firing Sequence
55
2.4.1 Firing order
55
6 Task Description
2.2.1 Engine side and cylinder designations
2.3 Main Engine Dimensions

2.3.1 Engine Main dimensions
2.5 Technical Data

2.5.1 12V 4000 M23F engine data, RheinSchUO,
stage II, IMO Tier II
2.5.2 12V 4000 M23S engine data, RheinSchUO,
2.5.3 12V 4000 M23S engine data, IMO Tier II, EPA
Tier 2
2.5.4 16V 4000 M23F engine data, RheinSchUO,
2.5.5 16V 4000 M23S engine data, RheinSchUO,
2.5.6 16V 4000 M23S engine data, IMO Tier II, EPA
Tier 2
52
53
56
56
3.1 Controls
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months)
3.3 Putting the engine into operation after
scheduled out-of-service-period
3.4 Starting the engine
3.5 Operational checks
3.6 Tasks after extended out-of-service periods
(>3 weeks)
3.7 Checks prior to start-up
6.1 Engine
6.1.1 Engine Barring manually
6.1.2 Engine Barring with starting system
6.2 Cylinder Liner

59
62
65
68
71
3 Operation
DCL-ID: 0000005758 - 004
5 Troubleshooting
74
75
76
77
78
79
80
6.2.1 Cylinder liner Endoscopic examination

6.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners
6.3 Crankcase Breather

6.3.1 Crankcase breather Overview
6.3.2 Crankcase breather Oil mist fine separator
replacement
6.4 Valve Drive

6.4.1 Valve gear Lubrication
6.4.2 Valve clearance Check and adjustment
6.4.3 Cylinder head cover Removal and
installation
6.5 Injection Pump / HP Pump

6.5.1 HP pump Filling with engine oil
6.5.2 HP pump Relief bore check
6.6 Injection Valve / Injector

6.6.1 Injector Replacement
6.6.2 Injector Removal and installation
6.7 Fuel Filter

6.7.1 Supplementary fuel filter Overview
6.7.2 Additional fuel filter Replacement
92
95
96
97
162
162
164
165
165
167
169
169
171
172
172
173
176
177
177
178
179
179
180
185
185
186
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6.8 Exhaust Turbocharger

6.8.1 Overview of turbocharger
6.8.2 Compressor wheel Cleaning
6.9 Charge-Air Cooling

6.9.1 Intercooler Checking condensate drain for
water discharge and obstruction
6.10 Air Filter

6.10.1 Air filter Replacement
6.10.2 Air filter Removal and installation
6.11 Air Intake

6.11.1 Service indicator Signal ring position check
(optional)
6.12 Starting Equipment
187
189
6.15.1
6.15.2
6.15.3
6.15.4
6.15.5
6.15.6
6.15.7
Drain and vent points

Engine coolant level Check
Engine coolant Change
Engine coolant Draining
Engine coolant Filling
HT coolant pump Relief bore check
Engine coolant Sample extraction and
analysis
6.15.8 Engine coolant filter Replacement
6.15.9 Preheating unit
6.15.10 Preheater Overhaul
249
250
250
195
6.18 Battery-Charging Generator
251
197
198
198
205
213
213
214
214
215
216
216
217
218
6.15 Coolant Circuit, General, High-Temperature

Circuit
249
6.17.1 Engine mounting Check
6.13 Lube Oil System, Lube Oil Circuit
6.14.1 Engine oil filter Replacement

6.14.2 Oil indicator filter Cleaning and check
6.14.3 Centrifugal oil filter Cleaning and filter
sleeve replacement
6.16.1 Raw water pump Relief bore check
6.17 Engine Mounting / Support
217
6.14 Oil Filtration / Cooling
6.16 Raw Water Pump with Connections
248
190
191
193
6.12.1 Starter Condition check

6.13.1 Engine oil Level check
6.13.2 Engine oil Change
6.13.3 Engine oil Sample extraction and analysis
6.15.11 Preheater Function and leak-tightness check
218
219
221
223
223
225
227
230
230
234
235
236
239
241
242
243
244
247
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6.18.1 Battery-charging generator drive Coupling

condition check
6.19 Auxiliary PTO

6.19.1 Bilge pump Relief bore check
6.20 Fuel Supply System

6.20.1 Water drain valve Check
6.20.2 Differential pressure gauge Check
6.20.3 Water level probe (3-in-1 rod electrode)
Check
6.20.4 Pump capacity Check
6.20.5 Coalescer filter element Replacement
6.21 Wiring (General) for Engine/Gearbox/Unit
251
252
252
253
253
254
255
256
257
259
6.21.1 Engine wiring harness Overview

6.21.2 Engine wiring Check
259
265
6.22 Accessories for (Electronic) Engine

Governor / Control System
266
6.22.1 CDC parameters Reset

6.22.2 Limit switch for start interlock Check
6.22.3 Engine Control Unit ECU 7 Checking plug
connections
6.22.4 Engine Monitoring Unit EMU 7 Plug
connection check
6.22.5 Interface module EIM plug connections
Check
6.22.6 Engine Control Unit ECU 7 Removal and
installation
6.22.7 EMU 7 Removal and installation
6.22.8 Engine Interface Module EIM Removal and
installation
6.22.9 Diagnostic features of EIM
266
267
268
269
270
271
272
273
274
7 Appendix A
7.1 Abbreviations
7.2 MTU contact persons/service partners
277
279
8 Appendix B
8.1 Special Tools
8.2 Index
280
285
DCL-ID: 0000005758 - 004
6.7.3 Fuel filter Replacement

6.7.4 Fuel system Venting
6.7.5 Fuel prefilter Differential pressure check
and adjustment of gauge
6.7.6 Fuel prefilter Draining
6.7.7 Fuel prefilter Flushing
6.7.8 Fuel prefilter with water separator Filter
element replacement
6.7.9 Fuel prefilter with water separator O-ring
replacement in rotary slide valve
1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
Incorrect use
Operation, maintenance and repair by unqualified personnel
Modifications or conversions
Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
Within the permissible operating parameters in accordance with the ( Technical data)
With fluids and lubricants approved by the manufacturer in accordance with the ( Fluids and Lubricants Specifications of the manufacturer)
With spare parts approved by the manufacturer in accordance with the ( Spare Parts Catalog/MTU
contact/Service partner)
In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (including engine control/parameters)
In compliance with all safety regulations and in adherence with all warning notices in this manual
In accordance with the maintenance requirements over the entire service life of the product ( Maintenance Schedule)
In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation. The manufacturer will accept no liability for such damage.
Modifications or conversions
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Unauthorized modifications to the product compromise safety.

The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
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1.2 Personnel and organizational requirements

Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safety-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
Training at the Training Center of the manufacturer
Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair and transport.
Working clothes and personal protective equipment

Wear proper protective clothing for all work.
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When working, always wear the necessary personal protective equipment (e.g. ear protectors, protective gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
8 | Safety | MS150068/01E 2014-01
1.3 Transport
Transport
Attach the engine at the lifting eyes provided only.

The lifting eyes are designed for engine transport only, not for the transport of propulsion units (engine
and gearbox).
Use only the transport and lifting gear approved by MTU.
The engine must only be transported in installation position, max. permissible diagonal pull 10.
Take note of the engine center of gravity.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the transport pallet or transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft
and engine mounts.
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Secure the engine against tilting during transportation. The engine must be especially secured against
slipping or tilting when going up or down inclines and ramps.
Setting the engine down after transport

Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to
do so.
MS150068/01E 2014-01 | Safety | 9
1.4 Safety regulations for maintenance and repair work

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

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassembly.
Carry out work only on assemblies or plants which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomer seals if they have carbonized or resinous appearance unless hands are properly
protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure components or assemblies are placed on stable surfaces.
10 | Safety | MS150068/01E 2014-01
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Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure particular cleanness during maintenance and repair work on the product. After completion of
maintenance and repair work, make sure that no unattached parts are in/on the product (e.g. cloths
and cable ties).
Safety regulations after completion of maintenance and repair work

Before barring, make sure that nobody is standing in the danger zone of the product.
After working on the product, check that all openings opened for work are closed again.
Check that all guards have been reinstalled and that all tools and loose parts have been removed after
working on the product (in particular, the barring tool).
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding
in its vicinity.
Before starting welding work:
Switch off the power supply master switch.
Disconnect the battery.
Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is
going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product.
The welding current may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand.
Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only
the specified jigs and fixtures for hydraulic removal/installation procedures.
Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
Vent the hydraulic installation/removal jig, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
For hydraulic installation, screw on the jig with the piston retracted.
For hydraulic removal, screw on the jig with the piston extended.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
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During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.
Gases emanating from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come in contact with skin or clothing.
Wear goggles and protective gloves.
Never place tools on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.
MS150068/01E 2014-01 | Safety | 11
Working on electrical and electronic assemblies

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

When working with laser equipment, always wear special laser-protection goggles (hazard due to heavily focused radiation).
Laser equipment must be equipped with the protective devices necessary for safe operation according
to type and application.
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For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
Laser devices of classes 1, 2 or 3A.
Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
12 | Safety | MS150068/01E 2014-01
1.5 Fire prevention and environmental protection, fluids and

lubricants, auxiliary materials
Fire prevention
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires therefore always keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on
the product. Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power
source to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with
their use.
Noise
Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.
Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A).
Environmental protection and disposal

Modification or removal of any mechanical/electronic components or the installation of additional components including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manufacturer. Noncompliance with these guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.
Fluids and lubricants and auxiliary materials
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The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to operation, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consumables and other chemical substances, follow the safety regulations that apply to the product. Take special care when using hot, chilled or caustic substances. When using flammable materials, prevent them
coming into contact with ignition sources and do not smoke.
Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.
MS150068/01E 2014-01 | Safety | 13
Lead
Adopt suitable measures to avoid the formation of lead dust.
Switch on extraction system.
When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale
lead vapors.
Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
Wear goggles when blowing dirt off workpieces or blowing away swarf.
Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.
Pay special attention to the pressure in the compressed air system or pressure vessel.
Assemblies or products to be connected must either be designed for that pressure, or, if the permissible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
Hose couplings and connections must be securely attached.
Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.
Carry out leak test in accordance with the specifications.
Paints and varnishes

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

When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
Do not inhale vapors.
If urea solution is swallowed, rinse out mouth and drink plenty of water.
If spilled onto clothing, remove the affected clothing immediately.
After contact with skin, rinse affected parts of the body with plenty of water.
Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possible.
14 | Safety | MS150068/01E 2014-01
TIM-ID: 0000040536 - 005

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

DANGER
WARNING
CAUTION
NOTICE
In the event of immediate danger.

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

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

Consequences: Minor or moderate injuries!
Remedial action.
In the event of a situation involving potentially adverse effects on the product.

Consequences: Material damage!
Remedial action.
Additional product information.
Safety notices
This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
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MS150068/01E 2014-01 | Safety | 15
2 Product Summary
2.1 Engine Layout
2.1.1
Product description
Description of the engine
Engine
The engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from driving
end), with direct injection, sequential turbocharging and charge air cooling.
The engine is monitored by an engine control and monitoring system (ADEC).
Fuel system
Electronically controlled common-rail-injection system with HP pump, pressure accumulator (rail) and
single injectors with integrated individual store.
The electronic control unit controls
Injection start
Injection quantity
Injection pressure
Exhaust system
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
low surface temperature,
reduced amount of heat to be dissipated by the coolant,
absolute gas-tightness.
Turbocharging
Sequential turbocharging with internal, engine-coolant-controlled charge air cooling. The right-hand exhaust turbocharger is cut-in and cut-out on 12V and 16V engines with electronically-controlled, hydraulically-actuated flaps.
Cooling system
Split-circuit engine cooling system with remote or engine-mounted heat exchanger.
Heating of the charge air in idle and low-load operation prevents white smoke formation.
Service block
The service components are mounted at the auxiliary PTO end.
The layout permits easy access for maintenance.
Service-components:
Raw water pump (if fitted), coolant pump
Centrifugal lube oil filter
Coolant expansion tank (only on engines with engine-mounted heat exchanger)
Coolant filter
16 | Product Summary | MS150068/01E 2014-01
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Seawater flows only through engine coolant cooler and fuel cooler as well as the raw water pump (if
fitted).
Intermittent oil priming for marine genset engines (M23-M43)

The standard configuration of these engines comprises intermittent oil priming.
Oil priming is activated every 30 minutes. The oil priming process ends as soon as oil pressure in the
main oil gallery reaches 0.4 bar or after 180 seconds, at the latest.
If a pressure of at least 0.2 bar is not attained after 180 seconds, an alarm is output.
To avoid engine damage from a hydraulic lock due to excessive oil supply to the combustion chambers,
the engine must be started at least once a month.
Electronic system
Electronic control and monitoring system with integrated safety and test system with interfaces to Remote Control System (RCS) and to Monitoring and Control System (MCS).
Engine Interface Module (EIM)
The Engine Interface Module (EIM) is the central connection box on the engine. It covers the complete
minimum scope of a marine engine. It does not comprise controls of components requiring maintenance.
Functions:
Starter control (start repetition, tooth alignment, starter protection)
Monitoring of the battery-charging generator
Open bus interface to the plant (SAE J1939)
Emergency stop function with line break monitoring
Redundant supply voltage input
Emergency air-shutoff flap control (option)
Key switch logic
Interface to ECU and EMU
MCS5 dialog interface
Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box)
Connection facility for an MTU Local Operating Station (LOS)
Serial RS422 interface for diagnosis
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The engine interface comprises two parts. The first part of signals is integrated in the engine wiring harness with a 62-pole Tyco connector X52. The second part refers to signals associated with higher currents. These signals are led out via M threaded pins and also integrated in the engine wiring harness.
Functions
ECU supply
EMU supply
Plant signals (ECU7 connector X1)
Bus interface (2x MCS5 CAN)
CAN dialog output (1xMCS5 CAN)
Emergency stop from EMU and ECU
Electric starter
Terminal 45 starter A/B (engaged)
Pneumatic starter
Starting-air pressure valve
Start-air pressure sensor
Barring gear (1 and 2)
Battery-charging generator (with exciter control)
Optional emergency-air shutoff flaps
Activation signal to air shut-off flaps 1+2
Feedback signal from air shut-off flaps 1+2
MS150068/01E 2014-01 | Product Summary | 17
Electronic engine governor (ECU)

Functions:
Engine speed control with fuel and speed limitation dependent on engine status and operating conditions
Control of sequential turbocharging, cylinder bank cut-out and air recirculation function
Data processing logistics for analog and binary signals
Interface for data transfer to CAN field bus for remote control and ship-side monitoring
Electronic Engine Monitoring Unit (EMU)
Functions:
Data processing logistics for analog and binary signals
Interface for data transfer to CAN field bus for remote control and ship-side monitoring
Low-load operation
12/16V4000M53R/M53/M63R/M63/M63L engines
2 Cleaning cycle
3 ditto
MTU marine engine Series 4000M53R to M93L may be operated in low-load operation. State-of-theart design and equipment features, e.g. TE coolant circuit, sequential turbocharging, jacketed, coolantcooled exhaust lines, Common Rail fuel injection and cylinder cutout allow engine operation at low load.
Nevertheless, low-load operation at engine load below 15% of the nominal rating is permitted for max.
100 hours. In order to avoid inadmissible oil carbon and/or carbon particle deposits in the engine, it is
recommended to carry out a cleaning cycle for at least 20 minutes after extended low-load operation
periods. During the cleaning cycle, engine speed (power) must be increased step by step until all exhaust turbochargers are running. The figure shows the basic speed/power run-up procedure for the
cleaning cycle to be carried out.
TIM-ID: 0000010054 - 009
1 Low-load operation
12/16V4000M23S/M23F/M33S/M33F/M43S engines
A Engine power
B Engine speed
ETC Exhaust turbocharger
MTU marine genset engine Series 4000M23/M33/M43 may be operated in low-load operation. Stateof-the-art design and equipment features e.g. TE coolant circuit, jacketed, coolant-cooled exhaust lines,
Common Rail fuel injection and cylinder cutout allow engine operation at low load.
Low-load operation (engine power up to approx. 20% of rated power) takes place in single-ETC mode
(with only one exhaust turbocharger running). To ensure the functionality of the control mechanism and
of the exhaust flap of the turbocharger which does not run in low-load operation, it is recommended to
operate the engine with both exhaust turbochargers running after 100 operating hours in low-load operation, at the latest.
SOLAS Fire protection specifications

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

pump
1 SOLAS clip on the fuel line: on fuel

filter head retainer
TIM-ID: 0000010054 - 009
1 SOLAS clip on the fuel line: on HP

pump
2 SOLAS clip on the fuel line: after fuel
filter head
1 SOLAS clips on the fuel line: on fuel

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

filter head
Lube oil system, oil lines with oil pressure >1.8 bar
TIM-ID: 0000010054 - 009
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are
shown.
1 SOLAS clips on exhaust flap switching cylinder ETC B1
1 SOLAS clips on air flap switching

cylinder ETC B1
2 SOLAS clips on flap control T adapter ETC B1
TIM-ID: 0000010054 - 009
1 SOLAS clips on distributor element

2 SOLAS clips on oil return
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
gallery
TIM-ID: 0000010054 - 009
1 SOLAS clips on recirculation valve
1 SOLAS clip on HP pump oil supply:

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

on equipment carrier
TIM-ID: 0000010054 - 009
1 SOLAS clip on ETC oil supply

2 SOLAS clip on ETC oil supply
1 SOLAS clips of oil line on equipment

carrier
1 Cover on oil filter cartridge
Special connections
TIM-ID: 0000010054 - 009
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.
Plugs and sensors (a)

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

The sleeve (3) covers the joint to prevent lateral spray.
Only leak-off along the line is possible, the pressure is decreases significantly if an O-ring (2) defect
occurs.
TIM-ID: 0000010054 - 009
The union is confirmed as being SOLAS-compliant by DNV and GL.
HP connections
1
2
3
4
5
6
7
Jacket pipe
HP fuel line
O-ring
Union nut
Recess for O-ring
Thrust ring
Leakage overflow bore
8
9
10
11
12
13
14
Thrust ring
Union nut
Union nut
Connecting piece
Snap ring
Thrust ring
Shim washers
15
16
17
18
19
20
Union nut
Thrust ring
HP line outer pipe
Internal pipe of HP line
Ball-type seal area
Leak-fuel connection
The HP fuel line is sealed by the thrust ring (8).

If leakage in the area of the thrust ring (8) or the HP line (2) occurs, the emerging fuel is routed to the
leakage chamber.
The leaking fuel is drained off without pressure via the leakage overflow-bore (7). The leakage chamber
is sealed toward the outside by the O-rings (3).
This prevents leakage egress.
TIM-ID: 0000010054 - 009
The union is confirmed as being SOLAS-compliant by DNV and GL.
2.1.2
Engine layout
Engines with remote heat exchanger and horizontal air intake
10
11
12
13
14
15
16
17
18
Recirculation line
Exhaust manifold
Engine mounts
Charge-air line
Oil pan
Oil filler neck
Crankcase
Cylinder head
Fuel filter
19
20
21
22
23
Battery-charging generator
HP fuel pump
Oil filter
Bilge pump (option)
Coolant outlet to remote
cooling system
24 Coolant inlet from remote
cooling system
KGS Free end
TIM-ID: 0000009990 - 007
1 Engine management and

monitoring
2 Oil cooler
3 Centrifugal oil filter
4 Crankcase breather
5 Dry-type air filter
6 Exhaust turbocharger
7 Exhaust outlet
8 Air pipe to intercooler
9 Intercooler
Engines with engine-mounted heat exchanger and horizontal air intake
10
11
12
13
14
15
16
17
18
Exhaust outlet
Air pipe to intercooler
Recirculation line
Exhaust manifold
Intercooler
Charge-air line
Engine mounts
Oil pan
Oil filler neck
19
20
21
22
23
24
25
26
KGS
Cylinder head
Crankcase
Fuel filter
HP fuel pump
Oil filter
Bilge pump (option)
Raw-water inlet
Free end
TIM-ID: 0000009990 - 007
1 Raw-water outlet
monitoring
3 Plate-core heat exchanger
4 Oil cooler
5 Coolant expansion tank
9 Exhaust turbocharger
Engines with remote heat exchanger and vertical air intake
1 Coolant outlet to remote

cooling system
2 Coolant inlet from remote
cooling system
monitoring
4 Oil cooler
8 Exhaust manifold
9 Recirculation line
10
11
12
13
14
15
16
17
18
Exhaust turbocharger
Exhaust outlet
Intercooler
Engine mounts
Charge-air line
Oil pan
Oil filler neck
Crankcase
19
20
21
22
23
24
KGS
Cylinder head
Fuel filter
Oil filter
HP fuel pump
Bilge pump (option)
Free end
TIM-ID: 0000009990 - 007
Overview drawing is also valid for 16V engines.
Engines with engine-mounted heat exchanger and vertical air intake
1 Raw-water outlet
monitoring
3 Oil cooler
4 Plate-core heat exchanger
5 Coolant expansion tank
9 Exhaust manifold
10
11
12
13
14
15
16
17
18
Recirculation line
Exhaust outlet
Intercooler
Charge-air line
Engine mounts
Oil pan
Oil filler neck
19
20
21
22
23
24
25
26
KGS
Crankcase
Cylinder head
Fuel filter
Oil filter
HP fuel pump
Bilge pump (option)
Raw-water inlet
Free end
Overview drawing is also valid for 16V engines.
Engine model designation
TIM-ID: 0000009990 - 007
Key to the engine model designations 12/16V 4000 Mxy z

12, 16
Number of cylinders
Cylinder arrangement: V-engine
4000
Series
Application (M= Marine)
Application load profile (0, 1, 2, 3...9)
Design index (0, 1, 2, 3...9)
R (power / speed reduction)

L (enhanced power / speed)
S (60 Hz)
F (50 Hz)
2.1.3
Overview of sensors and actuators

Top view of 12V 4000 M with external cooling
2 B4.A1-B4.B6 (single exhaust temp., A1-A6, B1B6)
3 B33 (fuel temperature in

common rail)
TIM-ID: 0000038758 - 002
1 B49 (charge-air temp., air

recirculation valve)
Y26 (air recirculation valve
A)
Aux. PTO end, 12V 4000 M, external cooling

common rail)
5 B48 (fuel pressure in common rail)
6 B1 (camshaft speed)
7 B54 (oil refill pump pressure)

8 B6.2 (coolant temperature)
9 B6 (coolant temperature)
TIM-ID: 0000038758 - 002
1 B7 (engine oil temp.)

2 B5.3 (oil pressure upstream of filter)
3 B5.1 (oil pressure downstream of filter)
Main PTO end, 12V 4000 M, external cooling
3 B13 (crankshaft speed)

4 S37.2 (safety switch)

6 B13.2 (crankshaft speed)
TIM-ID: 0000038758 - 002
1 B4.21 (exhaust temperature, A bank)

2 B4.22 (exhaust temperature, B bank)
Left side of engine, 12V 4000 M, external cooling
4 B10 (charge-air pressure)

5 B34.3 (fuel pressure upstream of filter)
7 B34.1 (fuel pressure downstream of filter)

8 F46 (fuel overflow level)
TIM-ID: 0000038758 - 002
1 B50 (crankcase pressure)

2 B3 (intake air temperature)
3 B44.1 (turbocharger A
speed)
Right side of engine, 12V 4000 M, external cooling
3 B16 (coolant pressure)

4 B9 (charge-air temperature)
TIM-ID: 0000038758 - 002
1 B44.2 (turbocharger B
speed)
2 Y27 (turbocharger control
valve)
Top view, 12V 4000 M, integral cooling

common rail)
3 F33 (coolant level)
TIM-ID: 0000038758 - 002
Aux. PTO end, 12V 4000 M, integral cooling

common rail)

TIM-ID: 0000038758 - 002

Main PTO end, 12V 4000 M, integral cooling


TIM-ID: 0000038758 - 002

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

TIM-ID: 0000038758 - 002

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

4 B21 (raw water pressure)
TIM-ID: 0000038758 - 002
speed)
valve)
Top view of 16V 4000 M with external cooling

common rail)
TIM-ID: 0000038758 - 002

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

common rail)

TIM-ID: 0000038758 - 002

Main PTO end, 16V 4000 M, external cooling


TIM-ID: 0000038758 - 002

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


TIM-ID: 0000038758 - 002

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

TIM-ID: 0000038758 - 002
speed)
valve)
Top view, 16V 4000 M, integral cooling

common rail)
3 F33 (coolant level)
TIM-ID: 0000038758 - 002
Aux. PTO end, 16V 4000 M, integral cooling

common rail)

TIM-ID: 0000038758 - 002

Main PTO end, 16V 4000 M, integral cooling


TIM-ID: 0000038758 - 002

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

TIM-ID: 0000038758 - 002

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

4 B21 (raw water pressure)
TIM-ID: 0000038758 - 002
speed)
valve)
2.2 Engine Side and Cylinder Designations

2.2.1
Engine side and cylinder designations

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

4 Driving end
TIM-ID: 0000002185 - 012
1 Left-hand side of engine

2 Free end
2.3 Main Engine Dimensions

2.3.1
Engine Main dimensions
Engines with horizontal air intake

With remote heat exchanger
TIM-ID: 0000010043 - 004
Engine model
Length (A)
16V 4000
approx. 3108 mm
M23S/23F/33S/33F/
43S
16V 4000 M53R/
53/63R/63/63L
Width (B) without

silencer
Width (B) with silencer
Height (C)
approx. 1690 mm
approx. 1850 mm
approx. 2064 mm
Width (B) without

silencer
Height (C)
approx. 1690 mm
approx. 1850 mm
approx. 2064 mm
With engine-mounted heat exchanger

Engine model
Length (A)
16V 4000
approx. 3388 mm
M23S/23F/33S/33F/
43S
Engine model
Length (A)
Width (B) without

silencer
Height (C)
16V 4000 M53R/

53/63R/63/63L
Engines with vertical air intake

With remote heat exchanger
Engine model
Length (A)
Width (B)
Height (C) without Height (C) with sisilencer

lencer
12V 4000
M23S/23F/33S/
33F
12V 4000 M53R/
53/63
approx. 2628 mm
approx. 1602 mm
approx. 2368 mm
approx. 2448 mm
16V 4000
approx. 3108 mm
M23S/23F/33S/33F/
43S
16V 4000 M53R/
53/63R/63/63L
approx. 1602 mm
approx. 2361 mm
approx. 2441 mm
With engine-mounted heat exchanger

Length (A)
Width (B)
Height (C) without Height (C) with sisilencer

lencer
12V 4000
M23S/23F/33S/
33F
12V 4000 M53R/
53/63
approx. 2857 mm
approx. 1602 mm
approx. 2368 mm
approx. 2448 mm
16V 4000
approx. 3388 mm
M23S/23F/33S/33F/
43S
16V 4000 M53R/
53/63R/63/63L
approx. 1602 mm
approx. 2361 mm
approx. 2441 mm
TIM-ID: 0000010043 - 004
Engine model
2.4 Firing Sequence

Firing order
Cylinders
Firing order
12 V
A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16 V
A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
TIM-ID: 0000023263 - 002
2.4.1
2.5 Technical Data

2.5.1
12V 4000 M23F engine data, RheinSchUO, stage II, IMO Tier II
Explanation:
DL
BL
A
G
R
L
N
X
Ref. value: Continuous power

Ref. value: Fuel stop power
Design value
Guaranteed value
Guideline value
Limit value, up to which the engine can be operated, without change (e.g. of power settings).
Not yet defined value
Not applicable
Applicable
Heat exchanger
mounted
Application group
Heat exchanger
separate
3A
3A
3A
3A
Intake-air temperature
25
32
25
32
Charge-air coolant temperature
Raw-water inlet temperature
25
45
25
45
Barometric pressure
mbar
1000
1000
1000
1000
Site altitude above sea level
100
100
100
100
POWER DATA (power ratings are net brake power as per ISO 3046)
Heat exchanger
mounted
Heat exchanger
separate
Rated engine speed
rpm
1500
1500
1500
1500
Continuous power ISO 3046 (10% overload capability, design power DIN 6280,
ISO 8528)
kW
1140
1140
1140
1140
GENERAL CONDITIONS (for maximum power)

Heat exchanger
separate
Intake depression (new filter)
mbar
15
15
15
15
Intake depression, max.
mbar
30
30
30
30
MODEL-RELATED DATA (basic design)

Heat exchanger
mounted
Cylinder arrangement: V-angle
Degrees
()
Bore
Heat exchanger
separate
90
90
90
90
mm
170
170
170
170
Stroke
mm
210
210
210
210
Cylinder displacement
Liters
4.77
4.77
4.77
4.77
Total displacement
Liters
57.2
57.2
57.2
57.2
TIM-ID: 0000022715 - 001
Heat exchanger
mounted
Heat exchanger
mounted
Heat exchanger
separate
Number of inlet valves per cylinder
Number of exhaust valves per cylinder
RAW-WATER CIRCUIT (open circuit)

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

system, max.
bar
--
--
LUBE-OIL SYSTEM
Heat exchanger
mounted
Heat exchanger
separate
Lube-oil operating temperature before en- R

gine, from
81
81
81
81

gine, to
89
89
89
89
Lube-oil operating pressure before engine, R

from
bar
5.0
5.0
5.0
5.0

to
bar
6.0
6.0
6.0
6.0
Lube-oil operating pressure (low idle)

(meas. point: before engine)
bar
FUEL SYSTEM
TIM-ID: 0000022715 - 001
Heat exchanger
mounted
Heat exchanger
separate
Fuel pressure at supply connection to engine, min. (when engine is starting)
bar
-0.1
-0.1
-0.1
-0.1
Fuel pressure at supply connection to engine, min. (when engine is running)
bar
-0.3
-0.3
-0.3
-0.3
Fuel pressure at supply connection to engine, max. (when engine is starting)
bar
1.5
1.5
1.5
1.5
Fuel supply flow, max.
Liters/
min
GENERAL OPERATING DATA

Heat exchanger
mounted
Heat exchanger
separate
Firing speed, from
rpm
80
80
80
80
Firing speed, to
rpm
120
120
120
120
STARTING SYSTEM (electric)

Heat exchanger
mounted
Rated starter voltage (standard design)
V=
24
Heat exchanger
separate
24
24
24
STARTING (with compressed air/hydraulic starter)

Heat exchanger
mounted
Heat exchanger
separate
Starting-air pressure before starter, min.
bar
Starting-air pressure before starter, max.
bar
10
10
10
10
CAPACITIES
Heat exchanger
mounted
Engine coolant, engine-side (with cooling
system)
Heat exchanger
separate
Liters
305
305
--
--
Engine oil, total, for initial filling (standard R

oil system) (option: max. operating inclinations)
Liters
Oil change quantity, max. (standard oil

system) (option: max. operating inclinations)
Liters
265
265
265
265
Oil pan capacity at dipstick mark "min."

(standard oil system) (option: max. operating inclinations)
Liters
195
195
195
195
Oil pan capacity at dipstick mark "max."

Liters
235
235
235
235
WEIGHTS / MAIN DIMENSIONS

Heat exchanger
mounted
Engine dry weight (with attached standard R
accessories, without coupling)
kg
7640
7640
Heat exchanger
separate
7240
7240
ACOUSTICS
Exhaust noise, unsilenced - DL (free-field R

sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
dB(A)
105
105
Heat exchanger
separate
105
105
TIM-ID: 0000022715 - 001
Heat exchanger
mounted
2.5.2
12V 4000 M23S engine data, RheinSchUO, stage II, IMO Tier II
Explanation:
DL
BL
A
G
R
L
N
X

Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Heat exchanger
mounted
Application group
Heat exchanger
separate
3A
3A
3A
3A
25
45
25
45
25
32
25
32
Barometric pressure
mbar
1000
1000
1000
1000
100
100
100
100
Heat exchanger
mounted
Heat exchanger
separate
Rated engine speed
rpm
1800
1800
1800
1800
ISO 8528)
kW
1380
1380
1380
1380

Heat exchanger
mounted
Heat exchanger
separate
mbar
15
15
15
15
mbar
30
30
30
30
TIM-ID: 0000022718 - 001

Heat exchanger
mounted
Degrees
()
Bore
Heat exchanger
separate
90
90
90
90
mm
170
170
170
170
Stroke
mm
210
210
210
210
Liters
4.77
4.77
4.77
4.77
Total displacement
Liters
57.2
57.2
57.2
57.2

Heat exchanger
mounted
Heat exchanger
separate
bar
-0.4
-0.4
--
--
bar
1.0
1.0
--
--

system, max.
bar
--
--
LUBE-OIL SYSTEM
Heat exchanger
mounted
Heat exchanger
separate

gine, from
84
85
84
85

gine, to
92
93
92
93

from
bar
5.5
5.5
5.5
5.5

to
bar
6.5
6.5
6.5
6.5

bar
FUEL SYSTEM
Heat exchanger
mounted
Heat exchanger
separate
bar
-0.1
-0.1
-0.1
-0.1
bar
-0.3
-0.3
-0.3
-0.3
bar
1.5
1.5
1.5
1.5
Liters/
min

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

Heat exchanger
mounted
V=
24
Heat exchanger
separate
24
24
24
TIM-ID: 0000022718 - 001
Heat exchanger
mounted

Heat exchanger
mounted
Heat exchanger
separate
bar
bar
10
10
10
10
CAPACITIES
Heat exchanger
mounted
system)
Heat exchanger
separate
Liters
305
305
--
--

Liters

Liters
265
265
265
265

L
Liters
195
195
195
195

L
Liters
235
235
235
235

Heat exchanger
mounted
kg
7640
7640
Heat exchanger
separate
7240
7240
ACOUSTICS
Heat exchanger
mounted
dB(A)
106
106
106
106
TIM-ID: 0000022718 - 001

Heat exchanger
separate
2.5.3
12V 4000 M23S engine data, IMO Tier II, EPA Tier 2
Explanation:
DL
BL
A
G
R
L
N
X

Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Heat exchanger
mounted
Application group
Heat exchanger
separate
3A
3A
3A
3A
25
45
25
45
25
32
25
32
Barometric pressure
mbar
1000
1000
1000
1000
100
100
100
100
Heat exchanger
mounted
Heat exchanger
separate
Rated engine speed
rpm
1800
1800
1800
1800
ISO 8528)
kW
1380
1380
1380
1380

Heat exchanger
mounted
Heat exchanger
separate
mbar
15
15
15
15
mbar
30
30
30
30
Heat exchanger
mounted
Degrees
()
Bore
Heat exchanger
separate
90
90
90
90
mm
170
170
170
170
Stroke
mm
210
210
210
210
Liters
4.77
4.77
4.77
4.77
Total displacement
Liters
57.2
57.2
57.2
57.2
TIM-ID: 0000022719 - 001

Heat exchanger
mounted
Heat exchanger
separate
bar
-0.4
-0.4
--
--
bar
1.0
1.0
--
--

system, max.
bar
--
--
LUBE-OIL SYSTEM
Heat exchanger
mounted
Heat exchanger
separate

gine, from
85
85
85
85

gine, to
93
93
93
93

from
bar
5.5
5.5
5.5
5.5

to
bar
6.5
6.5
6.5
6.5

bar
FUEL SYSTEM
Heat exchanger
mounted
Heat exchanger
separate
bar
-0.1
-0.1
-0.1
-0.1
bar
-0.3
-0.3
-0.3
-0.3
bar
1.5
1.5
1.5
1.5
Liters/
min
TIM-ID: 0000022719 - 001
Heat exchanger
mounted
Heat exchanger
separate
Firing speed, from
rpm
80
80
80
80
Firing speed, to
rpm
120
120
120
120

Heat exchanger
mounted
V=
24
Heat exchanger
separate
24
24
24

Heat exchanger
mounted
Heat exchanger
separate
bar
bar
10
10
10
10
CAPACITIES
Heat exchanger
mounted
system)
Heat exchanger
separate
Liters
305
305
--
--

Liters

Liters
265
265
265
265

L
Liters
195
195
195
195

L
Liters
235
235
235
235

Heat exchanger
mounted
kg
7640
7640
Heat exchanger
separate
7240
7240
ACOUSTICS
Heat exchanger
mounted
dB(A)
106
106
106
106
TIM-ID: 0000022719 - 001

Heat exchanger
separate
2.5.4
16V 4000 M23F engine data, RheinSchUO, stage II, IMO Tier II
Explanation:
DL
BL
A
G
R
L
N
X

Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Heat exchanger
mounted
Application group
Heat exchanger
separate
3A
3A
3A
3A
25
45
25
45
--
--
--
--
25
32
25
32
Barometric pressure
mbar
1000
1000
1000
1000
100
100
100
100
Heat exchanger
mounted
Heat exchanger
separate
Rated engine speed
rpm
1500
1500
1500
1500
ISO 8528)
kW
1520
1520
1520
1520

Heat exchanger
mounted
Heat exchanger
separate
mbar
15
15
15
15
mbar
30
30
30
30
TIM-ID: 0000022717 - 001

Heat exchanger
mounted
Degrees
()
Bore
Heat exchanger
separate
90
90
90
90
mm
170
170
170
170
Stroke
mm
210
210
210
210
Liters
4.77
4.77
4.77
4.77
Total displacement
Liters
76.3
76.3
76.3
76.3

Heat exchanger
mounted
Heat exchanger
separate
bar
-0.4
-0.4
--
--
bar
1.0
1.0
--
--

system, max.
bar
1.0
1.0
--
--
LUBE-OIL SYSTEM
Heat exchanger
mounted
Heat exchanger
separate

gine, from
80
80
80
80

gine, to
88
88
88
88

from
bar
5.0
5.0
5.0
5.0

to
bar
6.0
6.0
6.0
6.0

bar
--
--
--
--
FUEL SYSTEM
Heat exchanger
mounted
Heat exchanger
separate
bar
-0.1
-0.1
-0.1
-0.1
bar
-0.3
-0.3
-0.3
-0.3
bar
1.5
1.5
1.5
1.5
Liters/
min

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

Heat exchanger
mounted
V=
24
Heat exchanger
separate
24
24
24
TIM-ID: 0000022717 - 001
Heat exchanger
mounted

Heat exchanger
mounted
Heat exchanger
separate
bar
bar
CAPACITIES
Heat exchanger
mounted
system)
Heat exchanger
separate
Liters
350
350
--
--

Liters

Liters
280
280
280
280

L
Liters
210
210
210
210

L
Liters
250
250
250
250

Heat exchanger
mounted
kg
9020
9020
Heat exchanger
separate
8590
8590
ACOUSTICS
Heat exchanger
mounted
dB(A)
108
108
108
108
TIM-ID: 0000022717 - 001

Heat exchanger
separate
2.5.5
16V 4000 M23S engine data, RheinSchUO, stage II, IMO Tier II
Explanation:
DL
BL
A
G
R
L
N
X

Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Heat exchanger
mounted
Application group
Heat exchanger
separate
3A
3A
3A
3A
25
45
25
45
--
--
--
--
25
32
25
32
Barometric pressure
mbar
1000
1000
1000
1000
100
100
100
100
Heat exchanger
mounted
Heat exchanger
separate
Rated engine speed
rpm
1800
1800
1800
1800
ISO 8528)
kW
1840
1840
1840
1840

Heat exchanger
mounted
Heat exchanger
separate
mbar
15
15
15
15
mbar
30
30
30
30
Heat exchanger
mounted
Degrees
()
Bore
Heat exchanger
separate
90
90
90
90
mm
170
170
170
170
Stroke
mm
210
210
210
210
Liters
4.77
4.77
4.77
4.77
Total displacement
Liters
76.3
76.3
76.3
76.3
TIM-ID: 0000022720 - 001

Heat exchanger
mounted
Heat exchanger
separate
bar
-0.4
-0.4
--
--
bar
1.0
1.0
--
--

system, max.
bar
1.0
1.0
--
--
LUBE-OIL SYSTEM
Heat exchanger
mounted
Heat exchanger
separate

gine, from
84
87
84
87

gine, to
92
95
92
95

from
bar
5.3
5.3
5.3
5.3

to
bar
6.3
6.3
6.3
6.3

bar
--
--
--
--
FUEL SYSTEM
Heat exchanger
mounted
Heat exchanger
separate
bar
-0.1
-0.1
-0.1
-0.1
bar
-0.3
-0.3
-0.3
-0.3
bar
1.5
1.5
1.5
1.5
Liters/
min
TIM-ID: 0000022720 - 001
Heat exchanger
mounted
Heat exchanger
separate
Firing speed, from
rpm
80
80
80
80
Firing speed, to
rpm
120
120
120
120

Heat exchanger
mounted
V=
24
Heat exchanger
separate
24
24
24

Heat exchanger
mounted
Heat exchanger
separate
bar
bar
CAPACITIES
Heat exchanger
mounted
system)
Heat exchanger
separate
Liters
350
350
--
--

Liters

Liters
280
280
280
280

L
Liters
210
210
210
210

L
Liters
250
250
250
250

Heat exchanger
mounted
kg
9020
9020
Heat exchanger
separate
8590
8590
ACOUSTICS
Heat exchanger
mounted
dB(A)
109
109
109
109
TIM-ID: 0000022720 - 001

Heat exchanger
separate
2.5.6
Explanation:
DL
BL
A
G
R
L
N
X

Design value
Guaranteed value
Guideline value
Not applicable
Applicable
Heat exchanger
mounted
Application group
Heat exchanger
separate
3A
3A
3A
3A
25
45
25
45
--
--
--
--
25
32
25
32
Barometric pressure
mbar
1000
1000
1000
1000
100
100
100
100
Heat exchanger
mounted
Heat exchanger
separate
Rated engine speed
rpm
1800
1800
1800
1800
ISO 8528)
kW
1840
1840
1840
1840

Heat exchanger
mounted
Heat exchanger
separate
mbar
15
15
15
15
mbar
30
30
30
30
TIM-ID: 0000022721 - 001

Heat exchanger
mounted
Degrees
()
Bore
Heat exchanger
separate
90
90
90
90
mm
170
170
170
170
Stroke
mm
210
210
210
210
Liters
4.77
4.77
4.77
4.77
Total displacement
Liters
76.3
76.3
76.3
76.3

Heat exchanger
mounted
Heat exchanger
separate
bar
-0.4
-0.4
--
--
bar
1.0
1.0
--
--

system, max.
bar
1.0
1.0
--
--
LUBE-OIL SYSTEM
Heat exchanger
mounted
Heat exchanger
separate

gine, from
84
83
84
83

gine, to
92
91
92
91

from
bar
5.3
5.3
5.3
5.3

to
bar
6.3
6.3
6.3
6.3

bar
--
--
--
--
FUEL SYSTEM
Heat exchanger
mounted
Heat exchanger
separate
bar
-0.1
-0.1
-0.1
-0.1
bar
-0.3
-0.3
-0.3
-0.3
bar
1.5
1.5
1.5
1.5
Liters/
min

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

Heat exchanger
mounted
V=
24
Heat exchanger
separate
24
24
24
TIM-ID: 0000022721 - 001
Heat exchanger
mounted

Heat exchanger
mounted
Heat exchanger
separate
bar
bar
CAPACITIES
Heat exchanger
mounted
system)
Heat exchanger
separate
Liters
350
350
--
--

Liters

Liters
280
280
280
280

L
Liters
210
210
210
210

L
Liters
250
250
250
250

Heat exchanger
mounted
kg
9020
9020
Heat exchanger
separate
8590
8590
ACOUSTICS
Heat exchanger
mounted
dB(A)
109
109
109
109
TIM-ID: 0000022721 - 001

Heat exchanger
separate
3 Operation
3.1 Controls
Automation system controls
TIM-ID: 0000016959 - 003
Refer to automation system operating instructions
74 | Operation | MS150068/01E 2014-01
3.2 Putting the engine into operation after extended out-of-service

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

months)
Item
Task
Engine
Depreserve ( Preservation and Represervation Specifications A001070/..).
Lube oil system
Check engine oil level ( Page 218);

Preheat engine oil if required.
Fuel prefilter
Prime with fuel ( Page 195)
Fuel prefilter, pressure

gauge
Align adjustable pointer with position of pressure indicator ( Page 190).
HP fuel pump
Only for engines without oil priming pump:

Fill HP fuel pump with new engine oil ( Page 177).
Raw-water pump (if located Prime with water (approx. 3 4 l).

above waterline (only applicable to engines with engine-mounted heat exchanger or with optional remote
heat exchanger))
If engine is out of service for more than one year, change engine coolant
( Page 235).
Coolant circuit
Check coolant level ( Page 234).
Coolant circuit
Preheat coolant with preheating unit.
Engine control system
Refer to automation system operating instructions.
ECU
Check plug connections ( Page 268).
EMU
Check plug connections ( Page 269)
EIM
TIM-ID: 0000010092 - 005
Coolant circuit
MS150068/01E 2014-01 | Operation | 75
3.3 Putting the engine into operation after scheduled out-ofservice-period

Preconditions
Putting into operation

Task
Lube oil system
Check engine oil level ( Page 218);

Preheat engine oil if required.
Coolant system
Coolant system
Preheat coolant with preheating unit.
Fuel prefilter
Drain ( Page 191);

Check that suction-side pressure indicated at the fuel prefilter pressure
gauge is within the limit ( Page 190).
ECU
EIM
EMU
TIM-ID: 0000010655 - 004
Item
76 | Operation | MS150068/01E 2014-01
3.4 Starting the engine

Start the engine via the automation system
TIM-ID: 0000017525 - 003
MS150068/01E 2014-01 | Operation | 77
3.5 Operational checks

DANGER
WARNING
Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!
Only run the engine at low power. Keep away from the engine's danger zone.
High level of engine noise when the engine is running.

Risk of damage to hearing!
Wear ear protectors.
Operational checks
Measure
Engine under load

Engine at nominal speed
Check engine visually for leaks and general condition; Check air pipework between air filter and exhaust turbocharger for leaks and damage.
Check for abnormal running noise, vibration, and exhaust color ( Page 92).
Charge-air cooler
Check condensate drain ( Page 213).
Air filter
Check signal ring position of service indicator ( Page 216).

Replace air filter ( Page 214), if the signal ring is completely visible in the
service indicator control window.
HP fuel pump
Check relief bores for fuel discharge ( Page 178).
HT coolant pump
Check relief bore for oil and coolant discharge and obstructions
( Page 241).
Fuel prefilter (optional)
Check reading on differential pressure gauge ( Page 216);

Drain water and contaminants ( Page 193).
Raw water pump (only on

engines with engine-mounted or optional remote heat
exchanger)
( Page 249).
Bilge pump (optional)
( Page 252).
TIM-ID: 0000018474 - 003
Item
78 | Operation | MS150068/01E 2014-01
3.6 Tasks after extended out-of-service periods (>3 weeks)

Tasks after extended out-of-service periods (>3 weeks)
Operate fuel treatment system for at least 5 minutes.
Start up fuel treatment system ( Page 81).
Shut down fuel treatment system ( Page 85).
TIM-ID: 0000007730 - 005
Note:
1.
2.
MS150068/01E 2014-01 | Operation | 79
3.7 Checks prior to start-up

Checks prior to start-up
1.
2.
3.
4.
5.
6.
Result:
TIM-ID: 0000007736 - 005
7.
Result:
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.
Switch on fuel treatment system ( Page 84).
Check direction of rotation of pump.
Vent bypass and fuel lines of the system.
a) Open ball valve for pressure tank.
b) Open ball valve for overflow tank.
c) Close ball valve at the inlet to the fuel treatment system.
Bypass line is vented via the overflow tank.
d) Open ball valve at the inlet to the fuel treatment system.
Check the fuel treatment system for leaks.
The fuel treatment system is ready for operation.
80 | Operation | MS150068/01E 2014-01
3.8 Fuel treatment system Putting into operation

Overview of fuel treatment system
1
2
3
4
5
6
7
Pressure-free overflow
Bypass 1
Bypass 2
Safety valve, 3 bar
Ball valve, inlet
Pressure gage
Ventilation, sample extraction
8 Differential pressure gage
9
10
11
12
13
14
15
16
Ball valve, outlet

Check valve 700 mbar
Check valve 5 mbar
Return to overflow container
Engine
Overflow container
Water separator filter
Ball valve, drain
17 Automatic water drain

18 Water level electrode
19 Ball valve, sample extraction, inlet
20 Switchgear cabinet
21 Pump
22 Coarse filter
23 Fuel supply from tank
24 Tank
Switching on fuel treatment system
TIM-ID: 0000015773 - 006
1.
2.
Result:

Check differential pressure at differential pressure gage (8). Differential pressure in a new system:
0.1 bar to 0.3 bar.
If no differential pressure is measured, the coalescer filter element is probably being bypassed.
1. Remove coalescer filter element ( Page 257).
2. Check sealing surfaces on coalescer filter element and in the pressure tank.
MS150068/01E 2014-01 | Operation | 81
Initial operation: HAT

1.
Note:
2.
3.
Result:
4.
5.
6.
Note:
7.
8.
Result:
Replace fuel filter on engine ( Page 187).

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 84).
The fuel is drawn from tank (24), cleaned by the water separator filter (15) and then routed via overflow
tank (14) back to tank (24). Water that collects in the tank is separated.
Start engine ( Page 77).
Run engine at idling speed.
Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
If the suction pressure is within the permissible limits and engine operation is satisfactory.
Increase engine speed to 1000 rpm and monitor suction pressure.
Check suction pressure at the engine-mounted fuel delivery pump.
If the values are within the limits specified by the manufacturer, the system is ready to start filter replacement simulation with the engine running as part of the Harbor Acceptance Tests.
Simulation of filter replacement with the engine running: HAT

1.
2.
3.
4.
Result:
5.
Result:
6.
Note:
7.
Result:

Close ball valve (5) at inlet to fuel treatment system.
The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit
opens and fuel flows through bypass (3) and bypass (2).
Open ball valve (19) .
Fuel emerges. If no fuel emerges:
Open ball valve (5) at inlet to fuel treatment system.
No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3) .
Check suction pressure (see technical data of the engine) at the fuel delivery pump.
If all engine operating values are within the specified limits, open ball valve (5) at inlet to fuel treatment
system.
1.
2.
3.
4.
Result:
5.

Switch off pump (21) at switchgear cabinet (20).
The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
Note:
6.
Result:
If the suction pressure is within the specified limits, simulation was successful.
82 | Operation | MS150068/01E 2014-01
TIM-ID: 0000015773 - 006
Simulation of power failure (emergency): HAT
Simulation of power failure (emergency): SAT

Switch off pump (21) at switchgear cabinet (20).
The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
Note:
6.
Result:
Operate engine at full load and monitor suction pressure.
If the suction pressure is within the specified limits, simulation was successful.
TIM-ID: 0000015773 - 006
1.
2.
3.
4.
Result:
5.
MS150068/01E 2014-01 | Operation | 83
3.9 Fuel treatment system Switching on

Preconditions
The on-board power supply is switched on.
NOTICE
Risk of damage to engine/system.

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

Carry out checks prior to start-up ( Page 80).
Switch on master switch on switchgear cabinet.
Signal lamp Control voltage present lights up.
Switch on switch for pump.
Signal lamp Pump running lights up.
TIM-ID: 0000007731 - 006
1.
2.
Result:
3.
Result:
84 | Operation | MS150068/01E 2014-01
3.10 Fuel treatment system Shutdown

Shutting down fuel treatment system
1.
TIM-ID: 0000007732 - 005
2.
3.
4.
5.
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.
Open drain valve until pressure has escaped from fuel treatment system.
MS150068/01E 2014-01 | Operation | 85
3.11 Stopping the engine

Stopping the engine via the automation system
TIM-ID: 0000017528 - 004
86 | Operation | MS150068/01E 2014-01
3.12 Emergency engine stop

NOTICE
An emergency stop causes extreme stress to the engine plant.

Risk of overheating, damage to components!
Initiate emergency stop only in emergency situations.
Emergency stop
Follow instructions.
TIM-ID: 0000017530 - 005
1.
2.
MS150068/01E 2014-01 | Operation | 87
3.13 After stopping the engine

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

Item
Measure
Coolant circuit
Drain coolant ( Page 236) if:

freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze

additive;
the engine room is not heated;
the coolant is not kept at a suitable temperature;
the antifreeze concentration is insufficient for the engine-room temperature;
antifreeze concentration is 50% and engine-room temperature is below
-40 C.
Raw water (only on engines

with engine-mounted heat
exchanger)
Drain
if freezing temperatures are expected and the engine is to remain out
Switch off.
Air intake and exhaust system
Out-of-service-period > 1 week
of service for an extended period.
Seal engine on air and exhaust sides.
Out-of-service-period > 1 month

Preserve engine ( MTU Preservation and Re-preservation specifica-
TIM-ID: 0000010168 - 004
tions A001070/..).
88 | Operation | MS150068/01E 2014-01
3.14 Plant Cleaning

Preconditions
Operating voltage is not applied.
Special tools, Material, Spare parts

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

WARNING
WARNING
NOTICE
Compressed air gun ejects a jet of pressurized air.

Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
Never direct air jet at people.
Always wear safety goggles/face mask and ear defenders.
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
Never direct water jet at people.
Wear protective clothing, protective gloves and safety goggles/face mask.
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.

Entry of dirt and damage to components is possible!
Do not aim compressed air gun directly at seals or electronic components such as connectors
or ECUs.
Plant Cleaning
1.
2.
TIM-ID: 0000010171 - 028
3.
4.
Note:
5.
Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).
Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet
unit carefully and observe the safety precautions.
For external cleaning of the plant with water or steam-jet cleaners:
The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
A minimum distance between spray nozzle and plant of 1 m must be observed.
The temperature of the cleaning medium must not exceed 80C.
For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Never aim compressed air directly at electronic components.
Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.
MS150068/01E 2014-01 | Operation | 89
4 Maintenance
4.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
Maintenance tasks
W0500
Check engine oil level.
( Page 218)
W0501
Visually inspect engine for leaks and general condition.
( Page 78)
W0502
Check intercooler drain(s).
( Page 213)
W0503
Check maintenance indicator of air filter.
( Page 216)
W0504
Check telltale bores of HP fuel pump .
( Page 78)
W0505
Check relief bores of water pump(s).
( Page 241)
W0506
Check engine for abnormal running noises, exhaust color

and vibrations.
( Page 78)
W0507
Drain water and contaminants from fuel prefilter.
( Page 78)
Check reading on differential pressure gage of fuel prefilter.
( Page 78)
Replace fuel filter or fuel filter element.
( Page 187)
Replace air filter.
( Page 214)
Replace fuel injectors.
( Page 179)
Replace engine oil filter when changing engine oil, or when

the interval (years) is reached, at the latest.
( Page 223)
W1009
Check layer thickness of the oil residue, clean out and replace filter sleeve each time the oil is changed at the latest.
( Page 227)
W1011
Perform endoscopic examination.
( Page 165)
W0508
W1001
W1005
W1006
W1008
W1016
Check condition of coupling.
( Page 251)
W1047
Check and clean oil indicator filter.
( Page 225)
W1076
Clean compressor wheel.
( Page 205)
W1207
Check valve clearance and adjust as necessary. ATTENTION! ( Page 173)

First adjustment after 1,000 operating hours and after 1,000
operating hours following cylinder head overhaul.
W1244
Check function of rod electrode.
( Page 255)
W1245
Check alarm function of differential pressure gage.
( Page 254)
W1246
Check pump capacity.
( Page 256)
Check general condition of engine mounting (visual inspection).
( Page 250)
Overhaul preheater.
( Page 247)
W1463
W1477
W1481
W1581
Replace intermediate fuel filter or intermediate fuel filter ele- ( Page 186)
ment.
X
Replace impactors.
90 | Maintenance | MS150068/01E 2014-01
( Page 171)
TIM-ID: 0000048360 - 001
Task
Option
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
W1675
W1713
Option
Task
Maintenance tasks
Replace fuel prefilter or fuel prefilter element.
( Page 195)
Injector: Reset drift correction parameter (CDC).
( Page 266)
TIM-ID: 0000048360 - 001
Table 1: Maintenance task reference table [QL1]
MS150068/01E 2014-01 | Maintenance | 91
5 Troubleshooting
5.1 Troubleshooting
Engine does not turn when starter is actuated
Cause
Corrective action
Battery low or faulty
u Charge or replace (see separate documentation).
Battery: Cable connections

faulty
u Check firm seating of cable connections (see separate

documentation).
Engine cabling or starter faulty
u Check firm seating of cable connections, contact Service.
Engine cabling defective
u Check ( Page 265).
Loose plug connections on

engine governor
u Check plug connections ( Page 268).
Loose plug connections on

Engine Interface Module (EIM)
u Check plug connections ( Page 270).
Fuse F1 ( Page 259)in engine

wiring harness defective (fuse
lamp on EIM flashes with
relevant flashing code)
u Check fuse (replace if required) and re-start the system by

actuating the key switch.
Running gear blocked (engine

cannot be barred manually)
u Contact Service.
Engine turns on starting but does not fire

Cause
Corrective action
Poor rotation by starter: Battery

low or faulty
u Charge or replace battery (see separate documentation).
Engine governor defective
u Contact Service.
Engine fires unevenly

Corrective action
Injector faulty
u Replace ( Page 179).
u Contact Service.
Engine does not reach nominal speed

Cause
Corrective action
Easy-change fuel filter clogged
Air supply: Air filter clogged
u Check signal ring position of service indicator ( Page 216).
Fuel injection: Injector faulty
Engine: Overload
u Contact Service.
92 | Troubleshooting | MS150068/01E 2014-01
TIM-ID: 0000010520 - 004
Cause
Engine speed not steady

Cause
Corrective action
Speed transmitter defective
u Contact Service.
u Contact Service.
Charge-air temperature too high

Cause
Corrective action
Incorrect coolant concentration
u Check (MTU test kit).
Intercooler dirty
u Contact Service.
Engine room: Air-intake

temperature too high
u Check fans and air supply/ventilation ducts.
Charge-air pressure too low

Cause
Corrective action
Intercooler dirty
u Contact Service.
Exhaust turbocharger defective
u Contact Service.
Coolant leaks at intercooler

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

Cause
Corrective action
Engine: Overload
u Contact Service.
Blue exhaust gas
TIM-ID: 0000010520 - 004
Cause
Corrective action
Too much oil in engine
u Drain engine oil ( Page 219).
Oil separator or oil-preseparator

of crankcase breather clogged
u Replace.
Exhaust turbocharger, cylinder

head, piston rings, cylinder liner
defective
u Contact Service.
MS150068/01E 2014-01 | Troubleshooting | 93
White exhaust gas

Cause
Corrective action
u Run engine to reach operating temperature.
Intercooler leaky
u Contact Service.
TIM-ID: 0000010520 - 004
Engine is not at operating

temperature
5.2 Fuel treatment system Troubleshooting

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

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

Cause
The differential pressure
exceeded 1.3 bar.
Corrective action
u Replace coalescer filter element ( Page 257).
Illuminated pushbutton 'Replace filter element' is lit.
TIM-ID: 0000007734 - 008
Cause
The max. permissible differential
pressure of 1.5 bar was
exceeded. If the coalescer filter
element is not replaced,
pressure will increase further
and the safety valve will open.
Fuel will be led via the bypass
directly into the overflow tank.
Corrective action
1. Replace coalescer filter element ( Page 257).
2. Press illuminated pushbutton 'Replace filter element' for
acknowledgment.
5.3 Engine governor ADEC (ECU 7) fault messages for Series 4000
engines, marine application
The fault code numbers are generated by the engine governor and transmitted to the display below (if
fitted).
The fault code (1) comprises 3 digits.

Fault messages may also be caused by faulty sensors/actuators. Contact Service to have sensors/
actuators tested and replaced as necessary if troubleshooting as described in the table ( Page 97)
proves unsuccessful.
For explanations of alarm configuration parameters, refer to PR 2.8008.100.
TIM-ID: 0000016867 - 006
Fault code list ( Page 97).
5.4 Engine governor ADEC (ECU 7) Fault codes

3 HI T-Fuel
ZKP-Number: 2.0122.931
Fuel temperature too high (limit value 1)
Yellow alarm; warning
Cause
Fuel tank may be exposed to
heat.
Corrective action
1. Reduce power.
2. Contact Service.
4 SS T-Fuel
Fuel temperature too high (limit value 2)
Red alarm; engine shutdown
Cause
Fuel tank may be exposed to
heat.
Corrective action
u Contact Service.
5 HI T-Charge Air
Charge-air temperature too high (limit value 1)
Cause
Charge-air cooler not
functioning correctly.
Corrective action
1. Reduce power.
2. Check charge-air cooler.
3. Contact Service.
6 SS T-Charge Air
Charge-air temperature too high (limit value 2)
TIM-ID: 0000045495 - 001
Cause
Charge-air cooler not
functioning correctly.
Corrective action
1. Check charge-air cooler.
2. Contact Service.
9 HI T-Coolant charge-air cooler

Coolant temperature in charge-air cooler too high (limit value 1)
Cause
Coolant circuit for charge air
defective.
Corrective action
1. Reduce power.
2. Check charge-air cooler and coolant cooler.
3. Contact Service.
10 SS T-Coolant charge-air cooler

Coolant temperature in charge-air cooler too high (limit value 2)
Cause
Coolant circuit for charge air
defective.
Corrective action
1. Check charge-air cooler and coolant cooler.
2. Contact Service.
15 LO P-Lube Oil
Lube-oil pressure too low (limit value 1)
Cause
Insufficient oil.
Corrective action
1. Check oil level, top up as necessary ( Page 218).
2. Contact Service.
16 SS P-Lube Oil
Lube-oil pressure too low (limit value 2)
Insufficient oil.
Corrective action
2. Acknowledge alarm.
3. Restart engine ( Page 77).
4. Contact Service.
TIM-ID: 0000045495 - 001
Cause
19 HI T-Exhaust A
Exhaust temperature too high, A-side (limit value 1)
Cause
Wiring damage.
Corrective action
1. Check air filter and wiring ( Page 265).
2. Contact Service.
20 SS T-Exhaust A
Exhaust temperature too high, A-side (limit value 2)
Cause
Wiring damage.
Corrective action
2. Contact Service.
21 HI T-Exhaust B
Exhaust temperature too high, B-side (limit value 1)
Cause
Wiring damage.
Corrective action
2. Contact Service.
22 SS T-Exhaust B
Exhaust temperature too high, B-side (limit value 2)
Cause
TIM-ID: 0000045495 - 001
Wiring damage.
Corrective action
2. Contact Service.
23 LO Coolant Level
Coolant level too low (limit value 1)
Cause
Leak in coolant circuit.
Corrective action
u Check coolant level in expansion tank ( Page 234).
25 HI P-Diff. Lube Oil

Differential oil pressure at oil filter too high (limit value 1)
Cause
Oil filter not functioning
correctly.
Corrective action
u Replace oil filter ( Page 223).
26 HI P-Diff. Lube Oil

Differential oil pressure at oil filter too high (limit value 2)
Cause
Oil filter not functioning
correctly.
Corrective action
1. Replace oil filter ( Page 223).
2. Contact Service.
27 HI Level Leakage Fuel

Leak-off fuel level too high (limit value 1)
Cause
Fuel lines leaking.
Corrective action
1. Check fuel system.
2. Contact Service.
29 HI ETC Idle Speed Too High

Cause
Idling speed of one of the
secondary turbochargers is too
high.
Corrective action
u Contact Service.
Engine overspeed (limit value 2)
Cause
No fuel injection.
Corrective action
1. Restart engine. Fault can possibly be eliminated by a restart
( Page 77).
2. Contact Service.
TIM-ID: 0000045495 - 001
30 SS Engine Overspeed
31 HI ETC1 Overspeed
Speed of primary turbocharger too high (limit value 1)
Cause
Clogged charge-air circuit or
fault in turbocharger.
Corrective action
1. Reduce power.
2. Check air filter.
3. Contact Service.
32 SS ETC1 Overspeed
Speed of primary turbocharger too high (limit value 2)
Cause
Corrective action
1. Check air filter.
2. Contact Service.
33 HI P-Diff-Fuel
Fuel filter differential oil pressure too high (limit value 1)
Cause
Fuel filter not functioning
correctly.
Corrective action
1. Replace fuel filter ( Page 187).
2. Contact Service.
34 SS P-Diff-Fuel
Fuel filter differential oil pressure too high (limit value 2)
Cause
TIM-ID: 0000045495 - 001
Fuel filter not functioning

correctly.
Corrective action
2. Contact Service.
Speed of 1st secondary turbocharger too high (limit value 1)
Cause
Corrective action
1. Reduce power.
2. Contact Service.
Speed of 1st secondary turbocharger too high (limit value 2)
Cause
Corrective action
u Contact Service.
38 AL ETC Speed Deviation

Cause
Synchro fault between primary
turbocharger and one of the
secondary turbochargers.
Corrective action
u Contact Service.
39 AL ETC2 Cut-in Fault

Cause
ETC2 failed to cut in.
Corrective action
u Contact Service.
44 LO Coolant Level Charge-Air Cooler

Coolant level of charge-air cooler too low (limit value 1)
Cause
Insufficient charge-air coolant,
e.g. due to leaks in the chargeair coolant circuit.
Corrective action
1. Check coolant level ( Page 234).
2. Contact Service.
51 HI T-Lube Oil
Lube oil temperature too high (limit value 1)
Cause
Insufficient oil.
Corrective action
1. Reduce power.
2. Check engine oil level ( Page 218).
3. Contact Service.
TIM-ID: 0000045495 - 001
52 SS T-Lube Oil
Lube oil temperature too high (limit value 2)
Cause
Insufficient oil.
Corrective action
1. Check engine oil level ( Page 218).
2. Contact Service.
57 LO P-Coolant
Coolant pressure too low (limit value 1).
Cause
Corrective action
2. Check coolant circuit.
58 SS P-Coolant
Coolant pressure too low (limit value 2)
Red alarm - engine stop or reduced injection quantity
Cause
Corrective action
59 SS T-Coolant L3
Coolant temperature too high / low (limit value 3)
Red alarm; forced idle
Cause
TIM-ID: 0000045495 - 001
Coolant circuit not functioning

correctly (e.g. damage, leaks,
low coolant level).
Corrective action
1. Activate fan emergency operating mode if required.
2. Allow engine to cool down.
3. Check coolant cooler, clean if dirty.
6. Contact Service.
60 SS T-Coolant L4
Coolant temperature too high / low (limit value 4)
Cause
low coolant level).
Corrective action
1. Activate fan emergency operating mode if required.
2. Allow engine to cool down.
3. Check coolant cooler, clean if dirty.
6. Contact Service.
63 HI P-Crankcase
Crankcase pressure too high (limit value 1)
Cause
Crankcase exhaust system
clogged or leaking.
Corrective action
1. Reduce power.
2. Replace oil mist fine separator element.
3. Contact Service.
64 SS P-Crankcase
Crankcase pressure too high (limit value 2)
Cause
Crankcase exhaust system
clogged or leaking.
Corrective action
1. Reduce power.
2. Replace oil mist fine separator element.
3. Contact Service.
65 LO P-Fuel
Fuel supply pressure too low (limit value 1)
Cause
Leaking or clogged fuel lines or
fuel filter.
Corrective action
1. Check fuel lines for leakage.
2. Check filter, fuel low-pressure side.
TIM-ID: 0000045495 - 001
66 SS P-Fuel
Fuel supply pressure too low (limit value 2)
Cause
Leaking or clogged fuel lines or
fuel filter.
Corrective action
1. Check fuel lines for leakage.
2. Check filter, fuel low-pressure side.
4. Contact Service.
67 HI T-Coolant
Coolant temperature too high (limit value 1)
Cause
low coolant level).
Corrective action
1. Reduce power.
68 SS T-Coolant
Coolant temperature too high (limit value 2)
Cause
low coolant level).
Corrective action
u Check coolant circuit.
81 AL Rail Leakage
Leak
TIM-ID: 0000045495 - 001
Cause
Corrective action
During start: Insufficient

pressure gradient in rail (HP
system leaking, air in system).
1. Check engine for leaks.

2. Contact Service.
During stop: Pressure gradient

in rail too high.
1. Seal engine system.

2. Contact Service.
82 HI P-Fuel (Common Rail)

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

Rail pressure < set value
Red alarm - DBR fuel limitation
Cause
HP fuel control block defective
or leak in HP system.
Corrective action
u Contact Service.
085 HI T-Recirculation
Recirculation temperature too high (limit value 1)
Cause
Charge-air temperature before
recirculation valve too high.
Corrective action
u Reduce power.
086 SS T-Recirculation
Recirculation temperature too high (limit value 2)
Cause
Charge-air temperature before
recirculation valve too high.
Corrective action
u Reduce power.
89 SS Engine Speed too Low

Engine speed too low
Cause
Various causes possible.
Corrective action
2. Check for additional messages.
3. Contact Service.
TIM-ID: 0000045495 - 001
90 SS Starter Speed Not Reached

Idling speed not attained
Red alarm; warning
Cause
Corrective action
2. Contact Service.
91 SS Release Speed Not Reached

Runup speed was not attained
Red alarm; warning
Cause
Corrective action
2. Contact Service.
92 SS Starter Speed Not Reached

Starter speed not reached
Red alarm; warning
Cause
Starter rotates too slowly or
does not rotate at all.
Corrective action
2. Contact Service.
93 SS T-Preheat
Preheating temperature too low (limit value 2)
Red alarm; engine start interlock
Cause
TIM-ID: 0000045495 - 001
Preheating unit not functioning.
Corrective action
1. Check preheater.
2. Contact Service.
94 LO T-Preheat
Preheating temperature too low (limit value 1)
Cause
Coolant temperature too low for
engine start because preheating
unit is not functioning.
Corrective action
1. Check preheating unit.
2. Contact Service.
95 AL Prelubrication Fault
Oil priming fault
Cause
Corrective action
Priming oil pressure not

reached.
1. Check priming system.

2. Contact Service.
102 AL Fuel Cons. Counter Defect

Error in fuel consumption checksum
Cause
Corrective action
u Contact Service.
Consumption meter faulty.
104 AL Eng Hours Counter Defect

Operating hours monitoring system faulty
Cause
Corrective action
u Contact Service.
Hour meter faulty.
118 LO ECU Power Supply Voltage

Supply voltage too low (limit value 1)
Cause
Corrective action
Supply voltage at engine

governor too low.
1. Check engine governor supply voltage.

2. Contact Service.
119 LOLO ECU Power Supply Voltage

Supply voltage too low (limit value 2)
Red alarm; start cancelation
Cause
governor too low.
Corrective action
1. Check Engine Control Unit supply voltage.
2. Contact Service.
TIM-ID: 0000045495 - 001
120 HI ECU Power Supply Voltage

Supply voltage too high (limit value 1)
Cause
governor too high.
Corrective action
2. Contact Service.
121 HIHI ECU Power Supply Voltage

Supply voltage too high (limit value 2)
Red alarm - start cancelation of engine stop
Cause
governor too high.
Corrective action
2. Contact Service.
122 HI T-ECU
Electronics temperature too high (limit value 1).
Cause
Electronics overheated.
Corrective action
1. Reduce power.
2. Improve engine room ventilation.
141 AL Power too high

Maximum value exceeded
Cause
TIM-ID: 0000045495 - 001
Power mean value has exceeded

the specified maximum value in
the last 24 hours.
Corrective action
u Contact Service.
142 AL MCR exceeded 1 hour

MCR exceeded
Cause
MCR was exceeded in the last
12 hours for longer than one
hour.
Corrective action
u Contact Service.
176 AL LifeData not available

No (matching) LifeData backup system available
Cause
After a wait time has elapsed
after ECU reset: Backup system
has no LifeData function or CAN
bus to backup system
disconnected.
Corrective action
u Contact Service.
177 AL LifeData restore incomplete

Cause
This error message is generated
if a CRC is faulty during a data
upload (to the engine governor)
(indicated for each indiv.
module).
Corrective action
u Contact Service.
180 AL CAN1 Node Lost

Connection to a node on CAN bus 1 failed
Cause
Connection or communication
with a node on CAN bus 1 has
failed.
Corrective action
1. Check devices connected to CAN.
3. Contact Service.
181 AL CAN2 Node Lost

Connection to a node on CAN bus 2 failed
Cause
Connection or communication
with a node on CAN bus 2 has
failed.
Corrective action
3. Contact Service.
TIM-ID: 0000045495 - 001
182 AL CAN Wrong Parameters

Incorrect parameters on CAN
Cause
Wrong parameter value entered
in data record.
Corrective action
u Contact Service.
183 AL CAN No PU-Data

CAN PU data not present or available
Cause
The selected CAN mode
initializes communication by
means of the application
environment data module. A
faulted occurred during an
attempt to copy a received data
module to the engine governor.
Corrective action
2. Contact Service.
184 AL CAN PU-Data Flash Error

CAN PU data flash error
Cause
A program fault occurred while
trying to copy a received PU
data module into the flash
module.
Corrective action
u Contact electronic Service.
186 AL CAN1 Bus Off

CAN controller 1 is in "Bus-Off" status
TIM-ID: 0000045495 - 001
Yellow alarm; automatic changeover to CAN 2

Cause
Short circuit, massive
interference or Baud rate
incompatibility.
Corrective action
1. Check CAN bus for short circuit, rectify short circuit as
necessary.
2. Check shielding, improve shielding as necessary.
3. Contact Service.
187 AL CAN1 Error Passive

CAN controller 1 error
Cause
Missing associated node, minor
disruptions or temporary bus
overload.
Corrective action
necessary.
3. Contact Service.
188 AL CAN2 Bus Off

CAN controller 2 is in "Bus-Off" status
Yellow alarm; automatic changeover to CAN 1
Cause
Short circuit, massive
interference or Baud rate
incompatibility.
Corrective action
necessary.
3. Contact Service.
189 AL CAN2 Error Passive

CAN controller 2 error
Cause
Missing associated node, minor
disruptions or temporary bus
overload.
Corrective action
necessary.
3. Contact Service.
190 AL EMU Parameter Not Supported

EMU parameters are not

supported. ==> Incompatibility
Corrective action
u Contact Service.
TIM-ID: 0000045495 - 001
Cause
201 SD T-Coolant
Signal error, coolant temperature sensor
Cause
Corrective action
Coolant temperature sensor

faulty.
Short circuit or wire break.
1. Check sensor and wiring (B6), replace as necessary

( Page 265).
2. Fault is rectified when engine is restarted ( Page 77).
3. Contact Service.
202 SD T-Fuel
Signal error, fuel temperature sensor
Cause
Fuel temperature sensor faulty.
Corrective action
( Page 265).
3. Contact Service.
203 SD T-Charge Air

Signal error, charge-air temperature sensor
Cause
Charge air temperature sensor
faulty.
Corrective action
( Page 265).
2. Fault is rectified when engine is restarted. ( Page 77)
3. Contact Service.
204 SD Level Lube Oil

Signal error, lube oil level sensor
TIM-ID: 0000045495 - 001

Cause
Lube oil level sensor faulty.
Corrective action
1. Check sensor and wiring, replace as necessary ( Page 265).
3. Contact Service.
205 SD T-Coolant Charge-Air Cooler

Signal error, coolant temperature sensor
Cause
Coolant pressure sensor of
charge-air cooler faulty.
Corrective action
( Page 265).
3. Contact Service.
206 SD T-Exhaust A
Signal error, exhaust temperature sensor on A side
Cause
Exhaust temperature sensor on
A side faulty.
Corrective action
1. Check sensor and wiring (B4.21), replace as necessary
( Page 265).
3. Contact Service.
207 SD T-Exhaust B
Signal error, exhaust temperature sensor on B side
Cause
B-side faulty.
Corrective action
( Page 265).
3. Contact Service.
208 SD P-Charge Air

Signal error, charge-air pressure sensor
Cause
Charge air pressure sensor
faulty.
Corrective action
( Page 265).
3. Contact Service.
TIM-ID: 0000045495 - 001
211 SD P-Lube Oil

Signal error, lube oil pressure sensor
Cause
Corrective action
Lube-oil pressure sensor faulty.


( Page 265).
3. Contact Service.
212 SD P-Coolant
Signal error, coolant pressure sensor
Cause
Coolant pressure sensor faulty.
Corrective action
( Page 265).
3. Contact Service.
213 SD P-Coolant Charge-Air Cooler

Charge-air cooler coolant pressure sensor faulty
Cause
Charge-air cooler coolant
pressure sensor faulty.
Corrective action
( Page 265).
3. Contact Service.
214 SD P-Crankcase
Signal error, crankcase pressure sensor
TIM-ID: 0000045495 - 001

Cause
Crankcase pressure sensor
faulty.
Corrective action
( Page 265).
3. Contact Service.
215 SD P-HD
Signal error, rail pressure sensor
Yellow alarm; high-pressure regulator emergency operation
Cause
Rail pressure sensor faulty. ==>
high-pressure regulator
emergency operation.
Corrective action
( Page 265).
3. Contact Service.
216 SD T-Lube Oil

Signal error, lube oil temperature sensor
Cause
Lube oil temperature sensor
faulty.
Corrective action
( Page 265).
3. Contact Service.
219 SD T-Intake Air

Signal error, intake air temperature sensor
Cause
Intake air temperature sensor
faulty.
Corrective action
1. Check sensor and cabling (B3), replace as necessary
( Page 265).
3. Contact Service.
220 SD Level Coolant Water

Signal error, coolant level sensor
Cause
Coolant level sensor faulty.
Corrective action
1. Check sensor and cabling (F33), replace as necessary
( Page 265).
3. Contact Service.
TIM-ID: 0000045495 - 001
221 SD P-Diff Lube Oil

Signal error, lube oil differential pressure sensor faulty
Cause
Corrective action
Lube oil differential pressure

sensor faulty.
1. Check sensor and cabling (F25), replace as necessary

( Page 265).
3. Contact Service.
222 SD Level Leak-off Fuel

Signal error, leak fuel level sensor
Cause
Leak fuel level sensor faulty.
Corrective action
1. Check sensor and wiring (F46), replace as necessary
( Page 265).
3. Contact Service.
223 SD Level Coolant Charge-Air Cooler

Charge-air cooler coolant level sensor faulty
Cause
Charge-air cooler coolant level
sensor faulty.
Corrective action
1. Check sensor and wiring (F57), replace as necessary
( Page 265).
3. Contact Service.
227 SD P- Lube Oil before Filter

Signal error, lube oil pressure sensor before filter
TIM-ID: 0000045495 - 001

Cause
Lube oil pressure sensor before
filter faulty.
Corrective action
( Page 265).
3. Contact Service.
228 SD P-Fuel before Filter

Signal error, fuel pressure sensor
Cause
Fuel pressure sensor faulty.
Corrective action
( Page 265).
3. Contact Service.
229 AL Stop Camshaft Sensor Defect

Stop signal error, camshaft sensor
Cause
Camshaft sensor faulty (and a
fault that occurred previously in
the crankshaft sensor in the
same operating cycle).
Corrective action
1. Check sensor and wiring to connector B1, replace as necessary
( Page 265).
3. Contact Service.
230 SD Crankshaft Speed

Signal error, crankshaft sensor
Cause
Crankshaft sensor faulty.
Corrective action
( Page 265).
3. Contact Service.
231 SD Camshaft Speed

Signal error, camshaft sensor
Cause
Camshaft sensor faulty.
Corrective action
( Page 265).
3. Contact Service.
TIM-ID: 0000045495 - 001
232 SD Charger 1 Speed

Signal error, primary turbocharger speed sensor
Cause
Speed sensor of primary
turbocharger faulty.
Corrective action
( Page 265).
3. Contact Service.
233 SD Charger 2 Speed

Signal error, secondary turbocharger speed sensor
Cause
Speed sensor of secondary
turbocharger faulty.
Corrective action
( Page 265).
3. Contact Service.
239 SD P-Diff Fuel

Differential pressure sensor for fuel faulty (only occurs with SD alarm 'fuel before filter' or 'fuel after
filter'.
Cause
Fuel differential pressure sensor
faulty.
Corrective action
u Check for additional messages.
240 SD P-Fuel
Signal error, fuel pressure sensor
TIM-ID: 0000045495 - 001
Cause
Fuel pressure sensor faulty.
Corrective action
( Page 265).
3. Contact Service.
241 SD T-Recirculation
Cause
Recirculation sensor faulty;
Corrective action
u Check sensor and wiring (B49), replace as necessary.
Fault is rectified following engine restart.
242 SD T-Coolant (R)

Cause
Redundant coolant pressure
sensor faulty; Short circuit or
wire break.
Corrective action
u Check sensor and wiring, replace as necessary.
244 SD P-Lube Oil (R)

Cause
Redundant lube oil pressure
sensor faulty; Short circuit or
wire break.
Corrective action
245 SD ECU Power Supply Voltage

Signal error, engine governor supply voltage
Cause
Internal ECU fault. Electronics
faulty.
Corrective action
1. Replace Engine Control Unit.
2. Contact Service.
266 SD Speed Demand

Speed setting signal error
Analog speed setpoint faulty.

Corrective action
1. Check speed setting transmitter and wiring, replace as
necessary ( Page 265).
3. Contact Service.
TIM-ID: 0000045495 - 001
Cause
268 SD Spinning Value

Skid signal error
Cause
Analog skid signal faulty.
Corrective action
3. Contact Service.
269 SD Loadp.Analog filt.

Load pulse analog signal faulty
Cause
The filtered analog signal from
the load pulse is not present.
Corrective action
1. Check wiring, replace as necessary ( Page 265).
3. Contact Service.
270 SD Frequency Input

Signal error, frequency input
Cause
Frequency input faulty.
Corrective action
2. Check speed demand transmitter.
3. Contact Service.
301 AL Timing Cylinder A1

Time-of-flight measuring fault of injector
Cause
TIM-ID: 0000045495 - 001
Flight time value extremely low

or extremely high.
Corrective action
u Replace injector if the fault message appears frequently
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).


or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).
TIM-ID: 0000045495 - 001
Cause

Cause
or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).
311 AL Timing Cylinder B1

Cause
or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).

TIM-ID: 0000045495 - 001
Cause
or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).


or extremely high.
Corrective action
( Page 179).

Cause
or extremely high.
Corrective action
( Page 179).
TIM-ID: 0000045495 - 001
Cause
321 AL Wiring Cylinder A1

Wiring fault cylinder A1
Yellow alarm; misfire
Cause
Short circuit fault in injector
wiring cylinder A1.
Corrective action
1. Check injector solenoid, replace injector if necessary
( Page 179).
3. Contact Service.

Cause
wiring cylinder A2.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder A3.
Corrective action
( Page 179).
3. Contact Service.

TIM-ID: 0000045495 - 001

Cause
wiring cylinder A4.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder A5.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder A6.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder A7.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder A8.
Corrective action
( Page 179).
3. Contact Service.
TIM-ID: 0000045495 - 001

Cause
wiring cylinder A9.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder A10.
Corrective action
( Page 179).
3. Contact Service.
331 AL Wiring Cylinder B1

Wiring fault cylinder B1
Cause
wiring cylinder B1.
Corrective action
( Page 179).
3. Contact Service.

TIM-ID: 0000045495 - 001

Cause
wiring cylinder B2.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder B3.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder B4.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder B5.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder B6.
Corrective action
( Page 179).
3. Contact Service.
TIM-ID: 0000045495 - 001

Cause
wiring cylinder B7.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder B8.
Corrective action
( Page 179).
3. Contact Service.

Cause
wiring cylinder B9.
Corrective action
( Page 179).
3. Contact Service.

TIM-ID: 0000045495 - 001

Cause
wiring cylinder B10.
Corrective action
( Page 179).
3. Contact Service.
341 AL Open Load Cylinder A1

Injector wiring fault cylinder A1
Cause
Disruption fault in injector wiring
cylinder A1.
Corrective action
1. Check injector wiring for open circuit.
2. Exclude possible injector solenoid fault, replace injector if
3. Fault rectified after each working cycle.
4. Contact Service.

Cause
cylinder A2.
Corrective action
4. Contact Service.

Cause
cylinder A3.
Corrective action
4. Contact Service.

Cause
cylinder A4.
Corrective action
4. Contact Service.
TIM-ID: 0000045495 - 001

Cause
cylinder A5.
Corrective action
4. Contact Service.

Cause
cylinder A6.
Corrective action
4. Contact Service.

Cause
cylinder A7.
Corrective action
4. Contact Service.

TIM-ID: 0000045495 - 001
Cause
cylinder A8.
Corrective action
4. Contact Service.

Cause
cylinder A9.
Corrective action
4. Contact Service.

Cause
cylinder A10.
Corrective action
4. Contact Service.
351 AL Open Load Cylinder B1

Injector wiring fault cylinder B1
Cause
cylinder B1.
Corrective action
4. Contact Service.

Cause
cylinder B2.
Corrective action
4. Contact Service.
TIM-ID: 0000045495 - 001

Cause
cylinder B3.
Corrective action
4. Contact Service.

Cause
cylinder B4.
Corrective action
4. Contact Service.

Cause
cylinder B5.
Corrective action
4. Contact Service.

TIM-ID: 0000045495 - 001
Cause
cylinder B6.
Corrective action
4. Contact Service.

Cause
cylinder B7.
Corrective action
4. Contact Service.

Cause
cylinder B8.
Corrective action
4. Contact Service.

Cause
cylinder B9.
Corrective action
4. Contact Service.

Cause
cylinder B10.
Corrective action
4. Contact Service.
TIM-ID: 0000045495 - 001
361 AL Power Stage Low

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

Internal electronic fault.
Red alarm; engine shutdown possible
Cause
Electronics faulty.
Corrective action
1. Start ITS.
2. Replace engine governor if required.
5. Contact Service.
363 AL Stop Power Stage

Internal electronic fault.
Cause
1. Start ITS.
2. Replace engine governor.
5. Contact Service.
TIM-ID: 0000045495 - 001
Electronics faulty.
Corrective action
365 AL Stop MV-Wiring Ground

Injector wiring error
Red alarm - engine shutdown via Protection Module possible
Cause
Short circuit of injector positive
connection to ground of one or
more injectors.
Short circuit of the negative
injector connection or of one or
more injectors to ground.
Corrective action
2. Engine restart ( Page 77).
3. Replace wiring harness if necessary ( Contact Service).
371 AL Wiring TO 1
Line disruption
Cause
Short circuit or wire break on
transistor output 1 (TO 1).
Corrective action
1. Check charger valve/wiring, repair as necessary.
372 AL Wiring TO 2
Line disruption
Cause
Corrective action
1. Check recirculation valve/wiring, repair as necessary.
373 AL Wiring TO 3
Line disruption
Cause
Corrective action
u-
Line disruption
Cause
Corrective action
u-
TIM-ID: 0000045495 - 001
374 AL Wiring TO 4
381 AL Wiring TOP 1

Line disruption on digital input 1
Cause
transistor output, plant-side 1
(TOP 1).
Corrective action
u Check wiring to plant.
382 AL Wiring TOP 2

Cause
(TOP 2).
Corrective action
383 AL Wiring TOP 3

Cause
(TOP 3).
Corrective action
384 AL Wiring TOP 4

TIM-ID: 0000045495 - 001
Cause
(TOP 4).
Corrective action
390 AL MCR exceeded

Speed limiter/MCR function: the maximum continuous rate was exceeded
Yellow alarm; engine power limited to permissible continuous power
Cause
Engine was overloaded
continuously.
Corrective action
u With a continuous alarm, contact Service.
392 HI T-Coolant Red

Limit value 1
Cause
Redundant coolant temperature
reading too high.
Corrective action
1. Check wiring.
2. Contact Service.
393 SS T-Coolant Red

Limit value 2
Cause
Redundant coolant temperature
reading too high; engine stop.
Corrective action
1. Check wiring and sensor.
2. Contact Service.
394 LO P-Lube Oil Red

Limit value 1
Cause
reading too low.
Corrective action
2. Contact Service.
395 SS P-Lube Oil Red

Cause
reading too low.
Corrective action
2. Contact Service.
396 TD T-Coolant Sensor Deviation

Cause
Maximum coolant temperature
deviation.
Corrective action
2. Contact Service.
TIM-ID: 0000045495 - 001
Limit value 2
397 TD P-Oil Sensor Deviation

Cause
Maximum lube oil pressure
deviation.
Corrective action
2. Contact Service.
400 AL Open Load Digital Input 1

Cause
Wiring faulty.
No resistance over switch.
Corrective action
2. Check target device input.
3. Contact Service.

Cause
Wiring faulty.
Corrective action
3. Contact Service.

Cause
TIM-ID: 0000045495 - 001
Wiring faulty.
Corrective action
3. Contact Service.

Cause
Wiring faulty.
Corrective action
3. Contact Service.

Cause
Wiring faulty.
Corrective action
3. Contact Service.

Cause
Wiring faulty.
Corrective action
3. Contact Service.

Cause
Wiring faulty.
Corrective action
3. Contact Service.

Wiring faulty.
Corrective action
3. Contact Service.
TIM-ID: 0000045495 - 001
Cause
408 AL Open Load Emerg. Stop Input ESI

Line disruption at input for emergency stop
Cause
Wiring faulty or no resistance
over switch.
Corrective action
3. Contact Service.
410 LO U-PDU
Injector voltage too low (limit value 1)
Cause
Wiring damage or faulty current
supply.
Corrective action
2. Check supply.
3. Contact Service.
411 LOLO U-PDU

Injector voltage too low (limit value 2)
Cause
supply.
Corrective action
2. Check supply.
4. Contact Service.
412 HI U-PDU
Injector voltage too high (limit value 1)
TIM-ID: 0000045495 - 001
Cause
supply.
Corrective action
2. Check supply.
3. Contact Service.
413 HIHI U-PDU

Injector voltage too high (limit value 2)
Cause
supply.
Corrective action
2. Check supply.
4. Contact Service.
414 HI Level Water Fuel Prefilter

Water level in fuel prefilter too high (limit value 1)
Cause
Water content in fuel too high.
Water ingress in fuel tank.
Corrective action
u Empty fuel prefilter.
415 LO P-Coolant Charge-Air Cooler

Coolant pressure in charge-air cooler too low (limit 1)
Cause
Corrective action
u Top up coolant.
416 SS P-Coolant Charge-Air Cooler

Coolant pressure in charge-air cooler too low (limit 2)
Corrective action
u Top up coolant.
417 SD Level Water Fuel Prefilter

Signal error, fuel prefilter water level sensor
Cause
Fuel prefilter water level sensor
faulty.
Corrective action
2. Contact Service.
TIM-ID: 0000045495 - 001
Cause
419 SD T-Coolant b.Engine

Cause
Coolant inlet temperature
sensor faulty. Short circuit or
wire break
Corrective action
u Check sensor and wiring (B3), replace as necessary.
420 AL L1 Aux 1
Limit value 1
Cause
Input signal of Aux 1 has
exceeded/not attained limit
value 1, depending on
configuration.
Corrective action
u Determine cause of limit value violation and rectify fault.
421 AL L2 Aux 1
Limit value 2
Cause
Input signal of Aux 1 has
exceeded/not attained limit
configuration.
Corrective action
428 AL L1 T-Aux 1
Limit value 1
Cause
Temperature signal of Aux 1 has
exceeded / not attained limit
configuration.
Corrective action
TIM-ID: 0000045495 - 001
434 AL L2 P-Aux 1
Limit value 1
Cause
Coolant temperature too high.
Corrective action
u Check coolant circuit.
440 AL L1 P-Aux 1
Limit value 1
Cause
Pressure signal of Aux 1 has
configuration.
Corrective action
442 AL L2 P-Aux 1
Limit value 2
Cause
Pressure signal of Aux 1 has
configuration.
Corrective action
444 SD U-PDU
Injector power stage supply voltage fault
Cause
Sensor defect of injector power
stage, or internal fault of engine
governor.
Corrective action
u Replace Engine Control Unit.
445 SD P-Ambient Air

Signal error, ambient air pressure sensor
Cause
u Replace Engine Control Unit.

TIM-ID: 0000045495 - 001
Ambient air pressure sensor

faulty.
Corrective action
446 SD P-HD2
Signal error, rail pressure sensor
Yellow alarm; high-pressure regulator emergency operation
Cause
Rail pressure sensor faulty.
Corrective action
( Page 265).
2. Contact Service.
448 HI P-Charge Air

Charge-air pressure too high (limit value 1)
Cause
Fault at turbine bypass flap.
Corrective action
u Contact Service.
449 SS P-Charge Air

Charge-air pressure too high (limit value 2)
Cause
Fault at turbine bypass flap.
Corrective action
u Contact Service.
450 SD Idle/End-Torque Input [%]

Signal error, start/end torque
Cause
1. Check signal transmitter and wiring, replace as necessary.

( Page 265)
3. Contact Service.
TIM-ID: 0000045495 - 001
Input signal for start/end torque

faulty.
Corrective action
454 SS Power Reduction Active

Power reduction activated
Red alarm - power reduction activated
Cause
Engine operation outside
standard limit values.
This message has the following
possible causes: Intake
depression, exhaust back
pressure, charge-air coolant
temperature or intake air
temperature outside the limit
values
Corrective action
455 AL L1 Aux1 Plant

Limit value 1
Cause
Input signal of Aux 1 (plant side)
has exceeded/not attained limit
configuration.
Corrective action
456 AL L2 Aux1 Plant

Limit value 2
Cause
Input signal of Aux 1 (plant side)
has exceeded/not attained limit
configuration.
Corrective action
460 HI T-Exhaust EMU

Cause
EMU exhaust gas temperature
value too high.
Corrective action
1. Check wiring.
2. Contact Service.
TIM-ID: 0000045495 - 001
Limit value 1
461 LO T-Exhaust EMU

Limit value 1
Cause
EMU exhaust gas temperature
value too low.
Corrective action
1. Check wiring.
2. Contact Service.
462 HI T-Coolant EMU

Limit value 1
Cause
EMU coolant temperature value
too high / low.
Corrective action
u Check configuration with DiaSys.
464 SD P-AUX 1
Cause
Analog input signal for Aux 1
pressure faulty; short circuit or
wire break.
Corrective action
u Check pressure transmitter and wiring, replace as necessary.
467 AL L2 T-Aux 1
Limit value 2
Cause
Temperature signal of Aux 1 has
configuration.
Corrective action
468 SD T-AUX 1
TIM-ID: 0000045495 - 001
Signal error, temperature Aux 1

Cause
Analog input for Aux 2
temperature faulty.
Corrective action
u-
469 SD AUX 1
Cause
Corrective action
u Check signal sensor and wiring, replace as necessary.
Analog input signal for Aux 1

faulty; short circuit or wire
break.
470 SD T-ECU
Signal error, engine governor temperature
Cause
Corrective action
Temperature sensor for engine

governor faulty.

2. Engine restart ( Page 77).
3. Contact Service.
471 SD Coil Current

Signal error, HP fuel control block
Cause
Corrective action
Actuation of HP fuel control

block faulty.

2. Contact Service.
472 AL Stop SD
Engine stops
Corrective action
Engine stops because 'Sensor

faulty" present at channels.

2. Contact Service.
473 AL Wiring PWM_CM2

Cause
Wire break or short circuit on
channel PWM_CM2.
Corrective action
1. Check wiring.
2. Contact Service.
TIM-ID: 0000045495 - 001
Cause
474 AL Wiring FO
Wiring fault on FO
Cause
Corrective action

channel FO.

2. Contact Service.
475 AL CR Engine Shutdown Trigger

Crash recorder was triggered by an engine shutdown.
Cause
Corrective action
u Contact Service.
Crash recorder was triggered by

an engine shutdown.
476 AL Crash Rec. Init. Error

Initialization error of crash recorder.
Cause
Corrective action
u Contact Service.
Initialization error of crash

recorder.
478 AL Comb. Alarm Yel (Plant)

Yellow combined alarm from system
Cause
Corrective action
479 AL Comb. Alarm Red (Plant)

TIM-ID: 0000045495 - 001
Red combined alarm from system
Red alarm
Cause
Corrective action
480 AL Ext. Engine Protection

External engine protection function active
Cause
The external engine protection
function is active.
Monitoring of plant signal by
ECU active (plant side).
Corrective action
1. Check plant signal.
2. Contact Service.
482 SD T-Exhaust C
Cause
A side faulty. Short circuit or
wire break
Corrective action
u Check sensor and wiring (B4.23), replace as necessary.
483 SD T-Exhaust D
Cause
A side faulty. Short circuit or
wire break
Corrective action
u Check sensor and wiring (B4.24), replace as necessary.
484 HI T-Exhaust C
Limit value 1
Cause
Exhaust gas temperature (Cside) too high.
Corrective action
1. Reduce power.
2. Contact Service.
485 SS T-Exhaust C
Cause
Exhaust gas temperature (Cside) too high.
Corrective action
1. Reduce power.
2. Contact Service.
TIM-ID: 0000045495 - 001
Limit value 2
486 HI T-Exhaust D
Limit value 1
Cause
Exhaust gas temperature (Dside) too high.
Corrective action
1. Reduce power.
2. Contact Service.
487 SS T-Exhaust D
Limit value 2
Cause
Exhaust gas temperature (Dside) too high.
Corrective action
1. Reduce power.
2. Contact Service.

Speed of 2nd secondary turbocharger too high (limit value 1)
Cause
Corrective action
u Reduce power.

Speed of 2nd secondary turbocharger too high (limit value 2)
Cause
Corrective action
u Reduce power.
TIM-ID: 0000045495 - 001
Speed of the 3rd secondary turbocharger too high (limit value 1)
Cause
Corrective action
u Reduce power.

Speed of the 3rd secondary turbocharger too high (limit value 2)
Cause
Corrective action
u Reduce power.
492 AL ETC4 Cutin Failure

Cause
Corrective action
u Check control valve at turbocharger 4.
493 AL ETC3 Cutin Failure

Cause
Corrective action
u Check control valve at turbocharger 3.
500 AL Wiring POM Starter 1

Wiring fault, connection of starter 1 at POM
Cause
Missing consumer.
Short circuit or wire break
Corrective action
u Check connection between POM and starter.
501 AL Wiring POM Starter 2

Wiring fault, connection of starter 2 at POM
Cause
Missing consumer.
Short circuit or wire break
Corrective action
u Check connection between POM and starter.
TIM-ID: 0000045495 - 001
502 AL Open Load POM Battery-charging Generator

Power disruption, battery-charging generator connection of POM
Cause
Wiring faulty or no resistance
over switch.
Corrective action
u Check connection between POM and battery-charging
generator.
503 AL Battery Not Charging

No battery charge
Cause
Battery is not charged by
battery-charging generator.
Corrective action
u Check battery-charging generator and wiring ( Page 265).
504 AL CAN POM Node Failure

POM missing on CAN bus
Cause
If alarm 508 occurs in addition,
the resistor in the POM wiring is
missing.
Corrective action
u Check connection and POM.
506 AL Low Starter Voltage

The battery voltage is too low for the starting process
Cause
TIM-ID: 0000045495 - 001
Wiring faulty or battery is flat.
Corrective action
u Check starter battery and wiring ( Page 265).
507 AL POM Fault

A general POM fault occurred.
Cause
Fault in POM.
Corrective action
u Replace POM.
508 AL Incorrect POM ID

POM sends a different ID number than expected
Cause
Corrective action
u Check POM wiring harness.
If alarm 504 occurs in addition,

the resistor in the POM wiring is
missing.
510 AL Override applied

Override was activated
Cause
Corrective action
u Deactivate Override pushbutton again.
Override suppresses other

alarms.
515 AL Starter Not Engaged

Yellow alarm - possible start cancelation
Cause
Corrective action
Starter on POM could not be

engaged.
1. Repeat start.
2. Check POM, starter and wiring ( Page 265).
3. Contact Service.
519 Oil Level Calibration Error

Error writing calibration value into flash or SD of level sensor.
Corrective action
Oil level sensor or wiring faulty.

2. Contact Service.
531 AL Wiring PWM_CM1

Red alarm
Cause
channel PWM_CM1.
Corrective action
u Check wiring to TecJet throttle, replace TecJet throttle if
necessary.
TIM-ID: 0000045495 - 001
Cause
532 AL Wiring PWM1

Red alarm
Cause
channel PWM1.
Corrective action
u Check wiring to mixture throttle on A side, replace mixture
throttle on A side if necessary.
533 AL Wiring PWM2

Red alarm
Cause
channel PWM2.
Corrective action
u Check wiring to mixture throttle on B side, replace mixture
throttle on B side if necessary.
543 AL Multiple FDH Slaves

Yellow alarm
Cause
There is more than one device
activated as backup medium for
FDH.
Corrective action
u Contact Service (configuration fault).
544 AL Configuration Changed

Yellow alarm
Cause
This alarm is activated when the
system configuration was
changed, e.g. because the ECU
or SAM was exchanged.
Corrective action
u Contact Service (configuration fault).
549 AL Power Disruption
TIM-ID: 0000045495 - 001
Alarm from the emergency stop counter function
Cause
Engine governor power has been
disconnected with the engine
still running. This may lead to
overpressure in the HP system
which can damage the engine.
Corrective action
u Instruct operators to switch off the power supply only after the
engine has come to a standstill.
551 SS Engine Overspeed Camshaft

Limit value 2
Cause
Camshaft overspeed.
Corrective action
2. Attempt engine restart.
555 AL Call MTU Field Service

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

Engine overload
Cause
Violation of corrected MCR or
DBR/MCR curve.
Corrective action
u Reduce power.
577 SD T-Lube Oil Pan

Cause
Oil pan temperature sensor
faulty.
Corrective action
u Check sensor and cabling, replace as necessary ( Page 265).
TIM-ID: 0000045495 - 001
Signal error, oil pan temperature sensor
582 AL Emergency Stop Failure

Emergency stop command was not executed
Flashing pre-alarm and alarm
Cause
Engine speed does not come to
a standstill within a configurable
period.
Corrective action
u Contact Service.
584 AL CAN Start clearance failed

Cause
Yellow alarm; warning; CAN
object Start clearance was not
received within the expected
time period.
Corrective action
u Contact Service.
586 LO P-Oil Refill Pump

Oil pressure in refill pump is too low - limit value 1
Cause
Oil level in oil refill tank too low.
Corrective action
2. Contact Service.
588 SD P-Oil Refill Pump

Signal error, refill pump oil pressure sensor
Cause
Pressure sensor defective.
Corrective action
2. Contact Service.
TIM-ID: 0000045495 - 001
593 AL T-Lube Oil in Oil Pan too Low

Lube oil temperature in oil pan is too low.
Cause
Preheating time is insufficient.
Corrective action
1. Extend preheating period.
2. Contact Service.
596 AL Test Parameters

Cause
The parameter set is used for
trials. The alarm remains set
until a series parameter set is
loaded.
Corrective action
u Contact Service.
600 SD T-Exhaust A+B

Signal error, exhaust temperature sensor A- and B-side
Cause
A- and B-side faulty.
Corrective action
2. Contact Service.
601 SD ETC1+ETC2
Signal error, ETC speed sensor 1 and 2
Cause
ETC speed sensors 1 and 2
faulty.
Corrective action
2. Contact Service.
602 AL CAN Engine Start Lock

Start interlock from plant pending
Start interlock initiated by plant.
Corrective action
u The alarm is reset by canceling the engine start instruction or
the CAN request.
TIM-ID: 0000045495 - 001
Cause
606 AL Double Nodes Lost CAN 1+2

ECU does not detect a monitored CAN bus.
Cause
A node on both CANs has failed.
Corrective action
1. Check wiring and power supply of plant ( Page 265).
4. Contact Service.
614 AL L1 P-Fuel Supp. Filt. Diff.

Fuel prefilter differential pressure too high
Cause
Fuel prefilter not functioning
correctly.
Corrective action
1. Replace fuel prefilter.
2. Contact Service.
625 SD P-Fuel b. Supp. Filter

Signal error, fuel pressure sensor before supplementary filter
Cause
Analog input signal for fuel
pressure before supplementary
filter faulty.
Corrective action
1. Check pressure transmitter and wiring, replace as necessary
( Page 265).
3. Contact Service.
641 AL System Restart by Watchdog

System is restarted by watchdog
TIM-ID: 0000045495 - 001
Cause
System restart by watchdog
detected.
Corrective action
u-
687 SD Oil Level Switch

Level switch faulty
Cause
Lube oil level switch is faulty.
==> Short circuit or wire break.
Corrective action
1. Check sensor and wiring (B24), replace as necessary. Alarm is
reset when fault is eliminated ( Page 265).
2. Contact Service.
690 AL Oil Level too Low

Cause
Alarm, lube oil level is too low.
Corrective action
u-
759 AL L1 T-Fuel b. Engine

Fuel before engine (limit 1)
Cause
Fuel temperature before engine
too high.
Corrective action
u-
760 AL L2 T-Fuel b. Engine

Fuel before engine (limit 2)
Cause
Fuel temperature before engine
too high.
Corrective action
u-
761 SD T-Fuel b. Engine

Cause
Oil pan temperature sensor
faulty.
==> Short circuit or wire break.
Corrective action
1. Check sensor and wiring (B24), replace as necessary.
( Page 265).
2. Contact Service.
782 SD P-Lube oil ETC A

Cause
SD turbocharger lube oil
pressure.
Corrective action
u-
Cause
The cyl. cutout system has
detected an invalid turbocharger
speed at turbochargers 1 or 2.
Corrective action
u-
TIM-ID: 0000045495 - 001
788 Cyl. cutout detects turbocharger speed error
850 SD Alive FIP

Frequency input faulty.
Cause
Fault in Backup ECU, Alive signal
not transmitted
Corrective action
u-
856 SD P-Lube oil ETC B

Cause
ETC oil pressure sensor faulty.
Corrective action
858 AL L1 P-Lube Oil ETC B

Limit value 1
Cause
Lube oil pressure too low.
Corrective action
u Check ETC oil lubrication.
867 AL L1 P-Lube Oil ETC A

Limit value 1
Cause
Corrective action
868 AL L2 P-Lube Oil ETC A

Limit value 2
Cause
Corrective action
TIM-ID: 0000045495 - 001
869 AL L2 P-Lube Oil ETC B

Limit value 2
Cause
Corrective action
6 Task Description
6.1 Engine
6.1.1
Engine Barring manually

Preconditions

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

Before barring the engine, make sure that there are no persons in the engine's danger zone.
After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
Barring engine manually

Release screws (1) and remove end cover (2) from flywheel housing.
TIM-ID: 0000000917 - 010
1.
162 | Task Description | MS150068/01E 2014-01
2.
3.
Note:
4.
Result:
No resistance other than compression resistance must be encountered.

Rotate crankshaft in engine direction of rotation.
If the resistance exceeds the normal compression resistance, contact Service.
Barring device is removed by same procedure in reverse.
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5.
Engage barring device (2) in ring gear of flywheel and mount on flywheel housing.
Fit ratchet (1) onto barring device (2).
MS150068/01E 2014-01 | Task Description | 163
6.1.2
Engine Barring with starting system

Barring using the automation system
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6.2 Cylinder Liner

6.2.1
Cylinder liner Endoscopic examination

Preconditions
Engine is stopped and starting disabled

Designation / Use
Rigid endoscope
Part No.
Qty.
Y20097353
Preparatory steps
1.
2.
Remove cylinder head cover ( Page 176).

Remove injector ( Page 180).
Positioning crankshaft at BDC

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

Findings
Task
No action required.
Thin carbon coating around circumference of carbon scraper ring
Slight localized additive deposits at top edge
Localized smooth areas at bottom edge
Carbon deposits around circumference between top piston ring and
bottom edge of carbon scraper ring
First signs of marks left by top piston ring
Bright mark around circumference
Faultless, even honing pattern
First signs of marks left by lower cooling bores
Running pattern seems darker
Darker areas of even or varying color intensity

Beginning and end of the discoloration are not sharply defined and
do not cover the entire stroke area
Further endoscopic examination required as part of maintenance work.
Dark areas in the upper section of the cooling bore, remaining cir-
cumference cannot be faulted

Piston rings faultless
On the entire circumference not only bright discoloration (not critiTIM-ID: 0000000015 - 016
cal for operation) clearly visible darker stripes that begin at the top
piston ring
Heat discoloration in the direction of stroke and honing pattern
damage
Heat discoloration of piston rings
1.
2.
3.
Cylinder liner must be replaced,

contact Service.
Compile endoscopy report using the table.

Use technical terms for description of the liner surface ( Page 167).
Depending on findings:
Do not take any action or
Carry out further endoscopic examination as part of maintenance work or
Contact Service; cylinder liner must be replaced.
Final steps
Install injector ( Page 180).
Install cylinder head cover ( Page 176).
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1.
2.
6.2.2
Instructions and comments on endoscopic and visual examination of cylinder

liners
Terms used for endoscopic examination
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Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report.
Findings
Explanations/Action
Minor dirt scores
Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores
Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Scored area
These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Smoothened area
Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the surrounding running surface.
Bright area
Bright areas are on the running surface and show local removal of the honing pattern. Grooves from honing process are not visible any more.
Discoloration
This is caused by oxidation (surface discoloration through oil or fuel) and temperature differences around the liner. It appears rather darker within the honed structure in contrast to the bright metallic running surface. The honing pattern is undisturbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields /
spots
Corrosion fields / spots result from water (condensed water) with the valves in the
overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines
Black lines are a step towards heat discoloration. They are visible as a clear discoloration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark
This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be replaced.
Seizure marks, scuffing
Irregular circumference lengths and depths. Can be caused either by the piston
skirt or the piston crown. Material deposits on the liner (smear), heavy discoloration. Severe, visible scoring.
Replace liner.
Evaluation of findings and further measures
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The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough
investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To
avoid unnecessary disassembly work, it is recommended that another inspection be carried out after
further operation of the engine.
6.3 Crankcase Breather

6.3.1
Crankcase breather Overview

For 12V engines
Vent pipe
Plug
Oil separator
Impactor carrier
5
6
7
8
Bracket
Oil line
Service block
Vent housing
9
10
11
12
Spigot pipe
Drain pipe
Bracket
Connection
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1
2
3
4
For 16V engines
Vent pipe
Impactor carrier
Bracket
Oil line
5
6
7
8
Service block
Vent housing
Spigot pipe
Drain pipe
9 Bracket
10 Plug
11 Oil separator
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1
2
3
4
6.3.2
Crankcase breather Oil mist fine separator replacement

Preconditions

Designation / Use
WARNING
Part No.
Engine oil
Oil mist fine separator
( Spare Parts Catalog)
O-ring
Qty.
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Replacing oil mist fine separator

1.
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2.
3.
4.
Remove screws (1) and take off together

with holder (2).
Replace oil mist fine separator (3).
Replace O-ring (4) if necessary.
Replace further oil mist fine separators in
the same way.
6.4 Valve Drive

6.4.1
Valve gear Lubrication

Preconditions

Designation / Use
Part No.
Qty.
Engine oil
Valve gear Lubrication

1.
2.
3.
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4.
Remove cylinder head covers

( Page 176).
Fill oil chambers of valve bridges with oil.
Fill oil chambers of rocker arms and adjusting screws with oil.
Install cylinder head covers ( Page 176).
6.4.2
Valve clearance Check and adjustment

Preconditions
Engine coolant temperature is max. 40 C.
Valves are closed.

Designation / Use
Part No.
Qty.
Feeler gage
Y20010128
Torque wrench, 60-320 Nm
F30452768
Socket wrench, 24 mm
F30039526
Engine oil
Preparatory steps
Install barring gear ( Page 162).
3.
The OT mark (1) on the flywheel (if applicable) must not be used for reference.
TIM-ID: 0000012224 - 007
1.
2.
4.
Rotate crankshaft with barring tool in engine direction of rotation until marking OTA1 and pointer are aligned.
Diagram for 12V engines (two

crankshaft positions)
1
2
I
X
Cylinder A1 is in firing TDC

Cylinder A1 is in overlap TDC
Inlet valve
Exhaust valve
Diagram for 16V engines (two

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

1.
2.
3.
4.
5.
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:
Inlet valves (long rocker arm) = 0.2 mm
Exhaust valves (short rocker arm) = 0.5 mm
Check all valve clearances at two crankshaft positions (firing and overlap TDC for cylinder A1) as per
diagram.
Use feeler gage to determine the distance between valve bridge and rocker arm.
If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.
Adjusting valve clearance

1.
2.
3.
Note:
4.
5.
6.
7.
Release locknut (1).

Insert feeler gage (3) between valve bridge
and rocker arm.
Using Allen key, set adjusting screw (2) so
that the specified valve clearance is provided.
Feeler gage must just pass through the
gap.
Pull feeler gage (3) between valve bridge
and rocker arm.
Tighten locknut (1) to the specified tightening torque, holding adjusting screw (2) firmly.
Name
Size
Type
Lubricant
Value/Standard
Locknut
M16 x 1.5 Tightening torque
(Engine oil)
90 Nm + 9 Nm
Replace or rectify adjusting screws and/or locknuts which do not move freely.
Check valve clearance.
Final steps
Remove barring gear ( Page 162).
Enable engine start.
TIM-ID: 0000012224 - 007
1.
2.
3.
6.4.3
Cylinder head cover Removal and installation

Preconditions

Designation / Use
Assembly compound (Kluthe Hakuform 30-11C/Emulgier)
O-ring
Part No.
Qty.
X00059351
Removing cylinder head cover

1.
2.
3.
Clean very dirty cylinder head covers (1)

prior to removal.
Remove screws (3, 4) with washers (2, 5).
Take off cylinder head cover (1) with Oring (6) from cylinder head (7).
Installing cylinder head cover

Clean mounting surface.
Check O-ring (6) for damage, replace as necessary.
Coat O-ring (6) with assembly compound.
Position O-ring (6) in groove of cylinder head cover (1).
Fit cylinder head cover (1) on cylinder head (7).
Install cylinder head cover (1) with screws (3, 4) and washers (2, 5).
TIM-ID: 0000012309 - 012
1.
2.
3.
4.
5.
6.
6.5 Injection Pump / HP Pump

6.5.1
HP pump Filling with engine oil

Preconditions

Designation / Use
Part No.
Qty.
Engine oil
WARNING
WARNING
NOTICE
Fuels are combustible.

Risk of fire and explosion!
Avoid open flames, electrical sparks and ignition sources.
Do not smoke.
Oils/oil vapors are combustible/explosive.
Avoid open flames, electric sparks and ignition sources.
Do not smoke.
HP fuel pump not filled with engine oil.
Damage to components, major material damage!
Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.
Filling HP pump
1.
2.
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3.
Remove plug screw (1).

Use pump oiler to fill HP pump with engine
oil until engine oil emerges.
Install plug screw (1).
6.5.2
DANGER
WARNING
HP pump Relief bore check


HP pump Relief bore check

1.
2.
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3.
Visually inspect relief bore (1) for fuel discharge.

For jacketed HP lines, leakage is indicated
by the yellow combined alarm.
If fuel discharge is found or indicated, contact Service.
6.6 Injection Valve / Injector

6.6.1
Injector Replacement
Designation / Use
Part No.
Injector
Qty.
Replacing injector
Remove injector and install new injector ( Page 180).
TIM-ID: 0000000022 - 016
6.6.2
Injector Removal and installation

Preconditions

Designation / Use
Part No.
Qty.
Installation/removal jig
F6789889
Milling cutter
F30452739
Torque wrench, 0.5-5 Nm
0015384230
F30452769
Ratchet adapter
F30027340
F30452768
Ratchet adapter
F30027341
40477
X00059351
Assembly paste(Optimoly Paste White T)

Assembly compound (Kluthe Hakuform 30-11C/Emulgier)
Engine oil
O-ring
WARNING

Do not smoke.
Preparatory steps
1.
2.
Shut off fuel supply to engine.

Removing injector
Disconnect connectors on injector.
TIM-ID: 0000000925 - 012
1.
2.
Note:
3.
4.
5.
6.
7.
8.
9.
While the adapter is removed, the injector

is drained.
Remove adapter (3).
Remove screw (2) and take off hold-down
clamp (1).
Install installation/removal jig on cylinder

head.
Remove injector with installation/removal
jig.
Remove installation/removal jig.
Remove sealing ring (4) from injector or

use a self-made hook to take it out of the
cylinder head.
Remove O-rings (3), O-ring (2) and damper
ring (1) from injector.
Clean all mating and sealing surfaces.
Cover all connections and bores, or seal
with suitable plugs.
TIM-ID: 0000000925 - 012
10.
11.
Remove HP fuel line 4).
Installing injector
1.
2.
3.
4.
5.
6.
7.
Fit new O-rings (3) (included in the scope

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

jig.
Remove installation/removal jig.
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8.
Remove plug before installing the injector. (Do not remove the plug from the HP
line before installing the adapter).
Coat injector with assembly paste at the
seat of the nozzle retaining nut.
Fit new sealing ring (included in the scope
of delivery of the injector) with assembly
compound on injector, observe installation
position of sealing ring.
9.
10.
Note:
11.
12.
Coat screw head mating face (2) and

thread with engine oil.
Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the specified initial tightening torque.
Name
Size
Type
Lubricant
Value/Standard
Screw
M12
Preload torque
(Engine oil)
5 Nm to 10 Nm
Ensure special cleanness.

Coat thread and sealing cone of adapter (3) with engine oil.
Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
Name
Size
Adapter
13.
14.
TIM-ID: 0000000925 - 012
Value/Standard
Preload torque
(Engine oil)
5 Nm to 10 Nm
Name
Size
Type
Screw
M12
Tightening torque
Lubricant
Value/Standard
100 Nm + 10 Nm
Tighten adapter (3) with torque wrench to the specified tightening torque.
Size
Adapter
16.
Lubricant
Tighten screw (2) with torque wrench to the specified tightening torque.
Name
Note:
15.
Type
Type
Lubricant
Tightening torque
Value/Standard
100 Nm + 10 Nm
Ensure special cleanness.

Coat thread and sealing cone of HP line (5) with engine oil.
Mount jacketed HP line (5) and use torque wrench to tighten to the specified torque. Tightening sequence:
1 Adapter (4)
2 Rail (6)
Name
Union nut / thrust
screw
Size
Type
Lubricant
Tightening torque
Value/Standard
40 Nm + 5 Nm
17.
Note:
18.
Fit connectors on injector.

Failure to reset drift compensation (CDC)
will void the emissions certification.
Reset drift compensation (CDC) with DiaSys ( E531920/...). If DiaSys is not
available, contact Service.
Final steps
Open fuel supply to engine.
TIM-ID: 0000000925 - 012
1.
2.
6.7 Fuel Filter

6.7.1
Supplementary fuel filter Overview
3 Passive standard prefilter

with water separator
4 LP pump
5 Supplementary fuel filter

6 Main engine filter
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1 Storage tank
2 Day tank
6.7.2
Additional fuel filter Replacement

Preconditions

Designation / Use
Filter wrench
DANGER
WARNING
WARNING
NOTICE
Part No.
Qty.
F30379104
Diesel fuel
Easy-change filter
Synthetic ring


Do not smoke.
Damage to component!
Severe material damage!
For filter replacement with the engine running, operate the engine at low engine load.
The filter which is to be replaced must be cut out for a brief period only.
Additional fuel filter Replacement

Replace additional fuel filter with the engine stopped ( Page 187).
Replace additional fuel filter with the engine running ( Page 187).
TIM-ID: 0000012645 - 003
1.
2.
6.7.3
Fuel filter Replacement

Preconditions

Designation / Use
Filter wrench
DANGER
WARNING
WARNING
NOTICE
Part No.
Qty.
F30379104
Diesel fuel
Easy-change filter
Synthetic ring


Do not smoke.
Replacing fuel filter with the engine stopped

1.
TIM-ID: 0000045359 - 001
2.
3.
4.
5.
6.
7.
8.
Cut out the filter to be replaced (1):

B Left filter cut out
C Right filter cut out
Remove the cut-out oil filter (1) using an oil
filter wrench.
Clean sealing surface on filter head.
Check sealing ring of new filter (1) and coat
with fuel.
Screw on filter (1) and tighten manually.
Turn three-way cock into position (A) where
both filters are operational.
Replace other fuel filters in the same way.
Venting fuel system ( Page 189)
Replacing fuel filter with the engine running

1.
2.
3.
4.
5.
6.
TIM-ID: 0000045359 - 001
7.
Cut out the filter to be replaced (1):

B Left filter cut out
C Right filter cut out
Remove the cut-out oil filter (1) using an oil
filter wrench.
Clean sealing surface on filter head.
Check sealing ring of new filter (1) and coat
with fuel.
Screw on filter (1) and tighten manually.
Turn three-way cock into position (A) where
both filters are operational.
Replace other fuel filters in the same way.
6.7.4
Fuel system Venting

Preconditions

Designation / Use
Part No.
Qty.
Diesel fuel
WARNING

Do not smoke.
Venting LP fuel system

1.
2.
3.
4.
5.
6.
7.
8.
TIM-ID: 0000012552 - 004
Result:
Turn three-way cock (3) into position (C)

where both filters are operational.
Open threaded vent plugs (1).
Unlock fuel priming pump (2), screw out
handle by turning it counterclockwise.
Operate fuel priming pump (2) until bubblefree fuel emerges from the threaded vent
plugs (1).
Close threaded vent plugs (1).
Screw in handle by turning it clockwise.
Verify that fuel priming pump (2) is locked:
Handle must be tightened.
Put filters back into operation:
A Right filter in operation
B Left filter in operation
During operation, one filter is cut in.
6.7.5
DANGER
WARNING
Fuel prefilter Differential pressure check and adjustment of gauge


Setting adjustable pointer of differential pressure gauge

1.
2.
After installation of a new filter element,

align adjustable pointer (2) with pressureindicating pointer (3) of pressure gauge (1).
Verify that differential pressure is within
the limit.
Fuel prefilter Checking differential pressure

With the engine running at full load or rated power, read off pressure at gauge (1).
If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating
pointer (3) of pressure gauge is 0.3 bar, flush filter element of the cut-in filter ( Page 193).
TIM-ID: 0000004925 - 008
1.
2.
6.7.6
Fuel prefilter Draining

Preconditions
WARNING

Do not smoke.
Draining fuel prefilter

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

1 Filter A cut out
2 Filter B cut out
2.
3.
4.
Open vent plug (1) of filter to be drained.

Open drain valve (2).
Drain water and contaminants from filter
until pure fuel emerges.
Close drain cock (2).
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5.
6.
7.
8.
9.
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10.
11.
Connect filling pump to filling connection

(1) on the suction side of the filter.
Open vent valve (2) and fill with fuel until
fuel emerges from the vent pipe (3).
Close vent valve (2).
Open rotary slide valve (4) a little (by approx. 30) and open vent valve(s) (2), until
Close vent valve(s) (2).
Turn rotary slide valve (4) back to locked
position.
6.7.7
Fuel prefilter Flushing

Designation / Use
Part No.
Qty.
Diesel fuel
DANGER
WARNING
WARNING


Do not smoke.
Flushing fuel prefilter

Cut out dirty filter.
1 Filter A cut out
2 Filter B cut out
TIM-ID: 0000012728 - 006
1.
2.
3.
Result:
4.
Open vent plug (1) of filter to be flushed.

Open drain valve (2) and drain fuel.
Fuel flows from filtered side back to the unfiltered side, flushing the filter deposits
downwards out of the filter.
Close vent plug (1) and drain valve (2).
Fuel prefilter Filling with fuel

1.
Stop engine ( Page 86) and disable engine start.
2.

position.
Check differential pressure ( Page 190).
Replace filter element in fuel prefilter
( Page 195) if flushing did not improve differential pressure.
3.
4.
5.
6.
7.
TIM-ID: 0000012728 - 006
8.
Result:
6.7.8
Fuel prefilter with water separator Filter element replacement

Preconditions
System is at atmospheric pressure.

Designation / Use
WARNING
WARNING
WARNING
Part No.
Qty.
F30452769
Ratchet adapter
F30027340
Filter element
O-ring
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
Open tank slowly.
Wear goggles or safety mask.
Do not smoke.
Component is hot.
Risk of burning!
Wear protective gloves.
Fuel prefilter with water separator Filter element replacement

Cut out the filter to be replaced (A or B):
1 Filter A cut out
2 Filter B cut out
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1.
2.
3.
4.
5.
6.
7.
8.
9.
Open vent valve (1) of the filter to be replaced.

Open drain valve (5) and drain fuel.
Loosen screws (3) and screw out filter
housing (A or B).
Remove filter element (4).
Insert new filter element in filter housing.
Fit O-ring.
Reinstall filter housing (A or B) with filter element (4).
Tighten screws (6 or 3) with torque wrench to the specified tightening torque (maximum half a turn per
screw).
Name
Screw
10.
11.
12.
13.
Type
Tightening torque
Lubricant
Value/Standard
40 Nm

position.
TIM-ID: 0000012750 - 006
14.
15.
Size
6.7.9
Fuel prefilter with water separator O-ring replacement in rotary slide valve
Preconditions
System is at atmospheric pressure.

Designation / Use
Part No.
O-ring
WARNING
WARNING
Qty.
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
Open tank slowly.
Wear goggles or safety mask.
Do not smoke.
Fuel prefilter with water separator O-ring replacement in rotary slide valve
1.
2.
3.
4.
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5.
6.
Open vent valves (1) carefully to make sure

that the system is not pressurized.
Open drain valves (6) and drain fuel.
Remove rotary slide valve retainer (4) with
handle (5).
Remove rotary slide valve (3) with O-rings
(2).
Replace O-rings (2).
For assembly, follow the reverse sequence
of working steps as described for disassembly.
6.8 Exhaust Turbocharger

6.8.1
Overview of turbocharger
Turbocharger
Impeller housing, left

Impeller housing, right
Washer
Nut
Shaft
6
7
8
9
10
Bearing bush
Shaft
Sprung pin
Sealing ring
Sealing flange
11 Bolt
12 Turbine housing, right
13 Turbine housing, left
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1
2
3
4
5
Turbine housing, left turbocharger
R-ring
Turbine housing
Turbine
Piston ring
Heat shield
Housing cover
Washer
Bearing bush
Washer
10
11
12
13
14
15
16
17
18
Circlip
Circlip
Washer
Bearing bush
O-ring
Bearing housing
Bolt
Nut
Dished washer
19
20
21
22
23
24
25
26
27
Dished washer
Dished washer
Stud bolt
Bolt
Washer
Blanking plate
Blanking plate
Washer
Bolt
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1
2
3
4
5
6
7
8
9
Impeller housing, left
O-ring
Bearing body
O-ring
Washer
Thrust bearing
Washer
Piston ring
Piston ring
Ring retainer
10
11
12
13
14
15
16
17
18
O-ring
Retaining ring
Impeller
Magnetic nut
Grooved pin
Identification plate
Impeller housing
Plug bolt
Sealing ring
19
20
21
22
23
24
25
Sealing ring
Plug bolt
Clamping piece
Washer
Bolt
Bolt
Washer
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1
2
3
4
5
6
7
8
9
Turbine housing, right turbocharger
R-ring
Turbine housing
Turbine
Piston ring
Heat shield
Housing cover
Washer
Bearing bush
Washer
Circlip
11
12
13
14
15
16
17
18
19
20
Circlip
Washer
Bearing bush
O-ring
Bearing housing
Bolt
Nut
Dished washer
Dished washer
Dished washer
21
22
23
24
25
26
27
28
29
Stud bolt
Bolt
Washer
Bush
Pin
Wastegate
Bolt
Washer
Bush
TIM-ID: 0000037654 - 001
1
2
3
4
5
6
7
8
9
10
Impeller housing, right turbocharger
O-ring
Bearing body
O-ring
Washer
Thrust bearing
Washer
Piston ring
Piston ring
Ring retainer
10
11
12
13
14
15
16
17
18
O-ring
Retaining ring
Impeller
Magnetic nut
Bolt
Washer
Clamping piece
Impeller housing
Plug bolt
19
20
21
22
23
24
25
Sealing ring
Identification plate
Grooved pin
Plug bolt
Sealing ring
Bolt
Washer
TIM-ID: 0000037654 - 001
1
2
3
4
5
6
7
8
9
Impeller housing
1 Impeller housing
2 Plug bolt
3 Sealing ring
TIM-ID: 0000037654 - 001
Bearing housing
1 Bearing housing
2 Sprung pin
Thrust bearing
1 Ball
2 Thrust bearing
TIM-ID: 0000037654 - 001
Magnetic nut
1 Magnetic nut
2 Magnet
6.8.2
Compressor wheel Cleaning

Preconditions
Engine is stopped and starting disabled

Designation / Use
Part No.
Qty.
F30452769
Ratchet adapter
F30027340
40377
Engine oil
Engine coolant
Sealing rings
Sealing rings
Cleaner
WARNING
NOTICE
Chemical substances.
Risk of irritation and chemical burns!
Observe the instructions of the cleaning agent manufacturer.
Inappropriate cleaning tool.

Risk of damage to component!
Use appropriate cleaning tool.
NOTICE
Incorrect installation of components and lines.

Ensure that components/lines are installed so that they are never under tension or strain.
Ensure correct installation position of components.
Preparatory steps Horizontal air intake

Drain engine coolant ( Page 236).
Remove air filter ( Page 215).
Seal all openings with suitable covers.
TIM-ID: 0000018629 - 006
1.
2.
3.
4.
5.
Remove charge-air pipework (1) from exhaust turbocharger to intercooler.

Remove oil lines (2).
6.
7.
Loosen clamp (1).

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

housing (3).
Remove coolant ventilation line (2) from
compressor housing (3).
TIM-ID: 0000018629 - 006
9.
10.
11.
Undo screws (1).

Remove compressor housing (2).
Cleaning compressor wheel

Note:
1.
2.
3.
4.
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 components.
Fit new sealing rings between bearing
housing/compressor housing and plug-in
sleeves if necessary.
Final steps Horizontal air intake

Install compressor housing (2).
TIM-ID: 0000018629 - 006
1.
Tighten screws (1) to specified torque using a torque wrench.

Name
Size
Screw
Type
Lubricant
Value/Standard
Tightening torque
(Engine oil)
20 Nm + 2.5 Nm
3.
Install coolant ventilation line and coolant lines on compressor housing.
4.
Install intake housing (3) with actuating cylinder (2).
5.
Align clamp (1) and tighten to specified torque using a torque wrench.
Name
Size
Clamp
6.
7.
8.
9.
Type
Lubricant
Tightening torque
Value/Standard
15 Nm + 2 Nm
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

A
(Engine oil)
40 Nm +4 Nm
Install charge-air pipework (1) between exhaust turbocharger and intercooler.

Install air filter ( Page 215).
Fill with engine coolant ( Page 239).
TIM-ID: 0000018629 - 006
2.
Preparatory steps Vertical air intake

1.
2.
3.

Remove air filter ( Page 215).
Seal all openings with suitable covers.
4.
Remove charge-air pipework (1) from exhaust turbocharger to intercooler.

Remove oil lines (2).
5.
Loosen clamp (1).

Remove intake housing (3) with actuating
cylinder (2).
TIM-ID: 0000018629 - 006
6.
7.
8.
9.
10.
11.
Remove coolant lines (1) from compressor

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

Remove compressor housing (2).
Note:
1.
2.
3.
4.
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 components.
Fit new sealing rings between bearing
housing/compressor housing and plug-in
sleeves if necessary.
TIM-ID: 0000018629 - 006
Cleaning compressor wheel
Final steps Vertical air intake

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

Name
Size
Screw
Lubricant
Value/Standard
Tightening torque
(Engine oil)
20 Nm + 2.5 Nm
3.
Install coolant ventilation line and coolant lines on compressor housing.
4.
Install intake housing (3) with actuating cylinder (2).
5.
Align clamp (1) and tighten to specified torque using a torque wrench.
Name
TIM-ID: 0000018629 - 006
Type
Clamp
Size
Type
Lubricant
Tightening torque
Value/Standard
15 Nm + 2 Nm
6.
Name
Size
Type
Lubricant
Value/Standard
Threaded adapter
10 G 1/4 Tightening torque

A
(Engine oil)
40 Nm +4 Nm
Install charge-air pipework (1) between exhaust turbocharger and intercooler.

Install air filter ( Page 215).
TIM-ID: 0000018629 - 006
7.
8.
9.
Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque
wrench.
6.9 Charge-Air Cooling

6.9.1
DANGER
WARNING
WARNING
Intercooler Checking condensate drain for water discharge and obstruction



Intercooler Checking condensate drain for water discharge

and obstruction
1.
Result:
2.
With the engine running, check if air

emerges from drain bore(s) on the left and
right sides on engine driving end.
If no air emerges:
Clean condensate drain bore(s).
Blow out with compressed air.
If a large amount of coolant is continuously
discharged, the intercooler is leaking. Contact Service.
TIM-ID: 0000013214 - 006
Emergency measures prior to engine start with a leaking intercooler

1.
2.
3.
4.
Remove injectors ( Page 180).

Bar engine manually ( Page 162).
Bar engine with starting system to blow out combustion chambers ( Page 162).
Install injectors ( Page 180).
6.10 Air Filter

6.10.1
Air filter Replacement

Designation / Use
Air filter
Part No.
Qty.
Replacing the air filter

Remove old air filter and install new air filter ( Page 215).
Reset signal ring of contamination indicator ( Page 216).
TIM-ID: 0000005447 - 009
1.
2.
6.10.2
Air filter Removal and installation

Preconditions
Air filter
1.
2.
3.
4.
5.
Loosen clamp (2).

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

1.
2.
3.
4.
TIM-ID: 0000013401 - 007
5.
Loosen clamp (2).

Remove air filter (1) and clamp (2) from intake silencer (3).
Clean intake silencer (3) and check for obstructions.
Attach air filter (1) with clamp (2) onto intake silencer (1).
Tighten clamp (2).
6.11 Air Intake

6.11.1
Service indicator Signal ring position check (optional)

Preconditions
Checking signal ring position

1.
2.
TIM-ID: 0000005484 - 008
Result:
If the signal ring is completely visible in the

control window (2), replace air filter
( Page 214).
After installation of new filter, press reset
button (1).
Engaged piston with signal ring moves
back to initial position.
6.12 Starting Equipment

6.12.1
Starter Condition check

Preconditions
Checking starter condition

Check securing screws of starter for secure seating and tighten if required.
Check wiring ( Page 265).
TIM-ID: 0000000905 - 017
1.
2.
6.13 Lube Oil System, Lube Oil Circuit

6.13.1
Engine oil Level check

Preconditions
Oil level check prior to engine

start
1.
2.
Note:
3.
4.
5.
Withdraw dipstick from guide tube and

wipe it.
Insert dipstick into guide tube to stop,
withdraw after approx. 10 seconds and
check oil level.
After extended standstill, the oil level may
be up to 2 cm above mark (1). This may be
caused e.g. by oil from oil filters and heat
exchanger flowing back into the oil pan.
The oil level must reach mark (1) or exceed
mark (1) by up to 2 cm.
Top up with oil to mark (1) as necessary
( Page 219).
Insert dipstick into guide tube up to the
stop.
Oil level check after the engine is stopped

5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
Insert dipstick into guide tube to stop, withdraw after approx. 10 seconds and check oil level.
Oil level must be between marks (1) and (2).
Top up with oil to mark (1) as necessary ( Page 219).
Insert dipstick into guide tube up to the stop.
TIM-ID: 0000000931 - 012
1.
2.
3.
4.
5.
6.13.2
Engine oil Change

Preconditions
Engine is at operating temperature.
MTU Fluids and Lubricants Specifications (A001061/..) are available.

Designation / Use
Part No.
Qty.
F30027337
Ratchet adapter
F30027341
Engine oil
Sealing ring
WARNING
Hot oil.
Oil change without semirotary hand pump: Draining oil via drain plug(s) on oil
pan
1.
2.
3.
Provide a suitable container to collect the oil.

Remove drain plug(s) and drain oil.
Install drain plug(s) with new sealing ring.
Oil change with semirotary hand pump: Oil extraction

1.
2.
Provide a suitable container to collect the oil.

Draw all oil from oil pan using the semirotary hand pump.
Draining residual oil at gearcase

1.
TIM-ID: 0000014099 - 003
2.
3.
Provide a suitable container to collect the

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

1.
2.
TIM-ID: 0000014099 - 003
3.
4.
5.
Open cap on filler neck.

Pour oil in at filler neck up to 'max.' mark
at oil dipstick.
Close cap on filler neck.
Check engine oil level ( Page 218).
Turn engine with starting system after oil
change ( Page 164).
6.13.3
Engine oil Sample extraction and analysis

Preconditions

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

Hot oil.
Engine oil Sample extraction

and analysis
1.
2.
3.
TIM-ID: 0000014113 - 005
4.
5.
With the engine running at operating temperature, open screw on centrifugal oil filter carrier by 1 to 2 rotations.
Drain approx. 2 liters engine oil to flush out
the oil sludge.
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);
Water content;
Dilution by fuel.
Engine oil Sample extraction

and analysis (engines with
switchable oil filter)
1.
2.
3.
TIM-ID: 0000014113 - 005
4.
5.
With the engine running at operating temperature, open screw on flange of centrifugal oil filter by 1 to 2 rotations.
Drain approx. 2 liters engine oil to flush out
the oil sludge.
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);
Water content;
Dilution by fuel.
6.14 Oil Filtration / Cooling

6.14.1
Engine oil filter Replacement

Designation / Use
Part No.
Filter wrench
F30379104
Engine oil
Oil filter
DANGER
WARNING
WARNING
NOTICE
Qty.


Hot oil.
Engine oil filter Replacement

1.
TIM-ID: 0000014238 - 006
2.
3.
4.
5.
6.
7.
8.

Unscrew oil filter using filter wrench.
Clean sealing surface on connecting piece.
Check condition of new oil filter sealing
ring and moisten it with oil.
Screw on and tighten new oil filter by hand.
Replace other oil filters in the same way.
Turn engine with starting system after every oil change and filter replacement
( Page 164).
Check oil level ( Page 218).
Oil filter with diverter (option):

Oil filter replacement with the
engine stopped
1.
2.
3.
4.
5.
6.
7.
8.
9.

Unscrew oil filter using oil filter wrench.
Fit SOLAS shield ( Page 16).
Turn engine with starting system after every oil change and filter replacement
( Page 164).
Oil filter with diverter (option):

Oil filter replacement with the
engine running
1.
To cut out the filter to be replaced, set the

three-way cock to the corresponding position.
Position A: Lower filters cut out
Position B: Both filters cut in (normal operating position)
Position C: Upper filters cut out.
2.
3.
4.
Unscrew oil filter using oil filter wrench.

Fit SOLAS shield ( Page 16).
TIM-ID: 0000014238 - 006
5.
6.
7.
8.
6.14.2
Oil indicator filter Cleaning and check

Preconditions

Designation / Use
WARNING
WARNING
NOTICE
Part No.
Qty.
Cleaning agent (Snow-White 11-0)
40460
Cleaning agent (Hakupur 312)
30390
Engine oil
Strainer
Square-section ring
O-ring
Hot oil.
Inappropriate cleaning tool.
Risk of damage to component!
Use appropriate cleaning tool.
Removing strainer
1.
TIM-ID: 0000006402 - 006
2.
3.
4.
Clean oil indicator filter before disassembling it.

Remove screws (1).
Take off cover (2) with O-ring (3).
Take strainer (5) from filter housing.
Checking strainer
Item
Findings
Action
Strainer
Metallic residues
Strainer
Damaged
Fit new part
Square-section ring
Damaged
Fit new part
O-ring
Damaged
Fit new part
Clean
Monitor engine operation
Check strainer daily
Contact Service
Cleaning strainer
1.
2.
3.
Wash strainer (5) with cleaner.

Remove stubborn deposits with soft brush.
Blow out strainer (5) with compressed air from inside.
Installing strainer
Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
Coat O-ring (3) with engine oil and fit in filter housing.
Fit cover (2) and secure with screws (1) and washers.
TIM-ID: 0000006402 - 006
1.
2.
3.
6.14.3
Centrifugal oil filter Cleaning and filter sleeve replacement

Preconditions

Designation / Use
WARNING
Qty.
F30027336
Filter wrench
F30379104
Cleaner Hakutex 60
Grease (Kluthe Hakuform 30-10/emulsifier)
X00029933
Filter sleeve
Sealing ring
Sealing ring
Sealing ring
Hot oil.
TIM-ID: 0000014256 - 004
WARNING
Part No.
Centrifugal oil filter Cleaning

and filter sleeve replacement
15.
Remove clamp (14).

Release Tommy nut (2) and take off cover (1).
Carefully lift rotor (11), allow oil to drain
and remove from housing.
Holding the rotor (11) firmly, release rotor
cover nut (3).
Take off rotor cover (4).
Remove filter sleeve (6).
Measure layer thickness of oil residues on
filter sleeve (6).
If the oil residues exceed the maximum layer thickness of 45 mm, shorten the maintenance interval.
Disassemble rotor tube (7), conical disk (8)
and rotor base (10).
Wash rotor cover (4), rotor tube (7), conical
disk (8) and rotor base (10) with cold
cleaner.
Blow out with compressed air.
Check sealing ring (9), fit new one if necessary.
Assemble rotor tube (7), conical disk (8)
and rotor base (10) with sealing ring (9).
Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the
outer wall.
Mount rotor cover (4) with sealing ring (5).
16.
Tighten rotor cover nut (3) with torque wrench to the specified torque.
3.
4.
5.
6.
7.
Result:
8.
9.
10.
11.
12.
13.
14.
Name
Size
Nut
Type
Lubricant
Tightening torque
35 Nm to 45 Nm
17.
18.
19.
20.
21.
Place rotor (11) in housing (12) and check for ease of movement.
Fit sealing ring (13) on housing (12).
Fit hood (1).
Tighten Tommy nut (2) by hand.
22.
Install clamp (14) and tighten with torque wrench to the specified torque.
Name
Size
Clamp
23.
Type
Value/Standard
Lubricant
Tightening torque
Value/Standard
8 Nm to 10 Nm
Tighten cover nut (2) with torque wrench to the specified torque.
Name
Screw
Size
Type
Tightening torque
Lubricant
Value/Standard
5 Nm to 7 Nm
TIM-ID: 0000014256 - 004
1.
2.
Cleaning centrifugal oil filter

and replacing filter sleeve (engines with switchable oil filter)
1.
2.
3.
4.
19.
20.
Undo and remove screw (1).

Remove clamp (3) and take off hood (2).
Carefully remove rotor (5) from housing.
Hold rotor assembly (5) firmly in position
with filter wrench and undo knurled nut (7).
Take off rotor cap (8).
Remove filter sleeve (9), stiffener plate (10)
and sealing ring (11).
Measure thickness of oil residues on filter
sleeve.
If maximum layer thickness of oil residues
exceeds 30 mm, shorten maintenance interval.
Remove standpipe (12) from lower rotor
section (13).
Wash hood (2), rotor cap (8), stiffener
plate (10), standpipe (12), lower rotor section (13) and nozzles (14) with cleaner and
blow out with compressed air. Do not use
sharp objects for cleaning.
Check nozzles (14) for obstructions.
Push standpipe (12) onto rotor lower section (13).
Insert new filter sleeve (9) with stiffener
plate (10) into rotor cap (8), ensuring that
the smooth surface of the filter sleeve (9)
faces the rotor cap (8).
Check sealing ring (11), replace if necessary. Coat sealing ring with grease and insert
in groove of rotor cap (8).
Place rotor cap (8) onto standpipe (12).
Hold rotor assembly (5) firmly in position
with filter wrench and tighten knurled
nut (7).
Lubricate bearings of rotor (5), insert in
housing (6) and check for ease of movement.
Check sealing ring (4), replace if necessary.
Fit sealing ring on housing (6).
Fit hood (2).
Tighten screw (1) by hand.
21.
Install clamp (3) and tighten to specified torque using a torque wrench:
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
TIM-ID: 0000014256 - 004
18.
Name
Size
Clamp
22.
Type
Lubricant
Tightening torque
Value/Standard
6 Nm + 1 Nm
Tighten screw (1) to specified torque using a torque wrench:

Name
Screw
Size
Type
Lubricant
Tightening torque
Value/Standard
6 Nm + 1 Nm
6.15 Coolant Circuit, General, High-Temperature Circuit

6.15.1
Drain and vent points

Coolant lines on ETC
1 Vent point
Coolant line to intercooler
TIM-ID: 0000014545 - 004
1 Vent point
1 Vent point
Coolant line to raw water cooler
TIM-ID: 0000014545 - 004
1 Vent point
Vent line Distribution cross

1 Vent point
Coolant drain point, engine driving end
TIM-ID: 0000014545 - 004
1 Drain point
Coolant drain point, engine free end
TIM-ID: 0000014545 - 004
1 Drain point
6.15.2
Engine coolant level Check

Preconditions
WARNING
Coolant is hot and under pressure.

Risk of injury and scalding!
Let the engine cool down.
Checking engine coolant level at filler neck:

1.
2.
3.
Turn breather valve on coolant expansion tank (for engines with remote heat exchanger: the expansion
tank is part of the remote cooling system) counterclockwise up to the first stop and allow pressure to
escape.
Continue to turn breather valve counterclockwise and remove.
Check coolant level (coolant must be visible at the bottom edge of the cast-in eye in the filler neck).
Checking engine coolant level at

external cooler:
1.
2.
3.
4.
Check coolant level (coolant must be visible at marker plate).

Top up with treated coolant as necessary
( Page 239).
Check and clean breather valve.
Set breather valve onto filler neck and
close it.
Checking engine coolant level by means of level sensor:

Switch on engine control system and check readings on the display.
Top up with treated coolant as necessary ( Page 239).
TIM-ID: 0000014605 - 003
1.
2.
6.15.3
Engine coolant Change

Designation / Use
Part No.
Qty.
Coolant
Engine coolant change

TIM-ID: 0000000036 - 031
1.
2.
6.15.4

Preconditions
WARNING

Preparatory steps
1.
2.
Provide an appropriate container to drain the coolant into.

Switch off preheating unit.

2.
3.
Turn breather valve on expansion tank (for engines with remote heat exchanger: the expansion tank is
part of the remote cooling system) counterclockwise up to the first stop and allow pressure to escape.
Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck.
4.
Open vent valves on carrier housing (1).
TIM-ID: 0000014593 - 005
1.
Open vent valve on exhaust pipework (driving end) (1).
6.
Open vent valve on seawater cooler (1) (or

remote heat exchanger).
7.
Open drain plug (1) and drain coolant at

crankcase.
TIM-ID: 0000014593 - 005
5.
8.
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.
TIM-ID: 0000014593 - 005
1.
2.
6.15.5
Engine coolant Filling

Preconditions

Designation / Use
Part No.
Qty.
Engine coolant
WARNING
NOTICE

Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
Fill / top up coolant only into cold engine.
Preparatory steps
1.
TIM-ID: 0000014569 - 005
2.
Turn breather valve on expansion tank (for

engines with remote heat exchanger: the
expansion tank is part of the remote cooling system) counterclockwise up to the
first stop and allow pressure to escape.
Filling coolant through filler

neck
1.
2.
3.
4.
5.
6.
7.
8.
9.
Open vent points on charge-air cooler, exhaust turbochargers and on plate-core heat
exchanger (arrows).
Fill coolant through the filler neck of the
expansion tank (for engines with remote
heat exchanger: the expansion tank is part
of the remote cooling system) until the
coolant level at the top edge of the filler
neck remains constant.
When coolant emerges from the vent
points, close vent points one by one, proceeding from the lowest point upwards.
Check proper condition of breather valve
and clean sealing faces if required.
Set breather valve onto filler neck and turn
until the first stop.
After 10 seconds of running the engine
without load, shut down the engine
( Page 86).
Turn breather valve counterclockwise and
remove.
Check coolant level ( Page 234) and top
up engine coolant as required:
a) Repeat the steps from starting the engine ( Step 6) until no coolant needs
to be topped up any more.
b) Check proper condition of breather
valve and clean sealing faces if required.
c) Set breather valve onto filler neck and
close it.
Final steps
Start the engine and run it without load for some minutes.
Check coolant level ( Page 234) and top up engine coolant as required.
TIM-ID: 0000014569 - 005
1.
2.
6.15.6
DANGER
WARNING
HT coolant pump Relief bore check


HT coolant pump Relief bore

check
1.
2.
3.
TIM-ID: 0000006803 - 004
4.
Check relief bore for oil and coolant discharge.

Stop engine ( Operating instructions electronic system) and disable engine start.
Clean the relief bore with a wire if it is
dirty.
Permissible engine coolant discharge:
up to 10 drops per hour;
Permissible oil discharge: up to 5 drops
per hour.
If discharge exceeds the specified limits,
contact Service.
6.15.7
Engine coolant Sample extraction and analysis

Preconditions

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


Engine coolant Sample extraction and analysis

1.
2.
3.
4.
5.
TIM-ID: 0000014608 - 007
6.
Open drain valve (arrow) with the engine

running.
Flush sampling point by draining approx. 1
liter coolant.
Drain approx. 1 liter of engine coolant into
a clean container.
Close drain valve (arrow).
Use the equipment and chemicals of the
MTU test kit to check the coolant for:
Antifreeze concentration
Corrosion inhibitor concentration
pH value
Engine coolant change intervals ( MTU
Fluids and Lubricants Specifications).
6.15.8
Engine coolant filter Replacement

Preconditions

Designation / Use
Filter wrench
Engine oil
Engine coolant filter
WARNING
Part No.
Qty.
F30379104

Engine coolant filter Replacement

1.
2.
3.
4.
5.
6.
TIM-ID: 0000014677 - 008
7.
8.
Remove locking device (1).

Close shut-off cock (3).
Remove engine coolant filter (2) with filter
wrench.
Coat seal on new engine coolant filter (2)
with engine oil.
Screw on engine coolant filter (2) and tighten hand-tight.
Open shut-off cock (3).
Install locking device (1).
6.15.9
Preheating unit
Hotstart preheating unit
4 Shutoff valve
5 Continuous flow heater
6 Vent valve
7 Thermostat
8 Circulation pump
Cylinders
Nominal voltage / frequency
Heating power kW
12 V
230 V / 50 Hz
400 V / 50 Hz
230 V / 60 Hz
440 V / 60 Hz
230 V / 50 Hz
12
400 V / 50 Hz
12
230 V / 60 Hz
12
440 V / 60 Hz
12
16 V
Function
The preheating unit is intended to warm up the engine coolant. The circulating pump (8) ensures the
circulation of the preheated engine coolant through the engine.
The continuous flow heater (5) comprises a heating element. The thermostat (7) switches off the preheating unit via contactors when the engine coolant temperature has reached the setting of the thermostat (7).
In the event of excessive coolant temperature, the temperature limiter of the thermostat (7) opens the
control loop. The preheating unit is switched off.
The unit must be reset manually after the fault has been rectified.
TIM-ID: 0000014749 - 005
1 Plastic cap (drain)

2 On/Off switch
3 Plastic cap (supply line)
Hilzinger preheating unit
1 On/Off switch
Nominal voltage / frequency
Heating power kW
12 V and 16 V
230 V / 50 Hz
400 V / 50 Hz
230 V / 60 Hz
440 V / 60 Hz
TIM-ID: 0000014749 - 005
Cylinders
Hilzinger preheating unit, side view
1 Flange (supply and return)

2 Junction box
3 Non-return flap
4 Continuous flow heater
5 Thermostat
6 Circulation pump
Function
The preheating unit is intended to warm up the engine coolant. The circulation pump (6) ensures the
circulation of the preheated coolant through the engine.
The continuous flow heater (4) comprises a heating element. A non-return flap (3) prevents coolant
from flowing through the preheating unit when the engine is running.
When the coolant temperature has reached the value of the thermostat setting (5), the thermostat (5)
switches off the preheating unit via contactors.
In the event of excessive coolant temperature, the temperature limiter of the thermostat (5) opens the
control loop. The preheater is switched off.
TIM-ID: 0000014749 - 005
The unit must be reset manually after the fault has been rectified.
6.15.10
Preheater Overhaul
Preconditions
DANGER
WARNING
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!
Overhauling preheater
Disconnect power supply to heating element.
Close shut-off valve in coolant line before and after preheater.
Drain coolant at drain valve into a clean container.
Clean and flush coolant circuit.
Check hoses for cracks and other damage. Replace as necessary.
Check wiring for damage and overheating.
Remove heating element.
Clean heating element and tank.
Remove pump from volute (if applicable) and check for residues in impeller and lines.
Install heating element.
Connect heating element to power supply.
Connect hoses and open shut-off valves.
Check preheater for leakage and correct operation ( Page 248).
TIM-ID: 0000048876 - 001
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
6.15.11
Preheater Function and leak-tightness check

Preconditions
Preheater is switched on.
WARNING
Coolant is hot and highly pressurized.

Risk of injury! Risk of scalding!
Allow engine to cool down.
Wear protective clothing, protective gloves, and safety glasses / facial protection.
Checking operation
Note:
1.
2.
The coolant temperature must correlate to the control range of the thermostat when the preheater is
ready for operation.
Check coolant preheating temperature.
Set the thermostat accordingly if the temperatures are not in the control range.
Checking for leaks

Check leak-tightness at coolant inlet and outlet.
Tighten any leaking unions.
TIM-ID: 0000048882 - 001
1.
2.
6.16 Raw Water Pump with Connections

6.16.1
DANGER
WARNING
Raw water pump Relief bore check


Raw water pump Relief bore

check
1.
2.
3.
TIM-ID: 0000015173 - 005
4.
Check relief bore for oil and coolant discharge.

Clean the relief bore with a wire if it is
dirty.
Permissible engine coolant discharge:
up to 10 drops per hour;
per hour.
If discharge exceeds the specified limits,
contact Service.
6.17 Engine Mounting / Support

6.17.1
Engine mounting Check

Engine mounting Check
Item
Findings
Visually inspect mounts.
Replace (contact Service).
TIM-ID: 0000015370 - 004
Damage
Brittleness
Deformation
Crack formation
Swelling
visible
Action
6.18 Battery-Charging Generator

6.18.1
Battery-charging generator drive Coupling condition check

Preconditions
Battery-charging generator drive

Coupling condition check
1.
2.
3.
4.
TIM-ID: 0000007390 - 008
5.
Remove screws (1).

Remove protective cover (2).
Check resilient coupling (3) for cracks and
plastic deformation.
If there is serious deformation or crack formation, contact Service.
Install protective cover (2) with screws (1).
6.19 Auxiliary PTO

6.19.1
DANGER
WARNING
Bilge pump Relief bore check


Bilge pump Relief bore check

1.
2.
3.
TIM-ID: 0000015791 - 006
4.
Check relief bores for oil and water discharge.

Clean relief bores with a wire if dirty.
Permissible water discharge: up to 10
drops per hour;
per hour
If discharge exceeds the specified limits:
Contact Service.
6.20 Fuel Supply System

6.20.1
Water drain valve Check

Water drain valve Check
Open water drain valve.
Check water outlet for obstructions.
Close water drain valve.
TIM-ID: 0000007733 - 007
1.
2.
3.
6.20.2
WARNING
Differential pressure gauge Check

Do not smoke.
Checking differential pressure gauge

Set the alarm points at the differential pressure gauge to zero.
Alarm is initiated with preset delay.
Reset the alarm points at the differential pressure gauge to the specified values.
TIM-ID: 0000007737 - 005
1.
2.
Result:
3.
6.20.3
Water level probe (3-in-1 rod electrode) Check

Preconditions
System is put out of operation and emptied.
WARNING

Do not smoke.
Checking water level probe (3-in-1 rod electrode)

Disconnect connector from water level probe.
Unscrew water level probe.
Immerse water level probe into a tank filled with water until water level reaches the thread.
Switch system on.
Water drain valve opens.
Leave water level probe in tank.
Alarm must be triggered with the preset delay.
Switch off the system.
Remove water level probe from tank.
Screw in water level probe.
Connect connector for water level probe.
Fill and vent the system then put it into operation.
TIM-ID: 0000007739 - 007
1.
2.
3.
4.
5.
Result:
6.
Result:
7.
8.
9.
10.
11.
12.
6.20.4
WARNING
Pump capacity Check

Do not smoke.
Pump capacity Check

1.
2.
Note:
3.
4.
Install suitable pressure gauge at the neck of the intake side of the pump.
Check pump pressure.
a) Switch on fuel treatment system ( Page 84).
The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing fuel and can be disregarded.
b) Close ball valve at the outlet of the fuel treatment system.
c) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
Check pump pressure with reduced suction.
a) Reduce suction pressure of pump to -0.8 bar with the shutoff valve at the pump intake side.
b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
c) Open ball valve at inlet and outlet of fuel treatment system.
Calculate wear limit.
Example:
Measured value (normal condition).
3 bar
Measured value (reduced suction condition).
2.6 bar
TIM-ID: 0000007740 - 008
If the measured value (reduced suction condition) is 10% lower than the measured value (normal condition),
the wear limit is reached. Repair pump (contact Service).
6.20.5
Coalescer filter element Replacement

Preconditions
System is stopped and starting disabled.

Designation / Use
WARNING
NOTICE
Part No.
Qty.
F30027336
Ratchet
F30027339
Diesel fuel
Engine oil
Coalescer filter element
Gasket

Do not smoke.
Contamination of components.
Check components for special cleanliness.
NOTICE
Incorrect installation of components and lines.

Ensure that components/lines are installed so that they are never under tension or strain.
Ensure correct installation position of components.
Coalescer filter element Replacement
TIM-ID: 0000007735 - 009
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Close ball valve at the inlet and outlet of

the fuel treatment system.
Open drain valve.
Drain fuel.
Close drain valve.
Remove nuts (9) and washers (2).
Remove screws (1).
Remove cover with gasket (10).
Remove nut (3), washer (8) and end
plate (4).
Remove coalescer filter element (5).
Catch fuel as it runs out.
Clean housing with a non-linting cloth,
rinse with fuel if required.
Check housing for corrosion.
Clean housing sealing surfaces.
Install coalescer filter element (5).
Install end plate (4), washer (8) and nut (3).
16.
Name
Size
Type
Lubricant
Value/Standard
Nut
M16
Tightening torque
(Engine oil)
30 Nm +3 Nm
Fit gasket (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.
The fuel treatment system is ready for operation.
TIM-ID: 0000007735 - 009
17.
18.
19.
20.
21.
Result:
Tighten nut (3) to specified tightening torque using a torque wrench.
6.21 Wiring (General) for Engine/Gearbox/Unit

6.21.1
Engine wiring harness Overview

Engine wiring harnesses Terminal assignment
Description
Terminal assignment
Sensors
B1
Camshaft speed
B3
Intake air temperature
B4.21
Exhaust temperature, A side
B4.22
Exhaust temperature, B-side
B5.1
Oil pressure downstream of filter
B5.3
Oil pressure upstream of filter
B6
Coolant temperature
B7
Oil temperature
B9
Charge-air temperature
B10
Charge-air pressure
B13
Crankshaft speed
B16
Coolant pressure
B33
Fuel temperature
B34.1
Fuel pressure downstream of filter
B34.2
Fuel pressure upstream of filter
B34.3
Fuel pressure upstream of external filter
B44.1
Rotation speed, exhaust turbocharger A
B44.2
Rotation speed, exhaust turbocharger B
B48
HP fuel pressure
B49
Charge air before recirculation
B50
Crankcase pressure
B54
Replenishment pump pressure
F33
Coolant level
XF33
Coolant level adaptation
XXF33
Coolant level, hull-mounted cooling system
F46
Fuel overflow level
Pump
M8
Fuel pump
Limit switch
S37.1
Start interlock A
S37.2
Start interlock B
X2
ECU-7 governor
X4
ECU-7 governor
X37
Cranking start interlock
XG03
Y26
Charge-air recirculation
Y27
TIM-ID: 0000038739 - 002
Level monitor
Adaptation
Valves
Description
Terminal assignment
Injectors
Y39A1 to Y39AX
Engine A side
Y39B1 to Y39BX
Engine B side
Engine wiring harness for sensors, 12V engine
M8
B1
B6
X2
X37
XXF33
F33
B16
XF33
B54
B44.2
Y27
13
14
15
16
17
18
19
20
21
22
23
24
B4.22
B9
S37.1
B34.3
B34.2
B34.1
B50
B49
B44.1
Y26
B5.3
B3
25
26
27
28
29
30
31
32
33
34
B4.21
B10
B13
S37.2
B7
B5.1
B48
B33
F46
XG03
TIM-ID: 0000038739 - 002
1
2
3
4
5
6
7
8
9
10
11
12
Engine wiring harness for sensors, 16V engine
M8
B1
B6
X2
Y27
B44.2
X37
XF33
B54
B16
XXF33
F33
13
14
15
16
17
18
19
20
21
22
23
24
B4.22
B9
S37.1
B34.3
B34.2
B34.1
B50
B49
B44.1
Y26
B5.3
B3
25
26
27
28
29
30
31
32
33
34
B4.21
B10
B13
S37.2
B7
B5.1
B48
B33
F46
XG03
TIM-ID: 0000038739 - 002
1
2
3
4
5
6
7
8
9
10
11
12
Engine wiring harness for injectors, 12V engine
Y39A1
Y39A2
Y39A3
Y39A4
Y39A5
6
7
8
9
10
Y39A6
X4
Y39B6
Y39B5
Y39B4
11 Y39B3
12 Y39B2
13 Y39B1
TIM-ID: 0000038739 - 002
1
2
3
4
5
Engine wiring harness for injectors, 16V engine
Y39A1
Y39A2
Y39A3
Y39A4
Y39A5
Y39A6
7
8
9
10
11
12
Y39A7
Y39A8
X4
Y39B8
Y39B7
Y39B6
13
14
15
16
17
Y39B5
Y39B4
Y39B3
Y39B2
Y39B1
TIM-ID: 0000038739 - 002
1
2
3
4
5
6
Engine wiring harness for electric starter
2 Fuse F1
3 Connection terminals,
starter
TIM-ID: 0000038739 - 002
1 Connection terminals, EIM
6.21.2
Engine wiring Check

Preconditions

Designation / Use
Isopropyl alcohol
Part No.
Qty.
X00058037
Engine wiring Check

1.
2.
3.
4.
5.
6.
7.
Result:
Close male connectors that are not plugged in with the protective cap supplied.
Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 020
Note:
8.
9.
Check securing screws of cable clamps on engine and tighten loose threaded connections.
Ensure that cables are fixed in their clamps and cannot swing freely.
Verify that all cable clips are closed and in proper condition.
Replace cable clips if defective.
Check that cable clamps are firm, tighten loose cable clamps.
Replace faulty cable clamps.
Visually inspect the following electrical line components for damage:
Connector housing
Contacts
Sockets
Cables and terminals
Plug-in contacts
Contact Service if cable conductors are damaged.
6.22 Accessories for (Electronic) Engine Governor / Control System

6.22.1
CDC parameters Reset

Preconditions
Note:
Failure to reset drift compensation (CDC parameters) will void the emissions certification.
Resetting CDC parameters with DiaSys

u
( Dialog system DiaSys E531920/..).
Resetting CDC parameters without DiaSys

If no DiaSys is available, contact Service.
TIM-ID: 0000044684 - 001
6.22.2
Limit switch for start interlock Check

Preconditions
Note:
In the OFF position, the limit switch initiates a start interlock, i.e. the engine cannot be started.
Checking limit switch for start

interlock
1.
2.
3.
TIM-ID: 0000016782 - 006
4.
Check whether switches (3) and guard

plate (1) with engine support (4) are installed on both sides of flywheel housing (2).
Check whether both switches (3) are actuated.
If switches (3) and/or guard plate (1) with
engine support (4) is/are not installed:
Screw on guard plate (1) with engine
support (4).
Then screw on switch (3), ensuring that
the switch (3) is actuated by the guard
plate (1).
If switch (3) and guard plate (1) are installed, but switch (3) is in the OFF position:
Make certain that the guard plate (1) at
the side of the switch (3) is not distorted.
Release guard plate (1) and screw on
such that the switch (3) is actuated.
6.22.3
Engine Control Unit ECU 7 Checking plug connections

Preconditions
Check plug connections on ECU

7
1.
TIM-ID: 0000016847 - 006
2.
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. Ensure that cable clamps
are not faulty.
6.22.4
Engine Monitoring Unit EMU 7 Plug connection check

Preconditions
Checking EMU plug connections

1.
TIM-ID: 0000035355 - 002
2.
Check both connectors on EMU (2) for firm

seating. Ensure that the clips (1) are engaged.
Check screws (3) of cable clamps on
EMU (2) for firm seating. Ensure that cable
clamps are not faulty.
6.22.5
Interface module EIM plug connections Check

Preconditions
Checking EIM plug connections

1.
TIM-ID: 0000017034 - 004
2.
Check both Tyco plugs (62-pole) (2) on EIM

for firm seating. Ensure that clips (3) are
engaged.
Check screws (1) of cable clamps on EIM
for firm seating. Ensure that cable clamps
are not faulty.
6.22.6
Engine Control Unit ECU 7 Removal and installation

Preconditions
NOTICE
Wrong engine governor installed.

Engine damage!
When reassembling an engine, make sure that the governor with the data record for the given
engine is installed.
Removing Engine Control Unit

from engine
1.
2.
3.
4.
5.
6.
Note or mark assignment of cables and

connectors.
Remove all screws (3).
Undo clips (2) on connectors.
Remove all male connectors.
Remove screws (1).
Take off Engine Control Unit.
Installing Engine Control Unit on engine

Install in reverse order. Ensure correct assignment of connectors and sockets.
Check resilient mount before installing.
If resilient mount is porous or defective then replace it.
TIM-ID: 0000000049 - 008
1.
2.
Result:
6.22.7
EMU 7 Removal and installation

Preconditions
NOTICE
Wrong engine governor installed.

Engine damage!
When reassembling an engine, make sure that the governor with the data record for the given
engine is installed.
Removing ECU with EMU from

engine
1.
2.
3.
4.
5.
6.

connectors.
Remove all screws (2).
Undo latches (3) of the connectors.
Disconnect all connectors.
Remove screws (1).
Remove ECU (5) with EMU (4).
Removing EMU
1.
2.
Unscrew screws on base of EMU (4).

Remove EMU (4) from ECU (5).
Installing EMU
1.
2.
Place EMU (4) on ECU (5).

Screw in and tighten screws on base of EMU (4).
Installing ECU with EMU on engine

Install in reverse order. Ensure correct assignment of connectors and sockets in so doing.
Check resilient mount before installing.
Replace resilient mount if porous or defective.
TIM-ID: 0000016799 - 007
1.
2.
Result:
6.22.8
Engine Interface Module EIM Removal and installation

Preconditions
Removing EIM from the engine

1.
2.
3.
4.
5.
6.
7.

connectors.
Unscrew all screws (1).
Undo clips (2) on connectors.
Disconnect all connectors.
Unscrew power and starter cable.
Remove screws (3).
Take off EIM.
Installing EIM on the engine

1.
2.
Result:
Install in reverse order. When doing so, observe correct assignment between cables and plugs.
Check seal before installing.
Replace seal if porous or defective.
Downloading software
1.
TIM-ID: 0000017035 - 005
2.
The new EIM still does not have appropriate FSW and parameter/descriptor module (the diagnostic
lamp (DILA) indicates flashing code 4 when the power supply is connected, ( Page 274)).
The FSW and the parameter/descriptor module must first be downloaded from the central database
(CDB) based on the relevant engine number using the DiaSys software tool, and then loaded in the EIM.
6.22.9
Diagnostic features of EIM

Diagnostic lamp (DILA)
A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM).
It indicates the operating status of the EIM.
Functions of diagnostic lamp DILA
DILA lights
Engine Interface Module (EIM) is OK.
DILA dark
EIM supply voltage missing or diagnostic lamp activation is faulty.
DILA flashes
Hardware or software fault in the Engine Interface Module.
The diagnostic lamp (DILA) signals the following states:
1 Time in seconds
2 Timing: 1/8 s
3 Ready for operation
4 Application loader active

5 External RAM faulty
6 External FLASH faulty
7 No firmware
8 Application crashed
A second indicator is the fuse lamp.

This is also integrated in the housing of the Engine Interface Module. It indicates the status of the fuses.
An orange LED is provided to allow diagnosis of a tripped fuse fault directly at the unit as it is often
difficult to pinpoint a fault in the field without cabling diagrams.
This LED is activated by the controller.
Functions of fuse lamp SILA
SILA dark
Norma operating state.
SILA flashes orange
One or more fuses have tripped.
The fuse lamp (SILA) signals the following states:

TIM-ID: 0000038009 - 003
Fuse lamp (SILA)
1 Preamble
2 ECU current path failed
(S1)
3 MCS current path failed
(S2)
4 EMU current path failed
(S3)
5 Starter voltage: Terminal
30, 31 not connected and
PR 10.0600.001 has value
1 or 2 (S4)
6 VSP current path failed

(S5)
7 SLD current path failed
(S6)
8 DDV current path failed
(S7)
9 Gear monitoring current
path failed (S8)
10 Emergency stop current
path failed 24V internal
(S9)
11 ES pushbutton current
path failed 24V external
(S10)
12 Key switch current path
failed (S11)
13 SDAF 1+2 current path
failed (S12)
14 PIM current path failed
(S13)
15 Spare current path failed
(S14)
TIM-ID: 0000038009 - 003
The failed current paths are signaled consecutively following the preamble (LED on for 4 seconds (1)).
There is a pause lasting 4 seconds in between.
Sample flashing sequences
A Fuse S5 failure (1/2 second steps)
B Fuse S1 and fuse S4 failure (1/2 second steps)
Note:
These bit sequences are transmitted constantly.
TIM-ID: 0000038009 - 003
Information about the status of the current paths of the EIM is also provided in the CAN message Status internal power supply.
7 Appendix A
TIM-ID: 0000002050 - 005
7.1 Abbreviations
Abbreviation
Meaning
Explanation
ADEC
Advanced Diesel Engine Control
Engine governor
AL
Alarm
Alarm (general)
ANSI
American National Standards Institute
Governing body for US American standards
ETC
BR
Baureihe (Series)
BV
Betriebsstoffvorschrift
Fluids and Lubricants Specifications, MTU Publication

No. A01061/..
CAN
Controller Area Network
Data bus system, bus standard
CDC
Calibration Drift Compensation
Setting for drift correction with DiaSys in engine governor
CPP
Controllable Pitch Propeller
DILA
Diagnostic lamp
on EIM
DIN
Deutsches Institut fr Normung e. V.
German Standardization Organization, at the same

time identifier of German standards ("Deutsche Industrie-Norm")
DIS
Display unit
Display panel
DL
Default Lost
Alarm: Default CAN bus failure
ECS
Engine Control System
Engine management system
ECU
Engine Control Unit
Engine governor
EDM
Engine Data Module
Memory module for engine data
EIM
Engine Interface Module
Interface to engine monitoring system
EMU
Engine Monitoring Unit
SPC
Spare Parts Catalog
FPP
Fixed Pitch Propeller
GCU
Gear Control Unit
GMU
Gear Monitoring Unit
HAT
Harbor Acceptance Test
HI
High
Alarm: Measured value exceeds 1st maximum limit
HIHI
High High
Alarm: Measured value exceeds 2nd maximum limit
HT
High Temperature
ICFN
ISO - Continuous rating - Fuel stop

power - Net
Power specification in accordance with DIN-ISO

3046-7
IDM
Interface Data Module
Memory module for interface data
IIG
Initial Injector Equalization
Entering of injector code with DiaSys in engine governor
IMO
International Maritime Organization
ISO
International Organization for Standardization
International umbrella organization for all national

standardization institutes
KGS
Kraftgegenseite
Engine free end in accordance with DIN ISO 1204
MS150068/01E 2014-01 | Appendix A | 277
Abbreviation
Meaning
Explanation
KS
Kraftseite
Engine driving end in accordance with DIN ISO 1204
LCD
Liquid Crystal Display, Liquid Crystal

Device
LCU
Local Control Unit
LED
Light Emitting Diode
LMU
Local Monitoring Unit
LOP subassembly
LO
Low
Alarm: Measured value lower than 1st minimum limit
LOLO
Low Low
Alarm: Measured value lower than 2nd minimum limit
LOP
Local Operating Panel
Control console, control panel
LOS
Local Operating Station
MCS
Monitoring and Control System
MG
Message
MPU
Microprocessor Unit, Microprocessing

Unit
TDC
Top Dead Center
P-xyz
Pressure-xyz
Pressure measuring point xyz
PAN
Panel
Operating panel
PCU
Propeller Control Unit
PIM
Peripheral Interface Module
RCS
Remote Control System
RL
Redundancy Lost
Alarm: Redundant CAN bus failure
SAE
Society of Automotive Engineers
U.S. standardization organization
SAT
Sea Acceptance Test
SD
Sensor Defect
Alarm: Sensor failure
SDAF
Shut Down Air Flaps
Emergency-air shutoff flap(s)
SILA
Fuse lamp
on EIM
SOLAS
International Convention for the Safety

of Life at Sea
SS
Safety System
SSK
Emergency-air shutoff flap(s)
T-xyz
Temperature-xyz
Temperature measuring point xyz
TD
Transmitter Deviation
Alarm: Sensor comparison fault
BDC
Bottom Dead Center
VS
Voith Schneider
Voith-Schneider drive
WJ
Water Jet
Water jet drive
TC
Tool Catalog
ZKP
Zugehrigkeit-Kategorie-Parameter
278 | Appendix A | MS150068/01E 2014-01
LOP subassembly
Microprocessor (unit)
Numbering plan for ADEC ECU signals
TIM-ID: 0000002050 - 005
Indicated alarm is initiated by the safety system
7.2 MTU contact persons/service partners

Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: [email protected]
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: [email protected]
Tel.: +49 7541 908555
TIM-ID: 0000000873 - 015
Fax: +49 7541 908121
MS150068/01E 2014-01 | Appendix A | 279
8 Appendix B
8.1 Special Tools
Barring device
Part No.:
F6555766
Qty.:
Used in:
1
6.1.1 Engine Barring manually ( Page 162)
Part No.:
Y20010128
Qty.:
Used in:
1
( Page 173)
Part No.:
F30379104
Qty.:
Used in:
1
6.7.2 Additional fuel filter Replacement ( Page 186)
Qty.:
Used in:
1
6.7.3 Fuel filter Replacement ( Page 187)
Qty.:
Used in:
6.14.1 Engine oil filter Replacement ( Page 223)
Feeler gage
Qty.:
Used in:
1
6.14.3 Centrifugal oil filter Cleaning and filter sleeve
replacement ( Page 227)
Qty.:
Used in:
1
6.15.8 Engine coolant filter Replacement
( Page 243)
280 | Appendix B | MS150068/01E 2014-01
DCL-ID: 0000005758 - 004
Filter wrench
Installation/removal jig
Part No.:
F6789889
Qty.:
Used in:
1
6.6.2 Injector Removal and installation ( Page 180)
Part No.:
F30452739
Qty.:
Used in:
1
Part No.:
5605892099/00
Qty.:
Used in:
1
6.13.3 Engine oil Sample extraction and analysis
( Page 221)
Qty.:
Used in:
1
6.15.7 Engine coolant Sample extraction and analysis
( Page 242)
Part No.:
F30027339
Qty.:
Used in:
1
( Page 257)
Milling cutter
MTU test kit
DCL-ID: 0000005758 - 004
Ratchet
MS150068/01E 2014-01 | Appendix B | 281
Ratchet adapter
Part No.:
F30027340
Qty.:
Used in:
1
Qty.:
Used in:
1
6.7.8 Fuel prefilter with water separator Filter element replacement ( Page 195)
Qty.:
Used in:
1
6.8.2 Compressor wheel Cleaning ( Page 205)
Part No.:
F30027341
Qty.:
Used in:
1
Qty.:
Used in:
1
6.13.2 Engine oil Change ( Page 219)
Part No.:
F30006212
Qty.:
Used in:
1
6.1.1 Engine Barring manually ( Page 162)
Part No.:
Y20097353
Qty.:
Used in:
1
6.2.1 Cylinder liner Endoscopic examination
( Page 165)
Ratchet adapter
Ratchet with extension
DCL-ID: 0000005758 - 004
Rigid endoscope
282 | Appendix B | MS150068/01E 2014-01
Socket wrench, 24 mm
Part No.:
F30039526
Qty.:
Used in:
1
( Page 173)
Part No.:
Qty.:
Used in:
1
3.14 Plant Cleaning ( Page 89)
Part No.:
0015384230
Qty.:
Used in:
1
Part No.:
F30452769
Qty.:
Used in:
1
Qty.:
Used in:
1
6.7.8 Fuel prefilter with water separator Filter element replacement ( Page 195)
Qty.:
Used in:
1
6.8.2 Compressor wheel Cleaning ( Page 205)
Steam jet cleaner
Torque wrench, 0.5-5 Nm
DCL-ID: 0000005758 - 004
MS150068/01E 2014-01 | Appendix B | 283

Part No.:
F30027337
Qty.:
Used in:
1
6.13.2 Engine oil Change ( Page 219)
Part No.:
F30027336
Qty.:
Used in:
1
6.14.3 Centrifugal oil filter Cleaning and filter sleeve
replacement ( Page 227)
Part No.:
F30027336
Qty.:
Used in:
1
( Page 257)
Part No.:
F30452768
Qty.:
Used in:
1
( Page 173)
Qty.:
Used in:
1
284 | Appendix B | MS150068/01E 2014-01
DCL-ID: 0000005758 - 004
8.2 Index
Preheating unit244
Numerics
12V 4000 M23F engine data, RheinSchUO, stage II, IMO
Tier II56
12V 4000 M23S engine data, RheinSchUO, stage II, IMO
Tier II59
16V 4000 M23F engine data, RheinSchUO, stage II, IMO
Tier II65
16V 4000 M23S engine data, RheinSchUO, stage II, IMO
Tier II68
A
Abbreviations277
Actuators
Overview 32
Additional fuel filter
Replacement 186
ADEC (ECU 7)
Fault codes 97
Fault messages 96
After stopping the engine88
Air filter
Removal and installation 215
Replacement 214
B
Battery-charging generator drive
Coupling condition check 251
Bilge pump
Relief bore check 252
DCL-ID: 0000005758 - 004
C
CDC parameters
Reset 266
Centrifugal oil filter
Cleaning 227
Checks
Prior to start-up 80
Coalescer filter element
Replacement 257
Compressor wheel
Cleaning 205
Contact persons279
Controls74
Coolant
Change 235
Cooler
Charge-air
Checking condensate drain for water discharge and
obstruction 213
Crankcase breather
Oil mist fine separator
Replacement 171
Crankcase breather system

Overview 169
Cylinder
Designation 52
Cylinder head cover
Installation 176
Removal 176
Cylinder liner
Endoscopic examination 165
Instructions and comments on endoscopic and visual
examination 167
D
Designations
Engine sides and cylinders 52
Differential pressure gauge
Check 254
Drain and vent points230
Drift compensation
Reset 266
E
ECU 7
Installation 271
Removal 271
EMU 7
Installation 272
Plug connection check 269
Removal 272
Engine
Barring manually 162
Barring with starting system 164
Emergency stop 87
Main dimensions 53
Start 77
Stopping 86
Wiring check 265
Engine Control Unit ECU 7
Checking plug connections 268
Installation 271
Removal 271
Engine coolant
Change 235
Draining 236
Filter replacement 243
Sample analysis 242
Sample extraction 242
Engine coolant level
Check 234
Engine coolant Filling239
Engine governor ADEC (ECU 7)
Fault codes 97
Fault messages 96
Engine Interface Module EIM
Removal and installation 273
Engine layout28
MS150068/01E 2014-01 | Appendix B | 285
H
Hotline279
HP pump
Filling with engine oil 177
HT coolant pump
I
Injector
Installation 180
Removal 180
Replacement 179
Intercooler
Checking condensate drain for water discharge and
obstruction 213
Interface module EIM
Check 270
Fault codes
Engine governor ADEC (ECU 7) 97
Fault messages
Engine governor ADEC (ECU 7) 96
Filter
Coalescer element
Replacement 257
Engine coolant
Replacement 243
Filter sleeve
Replacement 227
Firing order55
Fuel
Treatment system
Switching on 84
Troubleshooting 95
treatment system
Shutdown 85
Fuel filter
Replacement 187
Fuel prefilter
Flushing 193
Fuel prefilter
Draining 191
Fuel prefilter with water separator
Filter element replacement 195
Fuel prefilter with water separator Rotary slide valve Orings
Replacement 197
Fuel prefilter Differential pressure gauge
Adjustment 190
Check 190
Fuel system
Venting 189
Fuel treatment system
Putting into operation 81
Shutdown 85
Switching on 84
Limit switch for start interlock

Check 267
286 | Appendix B | MS150068/01E 2014-01
M
Maintenance schedule
Maintenance task reference table [QL1] 90
MTU contact persons279
O
Oil indicator filter
Check 225
Cleaning 225
Operational checks78
P
Plant
Cleaning 89
Plug connections
Check 270
Preheater
Overhaul 247
Function and leak-tightness
check 248
Product description16
Pump capacity
Check 256
Putting the engine into operation after extended out-ofservice periods (>3 months)75
Putting the engine into operation after scheduled out-ofservice-period76
R
Raw water pump
S
Safety notices, standards15
DCL-ID: 0000005758 - 004
Engine Monitoring Unit EMU 7

Plug connection check 269
Engine mounting
Check 250
Engine oil
Sample extraction and analysis 221
Engine oil
Change 219
Engine oil filter
Replacement 223
Engine oil level
Check 218
Engine sides
Designation 52
Engine wiring
Check 265
Engine wiring harness
Overview 259
Safety regulations
Auxiliary materials 13
Environmental protection 13
Fire prevention 13
Fluids and lubricants 13
Important provisions 7
Maintenance work 10
Organizational requirements 8
Personnel requirements 8
Repair work 10
Safety notices, standards 15
Sensors
Overview 32
Service indicator
Signal ring position check 216
Service partners279
Spare parts service279
Starter
Condition check 217
Supplementary fuel filter
Overview 185
T
Tasks
After extended out-of-service periods 79
Tasks after extended out-of-service periods (>3 weeks)79
transport9
Troubleshooting92
Fuel treatment system 95
Turbocharger
Overview 198
V
Valve clearance
Adjustment 173
Check 173
Valve gear
Lubrication 172
W
DCL-ID: 0000005758 - 004
Water drain valve

Check 253
Water level probe (3-in-1 rod electrode)
Check 255
MS150068/01E 2014-01 | Appendix B | 287

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Operating Instructions

Important provisions for all products

3.8 Fuel treatment system Putting into

2.1.1 Product description

2.2 Engine Side and Cylinder Designations

2.4 Firing Sequence

2.4.1 Firing order

2.2.1 Engine side and cylinder designations

2.3 Main Engine Dimensions

2.5 Technical Data

6.2 Cylinder Liner

6.2.1 Cylinder liner Endoscopic examination

6.3 Crankcase Breather

6.4 Valve Drive

6.5 Injection Pump / HP Pump

6.6 Injection Valve / Injector

6.7 Fuel Filter

MS150068/01E 2014-01 | Table of Contents | 5

6.8 Exhaust Turbocharger

6.9 Charge-Air Cooling

6.10 Air Filter

6.11 Air Intake

6.12 Starting Equipment

Drain and vent points

6.18 Battery-Charging Generator

6.15 Coolant Circuit, General, High-Temperature

6.17.1 Engine mounting Check

6.13 Lube Oil System, Lube Oil Circuit

6.14.1 Engine oil filter Replacement

6.16.1 Raw water pump Relief bore check

6.17 Engine Mounting / Support

6.14 Oil Filtration / Cooling

6.16 Raw Water Pump with Connections

6.12.1 Starter Condition check

6.15.11 Preheater Function and leak-tightness check

6 | Table of Contents | MS150068/01E 2014-01

6.18.1 Battery-charging generator drive Coupling

6.19 Auxiliary PTO

6.20 Fuel Supply System

6.21 Wiring (General) for Engine/Gearbox/Unit

6.21.1 Engine wiring harness Overview

6.22 Accessories for (Electronic) Engine

6.22.1 CDC parameters Reset

DCL-ID: 0000005758 - 004

6.7.3 Fuel filter Replacement

Unauthorized modifications to the product compromise safety.

MS150068/01E 2014-01 | Safety | 7

1.2 Personnel and organizational requirements

Working clothes and personal protective equipment

TIM-ID: 0000040531 - 002

8 | Safety | MS150068/01E 2014-01

Attach the engine at the lifting eyes provided only.

TIM-ID: 0000002621 - 004

Setting the engine down after transport

MS150068/01E 2014-01 | Safety | 9

1.4 Safety regulations for maintenance and repair work

Safety regulations during maintenance and repair work

10 | Safety | MS150068/01E 2014-01

TIM-ID: 0000040535 - 004