MTU Technical Documentation
MTU Technical Documentation
MTU Technical Documentation
Technical Documentation
Diesel engine
12 V 4000 P63, P83
16 V 4000 P63, P83
20 V 4000 P63, P83
Application group 3A
Operating Instructions
MS150051/01E
Printed in Germany
2011 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation,
microfilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Commissioning Note
Important
Please complete and return the Commissioning Note card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support
(warranty, spare parts, etc.).
Postcard
MTU Friedrichshafen GmbH
Technical Information Management
Dept. VOT
88040 Friedrichshafen
GERMANY
Commissioning Note
*
Application : * Type : Tick appropriate box
Marine Rail
Genset ......................... Manufacturer:
Remarks:
Table of Contents MS150051/01E
1 Safety 9
1.3 Transport 11
2 General Information 23
3 Technical Data 31
4 Operation 43
4.1 Putting the engine into operation after extended out-of-service-periods (>3 months) 43
4.8 After stopping the engine putting the engine out of service 50
5 Maintenance 53
6 Troubleshooting 55
6.1 Troubleshooting 55
6.2 Engine governor ADEC (ECU 7) for Series 4000 Oil &Gas engines Fault messages 58
7 Task Description 75
7.1 Engine 75
7.1.1 Engine Barring manually 75
7.1.2 Engine Barring with starting system 76
7.1.3 Engine test run 77
8 Appendix A 151
9 Appendix B 155
1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory reg
ulations regarding accident prevention must be observed. This state-of-the-art engine has been designed to meet all
applicable laws and regulations. The engine may nevertheless present a risk of injury or damage in the following
cases:
Incorrect use
Operation, maintenance and repair by unqualified personnel
Modifications or conversions
Non-compliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envisaged for it on
delivery. Any other use is considered improper use. The engine manufacturer accepts no liability whatsoever for
resultant damage or injury in such case. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. The engine manufacturer accepts
no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided
in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
TIM ID: 0000000860 - 011
1.3 Transport
Engine transport
Material
Designation / Use Part No. Qty.
Engine oil
For installation and removal of the transport locking device, follow the instructions below:
1. The transport locking device must remain installed as long as possible during engine installation in order to avoid
damage.
2. Starting or barring the engine is allowed only with the transport locking device removed. If the generator is already
mounted on the engine, ensure that the transport locking device of the generator is also removed.
3. Prior to every engine transport, the transport locking device must be reinstalled on both sides according to the
instructions.
4. If the engine is to be moved together with the generator, the transport locking device for the generator must also
be installed.
Removing guard plates and engine mounting brackets (if applicable) on driving end (KS)
1. Remove screws (4) om both sides and take off with
washers (3), guard plates (1) and engine mounting
brackets (2).
2. Store the removed parts of the transport locking
device carefully for possible reuse.
Note:
Always use the screws supplied with or installed in the transport locking device to secure it on the engine.
2. Screw nut (3) onto screws (4) up to the end of the thread.
3. Fit the locks (1) through the openings of plates (2) and fasten with the screws (4).
4. Tighten screws (4) alternately with torque wrench to the specified tightening torque.
5. Screw on nuts (3) of both screws (4) at plates (2) and secure.
6. Fit label (7) to mark the engine as "Fitted with transport locking device".
Note:
Always use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure
them on the engine.
Installing guard plates and engine mounting brackets (if applicable) on driving end (KS)
1. Install engine mounting brackets (2) on both sides
with guard plates (1) washers (3), and screws (4).
2. Tighten screws (4).
Safety instructions
1. Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion due
to oil vapors).
induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal
Check the function and safe operating condition of tools and fixtures to be used. Use only the specified fixtures for
hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Pay special attention to the pressure level in the compressed air network and pressure vessel.
Assemblies and equipment to be connected must either be designed for this pressure, or, if the permitted pres
sure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve
(set to permitted pressure) must form an intermediate connection.
Hose couplings and connections must be securely attached.
Wear goggles when blowing off components or blowing away chips.
Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
First shut off compressed air lines before compressed air equipment is disconnected from the supply line, or
before equipment or tool is to be replaced.
Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers,
results in a risk of explosion.
Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying
purposes or to check for leaks, results in a risk of bursting.
Carry out leak test in accordance with the specifications.
Painting
When painting in other than spray booths equipped with extractors, ensure good ventilation. Make sure that
neighboring work areas are not impaired.
No open flames.
No smoking.
Observe fire prevention regulations.
Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
Avoid body contact (eyes, hands).
Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
Make sure that working area is well ventilated.
Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids and alkaline solutions
When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
If such solutions are spilled onto clothing, remove the affected clothing immediately.
Rinse injured parts of the body thoroughly with clean water.
Rinse eyes immediately with eyedrops or clean tap water.
Note:
This publication contains especially emphasized safety instructions in accordance with the American standard ANSI
Z535, which begin with one of the above signal words according to the degree of danger:
Safety notes
1. Read and familiarize yourself with all safety warnings before starting up or repairing the product!
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
TIM ID: 0000000881 - 009
2 General Information
2.1 Engine layout
Illustration is also valid for 12/16/20V engines
4000 Series
P Application
x Application segment (6,8 )
y Design index (3)
3 Technical Data
3.1 12 V 4000 P63, P83 engine data
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
Reference conditions
Engine model 12V4000 P63 12V4000 12V4000 P83 12V4000 P83
TAL opti P63 IMO Tier IMO IMO Tier II
mized II
Application group 3A 3A 3A 3A
Intake air temperature C 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 12 12 12 12
Rated engine speed A rpm 1500 1500 1800 1800
Continuous power ISO 3046 (10% over A kW 1350 1350 1455 1455
load capability, design power DIN 6280,
ISO 8528)
Number of cylinders 12 12 12 12
Compression ratio 16.4 16.4 16.4 16.4
Number of inlet valves per cylinder 2 2 2 2
Number of exhaust valves per cylinder 2 2 2 2
LUBE-OIL SYSTEM
Number of cylinders 12 12 12 12
Lube oil operating temperature before R C 90 86 92 92
engine, from
Lube oil operating temperature before R C 93 90 95 95
engine, to
Lube oil temperature before engine, warn R C 99 99 99 99
ing
Lube oil temperature before engine, shut L C 102 102 102 102
TIM ID: 0000022492 - 001
down
Lube oil operating pressure before engine 5.6 5.1 6.2 5.7
(measurement block)
Lube oil operating pressure before engine, R bar 5.1 4.0 5.7 4.5
from
Number of cylinders 12 12 12 12
Lube oil operating pressure before engine, R bar 6.1 6.0 6.7 6.5
to
FUEL SYSTEM
Number of cylinders 12 12 12 12
Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
CAPACITIES
Number of cylinders 12 12 12 12
Engine coolant, engine side (without cool R Liters 212 212 212 212
ing system)
Charge-air coolant, engine side R Liters 47 47 47 47
Engine oil on initial filling (standard oil sys R Liters 245 245 245 245
tem) (option: max. operating inclinations)
Oil change quantity, max. (standard oil sys R Liters 190 190 190 190
tem) (option: max. operating inclinations)
Oil pan capacity at dipstick mark min. L Liters 150 150 150 150
(standard oil system) (option: max. operat
ing inclinations)
Oil pan capacity at dipstick mark max. L Liters 190 190 190 190
(standard oil system) (option: max. operat
ing inclinations)
ACOUSTICS
Number of cylinders 12 12 12 12
Exhaust noise, unsilenced - DL (sound R dB(A) 123 123 124 124
power level LW, ISO 6798+3dB(A)
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 16 16
Rated engine speed A rpm 1500 1800
Continuous power ISO 3046 (10% overload capability, design A kW 1800 1940
power DIN 6280, ISO 8528)
Number of cylinders 16 16
Number of exhaust valves per cylinder 2 2
LUBE-OIL SYSTEM
Number of cylinders 16 16
Lube oil operating temperature before engine, from R C 82 85
Lube oil operating temperature before engine, to R C 92 95
Lube oil temperature before engine, warning R C 99 99
Lube oil temperature before engine, shutdown L C 102 102
Lube oil operating pressure before engine, from R bar 4 4.5
Lube oil operating pressure before engine, to R bar 5.5 6
FUEL SYSTEM
Number of cylinders 16 16
Fuel pressure at engine inlet connection, min. (when engine is L bar -0.1 -0.1
TIM ID: 0000022516 - 001
starting)
Fuel pressure at engine inlet connection, max. (when engine is L bar 1.5 1.5
starting)
CAPACITIES
Number of cylinders 16 16
Engine coolant, engine side (without cooling system) R Liters 260 260
Charge-air coolant, engine side R Liters 50 50
Engine oil on initial filling (standard oil system) (option: max. oper R Liters 300 300
ating inclinations)
Oil change quantity, max. (standard oil system) (option: max. oper R Liters 240 240
ating inclinations)
Oil pan capacity at dipstick mark min. (standard oil system) L Liters 210 210
(option: max. operating inclinations)
Oil pan capacity at dipstick mark max. (standard oil system) L Liters 240 240
(option: max. operating inclinations)
ACOUSTICS
Number of cylinders 16 16
Exhaust noise, unsilenced - DL (sound power level LW, ISO R dB(A) 124 125
6798+3dB(A)
Engine surface noise with attenuated intake noise (filter) - DL R dB(A) 128 128
(sound power level LW, ISO 6798+2dB(A) tolerance)
TIM ID: 0000022516 - 001
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 20 20
Rated engine speed A rpm 1500 1800
Continuous power ISO 3046 (10% overload capability, design A kW 2245 2425
power DIN 6280, ISO 8528)
Number of cylinders 20 20
Number of exhaust valves per cylinder 2 2
LUBE-OIL SYSTEM
Number of cylinders 20 20
Lube oil operating temperature before engine, from R C 88 88
Lube oil operating temperature before engine, to R C 98 98
Lube oil temperature before engine, warning R C 99 99
Lube oil temperature before engine, shutdown L C 102 102
Lube oil operating pressure before engine, from R bar 4,5 4,5
Lube oil operating pressure before engine, to R bar 6 6
FUEL SYSTEM
Number of cylinders 20 20
Fuel pressure at engine inlet connection, min. (when engine is L bar -0,1 -0,1
starting)
Fuel pressure at engine inlet connection, max. (when engine is L bar 1,6 1,6
TIM ID: 0000022523 - 001
starting)
Number of cylinders 20 20
Firing speed, from R rpm 80 80
Firing speed, to R rpm 120 120
CAPACITIES
Number of cylinders 20 20
Engine coolant, engine side (without cooling system) R Liters 290 290
Charge-air coolant, engine side R Liters 70 70
Engine oil on initial filling (standard oil system) (option: max. oper R Liters 335 335
ating inclinations)
Oil change quantity, max. (standard oil system) (option: max. oper R Liters 300 300
ating inclinations)
Oil pan capacity at dipstick mark min. (standard oil system) L Liters 205 205
(option: max. operating inclinations)
Oil pan capacity at dipstick mark max. (standard oil system) L Liters 300 300
(option: max. operating inclinations)
ACOUSTICS
Number of cylinders 20 20
Exhaust noise, unsilenced - DL (sound power level LW, ISO R dB(A) 123 124
6798+3dB(A)
Engine surface noise with attenuated intake noise (filter) - DL R dB(A) 105 109
(sound power level LW, ISO 6798+2dB(A) tolerance)
4 Operation
4.1 Putting the engine into operation after extended out-of-service-periods (>3
months)
Preconditions
Engine is stopped and starting disabled.
MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting the engine into operation after extended out-of-service-periods (>3 months)
Item Task
Engine Depreserve ( MTU Fluids and Lubricants Specifications A001061/..).
Valve drive Lubricate valve gear every 6 months ( Page 83).
Lube oil system Check engine oil level ( Page 112).
Fuel prefilter Fill with fuel (if fitted).
Coolant circuit If engine is out of service for more than one year, change engine coolant ( Page 124);
Change charge-air coolant ( Page 134).
Coolant circuit Check engine coolant level ( Page 123);
Check charge-air coolant level ( Page 133).
Coolant circuit Preheat coolant with preheating unit, if fitted.
Engine governor Check plug-in connections ( Page 148).
HP fuel pump Only for engines without oil priming pump:
Fill HP fuel pump with new engine oil ( Page 90).
TIM ID: 0000002200 - 001
Item Action
Lube oil system Check engine oil level ( Page 112).
Coolant circuit Check engine coolant level ( Page 123), check charge-air coolant level ( Page 133).
Coolant circuit Preheat engine coolant with coolant preheating unit, if fitted.
Fuel prefilter (if fitted) Drain water and contaminants, see manufacturer's documentation.
Engine control system Switch on.
Preparation
Item Task
Operating mode selector switch (if Change to manual mode.
provided)
Preheating pump (if provided) Switch ON.
Item Task
Switchgear cabinet, control panel If coolant temperature is
etc. (depending on manufacturer) > 40 C (with preheating equipment), or
> 5 C (without preheating equipment):
Press start button.
Automatic starting sequence is performed;
Engine speed display instrument indicates increasing crankshaft speed;
After the starting sequence is completed, engine is running at rated speed.
Connect generator to network (if provided), run engine to reach operating temperature )
Item Task
Switchgear cabinet, control panel Close the generator circuit breaker.
etc. (depending on manufacturer)
Engine Apply full load only after engine has reached operating temperature (coolant temperature
approx. 75 C).
TIM ID: 0000002226 - 001
Preparation
Item Task
Operating mode switch Set to emergency mode.
Item Task
Control cabinet Actuate switch/button for ECU override input.
Control cabinet Automatic starting procedure is performed; any safety functions and alarms leading
to engine shutdown are disregarded;
Tachometer indicates increasing crankshaft speed;
Engine is running at rated speed when the starting sequence is completed.
Item Task
Control cabinet If generator is not connected to mains: Close generator circuit breaker.
Engine Operate engine at rated power.
Operational checks
Item Task
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine oil Check engine oil level ( Page 112).
Engine operation Check engine visually for leaks and general condition;
Check for abnormal running noise, exhaust discoloration and vibrations ( Page 55).
Battery-charging generator Check battery-charging generator for contamination, clean as necessary ( Page 142).
Air filter Check differential pressure indication at gauge (if fitted).
Exhaust system Check exhaust color ( Page 55).
Fuel prefilter Drain water and contaminants at the drain cock of fuel prefilter (if fitted) ( Page 100)
Check reading on vacuum gauge of fuel prefilter (if fitted).
Intercooler Check condensate drain(s) for water discharge and obstruction ( Page 107).
Engine coolant pump Check relief bore ( Page 130).
Charge-air coolant pump Check relief bore ( Page 139).
TIM ID: 0000028413 - 001
Item Task
Engine After opening the generator breaker (if provided), allow to cool down off-load for approx. 5
minutes.
Item Task
Engine Allow to cool down for approx. 5 minutes at reduced engine speed. Observe natural reso
nance of engine (installation-dependent)!
Item Task
Switchgear cabinet, control panel Press stop button.
etc. (depending on manufacturer) Automatic stopping sequence is performed;
Engine is stopped.
Item Task
Coolant pump Allow to run on for sufficient time after stopping.
TIM ID: 0000002285 - 001
Emergency stop
Item Action
Emergency stop pushbutton Press EMERGENCY STOP button.
Engine is stopped by disconnecting the power supply to the ECU;
Emergency air shutoff flaps close (if provided);
signalization (e.g. by horn, beacon) is activated.
Item Action
Switchgear cabinet, control panel Press pushbutton for alarm acknowledgment.
etc. (depending on manufacturer) Audible and visual signalization stops.
Engine Manually open emergency air shutoff flaps (if provided).
Engine is ready for starting.
TIM ID: 0000002307 - 002
4.8 After stopping the engine putting the engine out of service
Preconditions
MTU Fluids and Lubricants Specifications (A001061/..) is available.
After stopping the engine
Item Task
Cooling system Drain engine coolant ( Page 125);
Drain charge-air coolant ( Page 135) if:
freezing temperatures are expected and the engine is to remain out of service for an
extended period and coolant has no antifreeze additive;
the engine room is not heated;
the coolant is not maintained at a suitable temperature;
the antifreeze concentration is insufficient for the engine-room temperature;
antifreeze concentration is 50 % and engine-room temperature is below -40C.
Engine/generator/pump controller Switch OFF.
Air intake and exhaust system If the engine is to remain out of service for more than 1 week, seal the engine's air and exhaust
sides. If the engine is to remain out of service for more than 1 month, preserve engine
( MTU Fluids and Lubricants Specifications A001061/.. ).
Material
Designation / Use Part No. Qty.
Cleaner (Hakupur 312) 30390 1
Cautions
Compressed air
Risk of injury!
WARNING Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
Water jet.
Risk of injury and scalding!
WARNING Do not direct water jet at persons.
Wear protective clothing, gloves, and goggles / safety mask.
Plant Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit care
fully and observe the safety precautions.
3. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
4. Carry out external cleaning as follows:
4.1 Remove coarse dirt.
4.2 Spray on cleaner sparingly and leave it for 1 to 5 minutes.
4.3 Use the high-pressure jet to remove the loosened dirt.
4.4 During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must
be observed. The temperature of the cleaning medium must not exceed 80C.
TIM ID: 0000010171 - 011
5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance
Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
Task
W0500 ( Page 47)
W0501 ( Page 47)
W0502 ( Page 47)
W0503 ( Page 47)
W0505 ( Page 47)
W0506 ( Page 47)
W0507 ( Page 47)
W0508 ( Page 47)
W0525 ( Page 142)
W0534 ( Page 77)
W1001 ( Page 99)
W1002 ( Page 84)
W1005 ( Page 108)
W1006 ( Page 91)
W1009 ( Page 121)
W1011 ( Page 78)
W1036 ( Page 131)
W1047 ( Page 119)
W1209 ( Page 145)
W1241 ( Page 141)
W1463 ( Page 140)
W1478 ( Page 116)
Table 1: Maintenance task reference table [QL1]
TIM ID: 0000022417 - 001
6 Troubleshooting
6.1 Troubleshooting
Engine does not turn when starter is actuated
6.2 Engine governor ADEC (ECU 7) for Series 4000 Oil &Gas engines Fault
messages
The fault code numbers are generated by the engine governor and transmitted to the display below.
necessary
015 LO P-Lube Oil Oil pressure too low (1st limit value). ( Page 112). 2.0100.921
Related
Fault code No. Designation Meaning Task parameter No.
1. Check oil level, top up
as necessary
( Page 112).
Oil pressure too low (2nd limit 2. Attempt to restart
016 SS P-Lube Oil value), automatic engine shutdown. engine ( Page 45). 2.0100.922
1. Check cabling
Exhaust temperature of cylinder ( Page 147).
019 HI T-Exhaust A bank A too high (1st limit value). 2. Contact Service. 2.0126.931
1. Check cabling
Exhaust temperature of cylinder ( Page 147).
020 SS T-Exhaust A bank A too high (2nd limit value). 2. Contact Service. 2.0126.932
1. Check cabling
Exhaust temperature of cylinder ( Page 147).
021 HI T-Exhaust B bank B too high (1st limit value). 2. Contact Service. 2.0127.931
1. Check cabling
Exhaust temperature of cylinder ( Page 147).
022 SS T-Exhaust B bank B too high (2nd limit value). 2. Contact Service. 2.0127.932
Check coolant level in
Coolant level too low (1st limit expansion tank
023 LO Coolant Level value). ( Page 123). 2.0152.921
Check coolant level in
Coolant level too low (2nd limit expansion tank
024 SS Coolant Level value). ( Page 123). 2.0152.912
Oil filter differential pressure too Replace oil filter candles
025 HI P-Diff-Lube Oil high (1st limit value). ( Page 116). 2.0154.931
Alarm configuration limit value 1;
Preliminary warning: Oil filter differ Replace oil filter candles
026 SS P-Diff-Lube Oil ential pressure too high. ( Page 116). 2.0154.932
Leak fuel level too high (1st limit 1. Check fuel system.
027 HI Level Leakage Fuel value). 2. Contact Service. 2.0151.931
029 HI ETC Idle Speed too High Idle speed of ETC 2 too high. Contact Service. 1.8004.206
1. Acknowledge alarm.
Engine overspeed; automatic 2. Attempt to restart
030 SS Engine Overspeed engine shutdown. engine. 2.2510.932
Alarm configuration limit value 1;
preliminary warning: speed of pri
031 HI ETC1 Overspeed mary turbocharger too high. Contact Service. 2.3011.931
Automatic power reduc
TIM ID: 0000016865 - 001
Related
Fault code No. Designation Meaning Task parameter No.
Alarm configuration limit value 2;
main warning: speed of secondary
turbocharger too high. Fuel limita 1. Reduce power.
037 SS ETC2 Overspeed tion to a fixed value. 2. Contact Service. 2.3013.912
Related
Fault code No. Designation Meaning Task parameter No.
1. Allow the engine to
cool down;
2. Contact Service.
3.
Check coolant cooler,
clean if necessary.
Coolant temperature too high 4. Restart engine
068 SS T-Coolant (2nd limit). ( Page 45). 2.0120.932
Pressure gradient in rail is too low
during starting or too high during
stopping; HP system leaky, air in
081 AL Rail Leakage system). Contact Service. 1.8004.046
Rail pressure > set value; DBR fuel
limitation, start of injection read
justed towards late; (suction restric
tor of HP fuel block jamming or HP
082 HI P-Fuel (Common Rail) fuel control block wiring faulty) Contact Service. 2.0104.931
Rail pressure <set value; DBR fuel
limitation; (suction restrictor of HP
fuel control block defective or leak
083 LO P-Fuel (Common Rail) age in HP fuel system) Contact Service. 2.0104.921
Preliminary warning: Recirculation
085 HI T-Recirculation temperature too high. Reduce power. 2.0128.931
Main warning: Recirculation tem
086 SS T-Recirculation perature too high. Reduce power. 2.0128.932
Engine speed did not attain 200 Check for additional
089 SS Engine Speed too Low rpm. A stop is activated. messages. 2.2500.030
Alarm configuration limit value;
090 SS Idle Speed Not Reached Idling speed was not attained. Contact Service. 2.1090.925
SS Release Speed Not Alarm configuration limit value;
091 Reached Runup speed was not attained. Contact Service. 2.1090.924
Alarm configuration limit value;
Starter speed was not attained; Ter
mination of starting sequence;
SS Starter Speed Not Starter rotates too slowly or does
092 Reached not rotate at all. Contact Service. 2.1090.923
Alarm configuration limit value 2;
Main warning: preheating tempera
ture too low; coolant temperature
too low for engine start; engine start
TIM ID: 0000016865 - 001
Related
Fault code No. Designation Meaning Task parameter No.
Alarm configuration; Oil priming Check oil priming sys
095 AL Prelubrication Fault fault. tem. 2.1090.920
Invalid fuel consumption display,
checksum error in EDM/EEPROM 1
102 AL Cons. Counter Defect (redundant data record 1). Contact Service. 1.8004.624
Checksum error of hour meter in
104 AL Eng Hours Counter Defect EDM/EEPROM 1 . Contact Service. 18004.623
Check ECU supply volt
LO ECU Power Supply Volt Supply voltage too low (1st limit age.
118 age value). Contact Service. 2.0140.921
Check ECU supply volt
LOLO Power ECU Supply Supply voltage too low (2nd limit age.
119 Voltage value). Contact Service. 2.0140.922
Check ECU supply volt
Supply voltage too high (1st limit age.
120 HI ECU Power Supply Voltage value). Contact Service. 2.0140.931
Supply voltage too high (2nd limit Check ECU supply volt
HIHI ECU Power Supply Volt value); automatic engine shutdown age.
121 age (configurable). Contact Service. 2.0140.932
1. Improve engine room
Temperature in ECU housing too ventilation.
122 HI T-ECU high (1st limit value). 2. Reduce power. 2.0132.921
Internal voltage (-15 VDC) faulty; Replace engine gover
134 15V POS ECU DEFECT automatic engine shutdown. nor.
Internal voltage (-15 VDC) missing;
136 15V NEG ECU DEFECT automatic engine shutdown. Contact Service.
Contact Service. Check
Supply voltage of temperature sen sensors; Replace
139 L1 TE BUFFER TEST sors faulty. engine governor.
Contact Service. Check
Supply voltage of temperature sen sensors; Replace
140 TE BUF. ECU DEFECT sors faulty. engine governor.
Power output stage for control of the
solenoid valves on bank 1 is faulty; Replace engine gover
142 BANK1 ECU DEFECT Engine does not start. nor.
Power output stage for control of the
solenoid valves on bank 2 is faulty; Replace engine gover
144 BANK2 ECU DEFECT Engine does not start. nor.
TIM ID: 0000016865 - 001
Related
Fault code No. Designation Meaning Task parameter No.
Supply voltage A/D converter too Replace engine gover
148 L1 AD-TEST2 SUPPLY low. nor.
Internal electronic fault; automatic Replace engine gover
149 AD-TEST2 ECU DEFECT engine shutdown. nor.
Internal electronic fault; automatic Replace engine gover
150 L1 AD-TEST3 SUPPLY engine shutdown. nor.
Internal electronic fault; automatic Replace engine gover
151 AD-TEST3 ECU DEFECT engine shutdown. nor.
Alarm configuration; No (appropri
ate) LifeData backup system avail
able, ECU reset after expiration of
176 AL LifeData not available time-out period. Contact Service. 2.4000.004
Alarm configuration; This error mes
sage is generated if a CRC is faulty
AL LifeData restore incom during a data upload to ADEC (indi
177 plete cated for each indiv. module). Contact Service. 2.4000.006
Alarm configuration; Connection to
180 AL CAN1 Node Lost a node on CAN bus 1 failed. Contact Service. 2.0500.680
Alarm configuration; Connection to
181 AL CAN2 Node Lost a node on CAN bus 2 failed. Contact Service. 2.0500.681
Alarm configuration; Incorrect
parameter values entered in data
182 AL CAN Wrong Parameters record. Contact Service. 2.0500.682
Alarm configuration; A CAN mode
has been selected in which commu
nication with the PU data module is
initialized. However, the required
PU data module is not available or
183 AL CAN No PU-Data not valid. Contact Service. 2.0500.683
Alarm configuration; A program
ming error occurred when attempt
ing to copy a received PU data mod
184 AL CAN PU-Data Flash Error ule into the Flash module. Contact Service. 2.0500.684
Contact Service. Inspect
CAN bus for short circuit
and rectify short circuit
CAN 1 in Bus-Off state: Either short as necessary. Check
circuit on bus. Or massive magnetic shielding, improve as
186 AL CAN1 Bus Off fields disrupting the bus. necessary. 2.0500.686
Contact Service. Check
TIM ID: 0000016865 - 001
Related
Fault code No. Designation Meaning Task parameter No.
Contact Service. Inspect
CAN bus for short circuit
and rectify short circuit
CAN 2 in Bus-Off state: Either short as necessary. Check
circuit on bus. Or massive magnetic shielding, improve as
188 AL CAN2 Bus Off fields disrupting the bus. necessary. 2.0500.688
Contact Service. Check
that at least one CAN
station is available.
Check cabling as
CAN 2 in Error-Passive state, minor required. Check shield
bus disruption or CAN station miss ing, improve as neces
189 AL CAN2 Error Passive ing. sary. 2.0500.689
AL EMU Parameter Not Sup Alarm configuration; EMU parame
190 ported ters are not supported. Contact Service. 2.0500.690
Related
Fault code No. Designation Meaning Task parameter No.
Related
Fault code No. Designation Meaning Task parameter No.
1. Check sensor and wir
ing.
240 SD P-Fuel Sensor B34 faulty (fuel pressure). 2. Contact Service. 1.8004.565
1. Check sensor and wir
Sensor B49 faulty (recirculation ing.
241 SD T-Umblasen temperature). 2. Contact Service. 1.8004.581
1. Check sensor and wir
Redundant coolant temperature ing.
242 SD T-Coolant (R) sensor faulty. 2. Contact Service. 1.8004.622
Check sensor and
cabling, replace as nec
SD alarm configuration; Redundant essary. Error cleared
lube oil pressure sensor faulty; after restarting the
244 SD P-Lube Oil (R) Short circuit or wire break. engine. 1.8004.621
SD ECU Power Supply Volt Sensor fault (ECU operating volt Replace engine gover
245 age age). nor. 2.8006589
1. Check cabling.
2. Check speed
266 SD Speed Demand External speed demand faulty. demand. 2.8006.586
Check cabling, replace
SD alarm configuration; Filtered as necessary.
analog signal of load pulse missing; Error cleared after
269 SD Loadp.Analog filt short circuit or wire break. restarting the engine. 2.8006.588
1. Check cabling.
2. Contact Service.;
Check setpoint speed
270 SD Frequency Input Frequency setting sensor faulty. transmitter. 2.8006.590
Replace injector con
cerned if the fault mes
Timing Bank 1 (solenoid valve 1) ... sage appears frequently
301 AL Timing Cylinder (A1-A10) Timing Bank 1 (solenoid valve 10) ( Page 91). 1.8004.500
302 1.8004.501
303 1.8004.502
304 1.8004.503
305 1.8004.504
306 1.8004.505
307 1.8004.506
308 1.8004.507
TIM ID: 0000016865 - 001
309 1.8004.508
310 1.8004.509
Related
Fault code No. Designation Meaning Task parameter No.
Replace injector con
cerned if the fault mes
Timing Bank 2 (solenoid valve 1) ... sage appears frequently
311 AL Timing Cylinder (B1- B10) Timing Bank 2 (solenoid valve 10) ( Page 91). 1.8004.510
312 1.8004.511
313 1.8004.512
314 1.8004.513
315 1.8004.514
316 1.8004.515
317 1.8004.516
318 1.8004.517
319 1.8004.518
320 1.8004.519
340 1.8004.539
Open Load Bank 1 (solenoid valve
AL Open Load Cylinder (A1- 1) ... Open Load Bank 1 (solenoid 1. Check solenoid valve.
341 A10) valve 10) 2. Contact Service. 1.8004.540
342 1.8004.541
Related
Fault code No. Designation Meaning Task parameter No.
343 1.8004.542
344 1.8004.543
345 1.8004.544
346 1.8004.545
347 1.8004.546
348 1.8004.547
349 1.8004.548
350 1.8004.549
Open Load Bank 2 (solenoid valve
AL Open Load Cylinder (B1- 1) ... Open Load Bank 2 (solenoid 1. Check solenoid valve.
351 B10) valve 10) 2. Contact Service. 1.8004.550
352 1.8004.551
353 1.8004.552
354 1.8004.553
355 1.8004.554
356 1.8004.555
357 1.8004.556
358 1.8004.557
359 1.8004.558
360 1.8004.559
Alarm configuration; Internal elec
tronic fault (electronics possibly
faulty: Start ITS). If the ITS diagno 1. Check solenoid valve
sis result is "electronics OK", note cabling.
further fault messages (e.g. cabling 2. Replace engine gov
361 AL Power Stage Low faults). ernor. 1.8004.496
Alarm configuration; Internal elec
tronic fault (electronics possibly
faulty: Start ITS). If the ITS diagno 1. Check solenoid valve
sis result is "electronics OK", note cabling.
further fault messages (e.g. cabling 2. Replace engine gov
362 AL Power Stage High faults). ernor. 1.8004.497
Related
Fault code No. Designation Meaning Task parameter No.
Alarm configuration; Injector cabling
fault. If bit "1.1020.021" (Power
Stage Failure: Stop Engine) is set,
engine will be shut down as addi
tional measure. 1. Short circuit of
positive connection of one or more
injectors to ground 2. Short circuit of 1. Check cabling.
negative connection of one or more 2. Attempt to restart
365 AL Stop MV-Wiring Ground injectors to ground . engine. 1.8004.561
1. Check turbocharger
valve/cabling, repair as
Alarm configuration; Short circuit or necessary
wire break on transistor output 1 2. Replace engine gov
371 AL Wiring TO 1 (TO 1). ernor. 1.8004.634
1. Check recirculation
valve/cabling, repair as
Alarm configuration; Short circuit or necessary
wire break on transistor output 2 2. Replace engine gov
372 AL Wiring TO 2 (TO 2). ernor. 1.8004.635
Alarm configuration; Short circuit or
wire break on transistor output 3
373 AL Wiring TO 3 (TO 3). - 1.8004.636
Alarm configuration; Short circuit or
wire break on transistor output 4
374 AL Wiring TO 4 (TO 4). - 1.8004.637
Alarm configuration; Short circuit or
wire break on transistor output,
381 AL Wiring TOP 1 plant-side 1 (TOP 1). Check cabling to plant. 2.8006.638
Alarm configuration; Short circuit or
wire break on transistor output,
382 AL Wiring TOP 2 plant-side 2 (TOP 2). Check cabling to plant. 2.8006.639
Alarm configuration; Short circuit or
wire break on transistor output,
383 AL Wiring TOP 3 plant-side 3 (TOP 3). Check cabling to plant. 2.8006.640
Alarm configuration; Short circuit or
wire break on transistor output,
384 AL Wiring TOP 4 plant-side 4 (TOP 4). Check cabling to plant. 2.8006.641
1. If alarm is only tempo
rary, no action required;
2. <if alarm is continu
Alarm configuration; DBR/MCR ously active, contact
TIM ID: 0000016865 - 001
390 AL MCR exceeded function: MCR has been exceeded. Service. 1.1085.009
Alarm configuration limit value 1;
Preliminary warning: Redundant
coolant temperature reading too 1. Check cabling.
392 HI T-Coolant Red high. 2. Contact Service. 2.0129.931
Related
Fault code No. Designation Meaning Task parameter No.
Alarm configuration limit value 1;
Main warning: Redundant coolant 1. Check sensor and wir
temperature reading too high; ing.
393 SS T-Coolant Red engine shutdown. 2. Contact Service. 2.0129.932
405 AL Open Load Digital Input 6 no resistance over switch. device. 2.8006.630
1. Check cabling.
Alarm configuration; Line disruption 2. Contact Service.;
on digital input 7; Cabling faulty or Check input of target
406 AL Open Load Digital Input 7 no resistance over switch. device. 2.8006.631
Related
Fault code No. Designation Meaning Task parameter No.
1. Check cabling.
Alarm configuration; Line disruption 2. Contact Service.;
on digital input 8; Cabling faulty or Check input of target
407 AL Open Load Digital Input 8 no resistance over switch. device. 2.8006.632
Related
Fault code No. Designation Meaning Task parameter No.
Alarm configuration limit value 1;
Preliminary warning: Temperature
signal of Aux 1 has exceeded / not Determine and rectify
attained limit value 1, depending on reason for limit value vio
428 L1 T-Aux 1 configuration. lation. 2.0130.921
Alarm configuration limit value 1;
Preliminary warning: Pressure sig
nal of Aux 1 has exceeded / not Determine and rectify
attained limit value 1, depending on reason for limit value vio
440 L1 P-Aux 1 configuration. lation. 2.0110.921
Alarm configuration limit value 2;
Preliminary warning: Pressure sig
nal of Aux 1 has exceeded / not Determine and rectify
attained limit value 2, depending on reason for limit value vio
442 L2 P-Aux 1 configuration. lation. 2.0110.931
SD alarm configuration; Injector
power stage sensor defect; Internal
444 SD U-PDU fault in ECU7. Replace ADEC (ECU 7). 1.8004.578
SD alarm configuration; Ambient air Replace engine gover
445 SD P-Ambient Air pressure sensor faulty. nor. 1.8004.580
Alarm configuration limit value 1;
Preliminary warning: Charge-air
448 HI P-Charge Air pressure too high. Contact Service. 2.0103.931
Alarm configuration limit value 2;
Main warning: Charge-air pressure
449 SS P-Charge Air too high. Contact Service. 2.0103.932
Check signal sensor and
cabling, replace as nec
SD alarm configuration; Input signal essary.
for initial/final torque faulty; Short Error cleared after
450 SD Idle/end Torque Input [%] circuit or wire break. restarting the engine. 2.8006.592
1. Note further fault mes
sages.
2. Determine and rectify
Alarm configuration; power reduc reason for power reduc
454 SS Power Reduction Active tion is active. tion. 2.7000.011
Alarm configuration limit value 1;
Input signal of Aux 1 (plant side) has Determine and rectify
exceeded/not attained limit value 1, reason for limit value vio
455 AL L1 Aux 1 Plant depending on configuration. lation. 2.8006.650
TIM ID: 0000016865 - 001
Related
Fault code No. Designation Meaning Task parameter No.
Alarm configuration limit value;
EMU exhaust temperature value too 1. Check cabling.
460 HI T-Exhaust EMU high. 2. Contact Service. 2.8006.652
Alarm configuration limit value;
EMU exhaust temperature value too 1. Check cabling.
461 LO T-Exhaust EMU low. 2. Contact Service. 2.8006.653
Alarm configuration limit value;
EMU coolant temperature value too Check configuration with
462 AL L1 T-Coolant EMU high/low. DiaSys. 2.8006.654
Check signal sensor and
cabling, replace as nec
SD alarm configuration; Analog essary.
input signal for Aux 2 faulty; Short Error cleared after
463 SD AUX 2 circuit or wire break. restarting the engine. 1.8004.591
Check pressure sensor
SD alarm configuration; Analog and cabling.
input signal for Aux 1 pressure Error cleared after
464 SD P-AUX 1 faulty; Short circuit or wire break. restarting the engine. 1.8004.589
Check pressure trans
mitter and cabling,
SD alarm configuration; Analog replace as necessary.
input signal for Aux 2 pressure Error cleared after
465 SD P-AUX 2 faulty; Short circuit or wire break. restarting the engine. 1.8004.588
Check temperature sen
sor and cabling, replace
SD alarm configuration; Analog as necessary. Error
input signal for Aux 2 temperature cleared after restarting
466 SD T-AUX 2 faulty; Short circuit or wire break. the engine. 1.8004.586
Alarm configuration limit value 2;
Preliminary warning: Temperature
signal of Aux 1 has exceeded / not Determine and rectify
attained limit value 2, depending on reason for limit value vio
467 AL L2 T-Aux 1 configuration. lation. 2.0130.922
SD alarm configuration; Analog Replace engine gover
468 SD T-AUX 1 input for Aux 1 temperature faulty. nor. 1.8004579
Check signal sensor and
cabling, replace as nec
SD alarm configuration; Analog essary. Error cleared
input signal for Aux 1 faulty; Short after restarting the
469 SD AUX 1 circuit or wire break. engine. 1.8004.590
TIM ID: 0000016865 - 001
Related
Fault code No. Designation Meaning Task parameter No.
Check sensor and
cabling, replace as nec
SD alarm configuration; Control of essary. Error cleared
HP fuel control block faulty; Short after restarting the
471 SD Coil Current circuit or wire break. engine. 1.8004.592
Alarm configuration; Engine stop,
since all shutdown channels have 1. Check cabling.
472 AL Stop SD "sensor faulty". 2. Contact Service. 2.8006.593
7 Task Description
7.1 Engine
7.1.1 Engine Barring manually
Preconditions
Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Barring device F6555766 1
Ratchet with extension F30006212 1
Cautions
Unguarded rotating and moving engine components.
Risk of serious injury Danger to life!
DANGER Before barring the engine, ensure that nobody is in the danger zone.
Preparatory steps
1. Remove cylinder head cover ( Page 89).
2. Remove injector ( Page 92).
Findings Task
Thin carbon coating on carbon scraper ring No action required
Slight localized additive deposits at top edge
Localized smooth areas at bottom edge
Carbon deposits on entire circumference between top piston ring and bottom edge
of carbon scraper ring
First signs of marks left by top piston ring
Bright mark on entire circumference
Faultless, even honing pattern
First signs of marks left by lower cooling bores
Running pattern seems darker
Dark areas with even or varying degrees of discoloration Further endoscopic examination
Beginning and end of the discoloration are not sharply defined and do not cover required as part of maintenance work
the entire stroke area
Dark areas in the upper section of the cooling bore, remaining circumference can
not be faulted
Piston rings cannot be faulted
On the entire circumference, apart from light areas of discoloration (do not impair Cylinder liner must be replaced; Serv
operation) clearly darker stripes that start at the top piston ring ice must be contacted
Heat discoloration in the direction of stroke and honing pattern damage
Heat discoloration of piston rings
2. Use technical terms for description of the liner surface ( Page 80).
3. Depending on findings:
Do not take any action or
carry out a further endoscopic examination as part of maintenance work or
contact Service; cylinder liner must be replaced.
Final steps
1. Install injector ( Page 92).
2. Install cylinder head cover ( Page 89).
TIM ID: 0000000015 - 005
Replace liner.
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Filter insert Spare Parts Catalog
Diaphragm Spare Parts Catalog
Seal Spare Parts Catalog
Cautions
Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Checking diaphragm
1. Remove cover (4).
2. Remove spring (5), seal (2) and diaphragm (3).
3. Check diaphragm (3) for damage, fit new diaphragm
if used one is damaged.
4. Install diaphragm (3) on housing (1).
5. Install new seal (2) and spring (5) together with cover
(4).
6. Use torque wrench to tighten the screws of cover (4)
to the specified torque.
Material
Designation / Use Part No. Qty.
Engine oil
Preparatory steps
1. Remove cylinder head cover ( Page 89).
2. Install barring device ( Page 75).
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Final steps
1. Remove barring device ( Page 75).
2. Install cylinder head cover ( Page 89).
Spare parts
Designation / Use Part No. Qty.
O-ring Spare Parts Catalog
Cautions
Fuels are combustible.
Risk of fire and explosion!
WARNING Avoid open flames, electrical sparks and ignition sources.
Do not smoke.
Material
Designation / Use Part No. Qty.
Assembly paste (Optimoly Paste White T) 40477 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-ring Spare Parts Catalog
Cautions
Fuels are combustible.
Risk of fire and explosion!
WARNING Avoid open flames, electrical sparks and ignition sources.
Do not smoke.
Preparatory steps
1. Shut off fuel supply to engine.
2. Remove cylinder head cover ( Page 89).
Removing injector
1. Disconnect cable connector on injector.
Installing injector
1. Remove plug before installing the injector. (Do not
remove the plug from the HP line before installing the
adapter.)
2. Coat injector with assembly paste at the seat of the
nozzle clamping nut.
3. Fit new sealing ring (4) (included in the scope of sup
ply of the injector) with grease on injector, observe
installation position of sealing ring (4).
Note:
Ensure special cleanness.
11. Coat thread and sealing cone of adapter (3) with engine oil.
12. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
TIM ID: 0000000925 - 005
13. Tighten screw (2) with torque wrench to the specified tightening torque.
14. Tighten adapter (3) with torque wrench to the specified tightening torque.
16. Coat thread and sealing cone of HP line (5) with engine oil.
Note:
Two HP line versions (single- and double-walled) with different torques as described below.
17. Mount single-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening sequence:
1 Rail (6)
2 Adapter (4)
18. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening sequence:
1 Adapter (4)
2 Rail (6)
Final steps
1. Install cylinder head cover ( Page 89).
2. Open fuel supply to engine.
Cautions
Fuels are combustible.
Risk of fire and explosion!
WARNING Avoid open flames, electrical sparks and ignition sources.
Do not smoke.
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Easy-change filter Spare Parts Catalog
Cautions
Fuels are combustible.
Risk of fire and explosion!
WARNING Avoid open flames, electrical sparks and ignition sources.
Do not smoke.
Spare parts
Designation / Use Part No. Qty.
Gasket Spare Parts Catalog
Cautions
Fuels are combustible.
Risk of fire and explosion!
WARNING Avoid open flames, electrical sparks and ignition sources.
Do not smoke.
Spare parts
Designation / Use Part No. Qty.
Gasket Spare Parts Catalog
Cautions
Unguarded rotating and moving engine components.
Risk of serious injury danger to life!
DANGER Take special care when working on a running engine.
Spare parts
Designation / Use Part No. Qty.
Filter element Spare Parts Catalog
Gasket Spare Parts Catalog
Cautions
Fuels are combustible.
Risk of fire and explosion!
WARNING Avoid open flames, electrical sparks and ignition sources.
Do not smoke.
Compressed air
Risk of injury!
WARNING Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
3. The oil level must reach mark (1) or exceed mark (1)
by up to 2 cm.
4. Top up with oil to mark (1) as necessary
( Page 113).
5. Insert dipstick into guide tube up to the stop.
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Sealing ring Spare Parts Catalog
Cautions
Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Cautions
Unguarded rotating and moving engine components.
Risk of serious injury danger to life!
DANGER Take special care when working on a running engine.
Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Spare parts
Designation / Use Part No. Qty.
O-ring Spare Parts Catalog
Oil filter candles Spare Parts Catalog
Cautions
Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Contamination of components.
Damage to component!
CAUTION Observe manufacturer's instructions.
Check components for special cleanness.
Cautions
Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Compressed air
Risk of injury!
WARNING Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
Removing strainer
1. Clean oil indicator filter before disassembling it.
2. Remove screws (1).
3. Take off cover (2) with Oring (3).
4. Take strainer (5) from filter housing.
TIM ID: 0000006402 - 001
Checking strainer
Cleaning strainer
1. Wash strainer (5) with cleaner.
2. Remove stubborn deposits with soft brush.
3. Blow out strainer (5) with compressed air from inside.
Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Coat Oring (3) with engine oil and fit in filter housing.
3. Fit cover (2) and secure with screws (1) and washers.
Material
Designation / Use Part No. Qty.
Cold cleaner (Hakutex 60) 50602 1
Spare parts
Designation / Use Part No. Qty.
Filter sleeve Spare Parts Catalog
Sealing ring Spare Parts Catalog
Sealing ring Spare Parts Catalog
Cautions
Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Compressed air
Risk of injury!
WARNING Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
TIM ID: 0000000934 - 003
18. Place rotor (6) in housing (5) and check for ease of movement.
19. Check sealing ring (4), fit new one if necessary.
20. Fit sealing ring (4) on housing (5).
21. Fit cover (2).
22. Tighten Tommy nut (1) by hand.
23. Install clamp (3) and tighten with torque wrench to the specified torque.
24. Tighten cover nut (1) with torque wrench to the specified torque.
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheating unit.
Final steps
1. Close all open drain points.
2. Set breather valve onto filler neck and close it.
Cautions
Coolant is hot and under pressure.
Risk of injury and scalding!
WARNING Let the engine cool down.
Wear protective clothing, gloves, and goggles / safety mask.
Preparatory steps
1. Turn breather valve of filler neck on coolant expan
sion tank counterclockwise to first stop and allow
pressure to escape.
2. Continue to turn breather valve counterclockwise and
remove.
TIM ID: 0000006720 - 001
Final steps
1. Start engine and operate it without load for a few minutes.
2. Check coolant level ( Page 123) and top up as required.
TIM ID: 0000006720 - 001
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Coolant filter Spare Parts Catalog
Cautions
Coolant is hot and under pressure.
Risk of injury and scalding!
WARNING Let the engine cool down.
Wear protective clothing, gloves, and goggles / safety mask.
Cautions
Unguarded rotating and moving engine components.
Risk of serious injury danger to life!
DANGER Take special care when working on a running engine.
Cautions
Coolant is hot and under pressure.
Risk of injury and scalding!
WARNING Let the engine cool down.
Wear protective clothing, gloves, and goggles / safety mask.
Cautions
Coolant is hot and under pressure.
Risk of injury and scalding!
WARNING Let the engine cool down.
Wear protective clothing, gloves, and goggles / safety mask.
Preparatory steps
1. Turn breather valve of filler neck on coolant expan
sion tank counterclockwise to first stop and allow
pressure to escape.
2. Continue to turn breather valve counterclockwise and
remove.
Final steps
1. Start engine and operate it without load for a few minutes.
2. Check coolant level ( Page 133) and top up if required.
Cautions
Spring/circlip/tensioning roller preload.
Risk of injury!
WARNING Only use specified tool and equipment.
7.19.3 Battery-charging generator drive Drive belt and belt tensioner replacement
Preconditions
Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Torque wrench 20-100 Nm F30026582 1
Ratchet adapter F30027340 1
Cautions
Heavy object.
Risk of crushing!
WARNING Use appropriate lifting devices and appliances.
Cautions
Heavy object.
Risk of crushing!
WARNING Use appropriate lifting devices and appliances.
8 Appendix A
8.1 Abbreviations
Abbreviation Meaning Explanation
AC Alternating Current
ADEC Advanced Diesel Engine Controller ENGINE MANAGEMENT SYSTEM
AL Alarm
ANSI American National Standards Institute Association of American standardization organizations
ETC Exhaust turbocharger
BDM Backup Data Module
BR Series
BV Fluids and Lubricants Specifications MTU Publication No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CRC Cyclic Redundancy Control Check sum procedure to detect data transmission faults
DC Direct Current
DIFF Difference
DIN Deutsches Institut fr Normung e. V. At the same time identifier of German standards (DIN =
Deutsche Industrie-Norm)
DL Default Lost Alarm: Default CAN bus failure
ECU Engine Control Unit Engine governor
SPC Spare Parts Catalog
FO Frequency Output
GND Ground
HP High pressure
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
ID Identification number
ISO International Organization for Standardization International umbrella organization for all national stand
ardization institutes
ITS Integrated Test System
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LED Light Emitting Diode
LO Low Alarm: Measured value lower than 1st minimum limit
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
TIM ID: 0000009959 - 002
9 Appendix B
9.1 Special Tools
Designation / Use Part No. Qty. Used in
Torque wrench, 10-60 Nm F30510423 1 1.4 Crankshaft transport locking device ( Page 12)
Torque wrench, 60-320 Nm F30047446 1 1.4 Crankshaft transport locking device ( Page 12)
1 7.4.2 Valve clearance Check and adjustment ( Page 84)
Steam jet cleaner - 1 4.9 Plant Cleaning ( Page 51)
Barring device F6555766 1 7.1.1 Engine Barring manually ( Page 75)
Ratchet with extension F30006212 1 7.1.1 Engine Barring manually ( Page 75)
Rigid endoscope Y20097353 1 7.2.1 Cylinder liner Endoscopic examination ( Page 78)
Torque wrench, 6-50 Nm F30027336 1 7.3.1 Crankcase breather Oil separator replacement, dia
phragm check and replacement ( Page 81)
1 7.14.3 Centrifugal oil filter Cleaning and filter-sleeve replace
ment ( Page 121)
Ratchet adapter F30027340 1 7.3.1 Crankcase breather Oil separator replacement, dia
phragm check and replacement ( Page 81)
1 7.19.2 Battery-charging generator drive Drive belt tension
adjustment ( Page 143)
1 7.19.3 Battery-charging generator drive Drive belt and belt
tensioner replacement ( Page 144)
Feeler gauge Y20010128 1 7.4.2 Valve clearance Check and adjustment ( Page 84)
Socket wrench, 24 mm F30039526 1 7.4.2 Valve clearance Check and adjustment ( Page 84)
Installation/removal tool F6789889 1 7.6.2 Injector Removal and installation ( Page 92)
Milling cutter F30452739 1 7.6.2 Injector Removal and installation ( Page 92)
Torque wrench, 0.5-5 Nm 0015384230 1 7.6.2 Injector Removal and installation ( Page 92)
Torque wrench, 10-60 Nm F30452769 1 7.6.2 Injector Removal and installation ( Page 92)
Torque wrench, 60-320 Nm F30452768 1 7.6.2 Injector Removal and installation ( Page 92)
Filter wrench F30379104 1 7.8.1 Fuel filter Replacement ( Page 99)
1 7.15.6 Coolant filter Replacement ( Page 131)
Torque wrench 40-200 Nm F30027337 1 7.13.2 Engine oil Change ( Page 113)
Ratchet adapter F30027341 1 7.13.2 Engine oil Change ( Page 113)
MTU test kit 5605892099/00 1 7.13.3 Engine oil Sample extraction and analysis
( Page 115)
1 7.15.7 Engine coolant Sample extraction and analysis
( Page 132)
Torque wrench 20-100 Nm F30026582 1 7.19.2 Battery-charging generator drive Drive belt tension
adjustment ( Page 143)
1 7.19.3 Battery-charging generator drive Drive belt and belt
tensioner replacement ( Page 144)
Torque wrench, 20-100 Nm F30026582 1 7.19.4 Battery-charging generator - Removal and installation
( Page 145)
Ratchet F30027340 1 7.19.4 Battery-charging generator - Removal and installation
( Page 145)
9.2 Index
12 V 4000 P63, P83 engine data 31 Cylinder head cover
16 V 4000 P63, P83 engine data 35 , 38 Removal and installation 89
Cylinder liner
A Endoscopic examination 78
Abbreviations 151 Instructions and comments on endoscopic 80
After stopping the engine putting the engine 50 and visual examination
out of service D
Air filter Removal and installation 109
Air filter Replacement 108 Drive belt
Air starter Manual operation 111 Condition check 141
ATEX (where applicable) 22 E
Automatic oil filter
Emergency stop
Filter candles
Engine 49
Replacement 116
Engine
Auxiliary materials 19
Barring manually 75
B Barring with starting system 76
Battery-charging generator Check 142 Emergency stop 49
Battery-charging generator drive Drive belt 144 Wiring
and belt tensioner replacement Check 147
Battery-charging generator drive Drive belt 143 Engine coolant
tension adjustment Change 124 ,
Battery-charging generator - Removal and 145 124
installation Level check 123
Sample extraction and analysis 132
C Engine coolant Draining 125
Centrifugal oil filter Engine coolant Filling 127
Cleaning 121 Engine coolant pump
Charge-air coolant Relief bore check 130
Change 134 Engine governor
Charge-air coolant Draining 135 Cleaning 149
Charge-air coolant Filling 136 Plug-in connections
Charge-air coolant level Check 148
Check 133 Engine governor ADEC (ECU 7) for Series 58
Charge-air coolant pump 4000 Oil &Gas engines Fault messages
Relief bore check 139 Engine layout 23
Connectors Engine Main dimensions 42
Cleaning 149 Engine mounting Check 140
Contact partners 153 Engine oil Change 113
Coolant Engine oil level
Charge-air Check 112
Change 134 Engine oil Sample extraction and analysis 115
Check 133 Engine side and cylinder
Coolant filter Designations 24
Replacement 131 Engine test run 77
Crankcase breather Engine wiring
Oil separator replacement Check 147
Diaphragm check 81 F
Crankshaft transport locking device
Removal/installation 12 Filter
O
Oil indicator filter Check 119