Operating Instruction - Motores Diesel

Operating Instructions
Diesel Engine
12V4000T95
12V4000T95x
16V4000T95
MS150120/02E
Engine model kW/cyl. Application group
12V4000T95 155 kW/cyl. 4D, Frac-operation (continuous operation with low load)
12V4000T95L 162 kW/cyl. 4D, Frac-operation (continuous operation with low load)
12V4000T95R 140 kW/cyl. 4D, Frac-operation (continuous operation with low load)
16V4000T95 140 kW/cyl. 4D, Frac-operation (continuous operation with low load)
Table 1: Applicability
© 2017 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 writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
Table of Contents
1 Safety 6 Maintenance
1.1 Important provisions for all products 5 6.1 Maintenance task reference table [QL1] 53
1.2 Correct use of all products 6
1.3 Personnel and organizational requirements 7 7 Troubleshooting
1.4 Safety regulations for initial start-up and
operation 8 7.1 Troubleshooting 55
1.5 Safety regulations for assembly, 7.2 Fault messages 12V- and 16V4000T95 58
maintenance, and repair work 10
1.6 Fire prevention and environmental 8 Task Description
protection, fluids and lubricants, indirect
8.1 Engine 125
materials 14 8.1.1 Engine – Barring manually 125
1.7 Standards for warning notices in the text 8.1.2 Engine – Barring with starting system 127
and highlighted information 16 8.1.3 Engine – Test run 128
8.2 Cylinder Liner 129

2 Transport
8.2.1 Cylinder liner – Endoscopic examination 129
2.1 Transportation 17 8.2.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 131
2.2 Lifting requirements 18
2.3 Crankshaft transport locking device 19 8.3 Crankcase Breather 133
8.3.1 Oil mist fine separator – Replacement 133
3 General Information 8.4 Valve Drive 135
8.4.1 Valve gear – Lubrication 135
3.1 Engine side and cylinder designations 23
8.4.2 Valve protrusion – Measurement 136
3.2 Engine – Overview 24 8.4.3 Valve clearance – Check and adjustment 140
3.3 Back Pack – Overview 28 8.4.4 Cylinder head cover – Removal and
3.4 Sensors and actuators – Overview 29 installation 143
8.5 Injection Pump / HP Pump 145

4 Technical Data
8.5.1 HP fuel pump – Filling with engine oil 145
4.1 Product data 12V4000T95R 12V4000T95 8.6 Injector 147
12V4000T95L 16V4000T95 33 8.6.1 Injector – Replacement 147
4.2 Firing order 38 8.6.2 Injector – Removal and installation 148
4.3 Engine – Main dimensions 39
8.7 Fuel System 155
8.7.1 Fuel system – Venting 155
5 Operation
8.8 Fuel Filter 156
5.1 Putting the engine into operation after 8.8.1 Fuel filter – Replacement 156
extended out-of-service periods (>3 months) 40 8.8.2 Additional fuel filter – Replacement 157
5.2 Putting the engine into operation after 8.8.3 Fuel prefilter – Draining 158
scheduled out-of-service period 41 8.8.4 Fuel prefilter – Filter element replacement 159
5.3 Operational monitoring 42 8.9 Exhaust Turbocharger 161
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5.4 Operating statuses of the Safety Function 8.9.1 Exhaust turbocharger – Turbine housing
System (SFS) 43 check 161
5.5 Emission label – Check 47 8.9.2 Exhaust turbocharger (HP) – Turbine housing
5.6 Engine – Starting in manual mode 48 check 162
5.7 Engine – Stopping in manual mode 49 8.9.3 Exhaust turbocharger (LP) – Turbine housing
check 168
5.8 Emergency engine stop 50
5.9 After stopping the engine – Putting the 8.10 Charge-Air Cooling 173
engine out of operation 51 8.10.1 Charge-air cooler – Leak check 173
5.10 Plant – Cleaning 52 8.11 Air Filter 174
MS150120/02E 2017-08 | Table of Contents | 3

8.11.1 Air filter – Replacement 174 8.18.5 Charge-air coolant pump – Relief bore check 219
8.12 Air Intake 175 8.19 Belt Drive 220

8.12.1 Service indicator – Signal ring position check 175 8.19.1 Drive belt – Condition check 220
8.12.2 Overspeed test – Emergency-air shutoff flap
functional check 176
8.20 Battery-Charging Generator 221
8.20.1 Battery-charging generator – Check 221
8.12.3 Emergency-air shutoff flaps – Manual opening 179
8.20.2 Battery-charging generator – Drive belt
8.13 Exhaust Gas Recirculation 180 tension adjustment 222
8.13.1 Exhaust flaps overview ‒ 12V and 16V 180 8.20.3 Battery-charging generator drive – Drive belt
8.13.2 Exhaust flaps – Checking coupling rod replacement 223
clearance and function 183
8.13.3 Exhaust flaps – Coupling rod replacement 185
8.21 Engine Mounting / Support 224
8.21.1 Engine mounting – Check 224
8.14 Starting Equipment 188
8.14.1 Starter – Condition check 188
8.22 Wiring (General) for Engine/Gearbox/Unit 225
8.22.1 Engine cabling – Check 225
8.15 Lube Oil System, Lube Oil Circuit 189
8.15.1 Engine oil level – Check at sight glass 189
8.23 Accessories for (Electronic) Engine
8.15.2 Engine oil – Level check with oil dipstick 190 Governor / Control System 226
8.15.3 Engine oil – Change 191 8.23.1 Actuators – Visual inspection and test 226
8.15.4 Engine oil – Sample extraction and analysis 193 8.23.2 Engine governor and connector – Cleaning 228
8.23.3 Engine governor plug connections – Check 229
8.16 Oil Filtration / Cooling 195 8.23.4 NOx sensor – Replacement 230
8.16.1 Engine oil filter – Replacement 195 8.23.5 Lambda sensor – Replacement 232
8.16.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 197 8.24 Exhaust System 234
8.24.1 Exhaust silencer – Condensate drain check 234
8.17 High-Temperature Circuit 200 8.24.2 Back Pack – Visual inspection of securing
8.17.1 Engine coolant – Level check 200 screws 235
8.17.2 Engine coolant – Change 202 8.24.3 Back Pack – Checking securing screws for
8.17.3 Engine coolant – Draining 203 firm seating 236
8.17.4 Engine coolant – Filling 205
8.17.5 Engine coolant pump – Relief bore check 208
8.17.6 Engine coolant – Sample extraction and 9 Appendix A
analysis 209
8.17.7 Valve cover – Replacement 210 9.1 List of abbreviations 238
9.2 MTU Contact/Service Partners 241
8.18 Low-Temperature Circuit 211
8.18.1 Charge-air coolant – Level check 211
10 Appendix B
8.18.2 Charge-air coolant – Change 212
8.18.3 Charge-air coolant – Draining 213 10.1 Special Tools 242
8.18.4 Charge-air coolant – Filling 216
10.2 Index 252
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1 Safety
1.1 Important provisions for all products
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
• Changes or modifications which are neither made nor authorized by the manufacturer
• Noncompliance with the safety instructions and warning notices
Nameplates
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.
Emission regulations and emission labels

Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents 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, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The product must be operated over its entire life cycle according to the conditions defined as "Intended use"
(→ Page 6).
Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Exception: Engines used exclusively in land-based, military applications other than by US government agen-
cies.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Emission labels shall not be transferred from the replaced part to the spare part.
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• The emission labels must be removed from the replaced part and destroyed.
MS150120/02E 2017-08 | Safety | 5

1.2 Correct use of all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• 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 preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-
so applies to engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• 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 re-
pair
The product must not be operated in explosive atmospheres unless the engine fulfills the conditions for such
use and approval has been granted.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer 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 websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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6 | Safety | MS150120/02E 2017-08

1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and repair based on this manual. In particular, per-
sonnel must have read and understood the safety requirements and warnings before starting work.
This is important in the case of personnel who only occasionally perform work on or around the product.
Such personnel must be instructed repeatedly.
Personnel requirements
All work on the product must be carried out by trained, instructed and qualified personnel only:
• Training at the Training Center of the manufacturer
• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.
Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-
tion, Authorisation and restriction of CHemicals): We recommend wearing protective gloves at all times in
order to reduce risk when working.
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MS150120/02E 2017-08 | Safety | 7

1.4 Safety regulations for initial start-up and operation
Safety regulations for initial start-up
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• All components must be properly grounded. Ground separately by means of a grounding stake as neces-
sary.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• The product must be free of any damage, this applies in particular to lines and cabling.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated e.g. +/- polarity, fuel line/urea solution line, sup-
ply/return.
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the monitoring, signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation

The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.
Take the following steps if any system malfunctions are detected or signaled by the system:
• inform supervisor(s) in charge,
• analyze the message,
• respond by taking any necessary emergency action, e.g. emergency stop.
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Contact Service if the root cause of the malfunction cannot be clearly identified.
Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
Do not inhale the exhaust gases of the product.
8 | Safety | MS150120/02E 2017-08

The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent.
Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.
Follow the applicable operating and safety instructions when operating the devices and heed warnings at all
times.
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MS150120/02E 2017-08 | Safety | 9

1.5 Safety regulations for assembly, maintenance, and repair
work
Safety regulations for work prior to assembly, maintenance, and repair
Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk
of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble containers of adequate capacity to catch fluids and lubricants.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out assembly, maintenance, or repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• Close supply line for hydraulic starting.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.
Before starting work on CaPoS, if used:
• Switch of the charging system (DC/DC converter).
• Discharge the UltraCap modules using the appropriate discharger.
• Short-circuit the UltraCap modules with a suitable wire jumper.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Before working on the exhaust gas treatment system close the shut-off valve on the urea solution tank. Take
into consideration that the urea solution pumps continue to run for a certain period when the engine was
stopped.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Safety regulations when performing assembly, maintenance, and repair work

Special tools and lifting equipment
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
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Setting down, lifting and climbing

Carry out work only on assemblies or plants which are properly secured.
Use appropriate lifting equipment for all components. Use all specified attachment points and observe the
center of gravity.
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down.
Ensure safe stand when performing assembly work.
10 | Safety | MS150120/02E 2017-08

Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Special instructions
for outdoor areas: There must be no risk of slipping e.g. due to icing.
Removing, installing and cleanliness

Pay particular attention to cleanliness at all times.
Take special care when removing ventilation or plug screws from the product.
Ensure that O-rings are not installed in a slanted/twisted condition.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Note cooling time for components which are heated for installation or removal (risk of burning).
Ensure that all retainers and dampers are installed correctly.
Remove any accumulation of condensate after assembling chilled components. Coat the components with a
suitable corrosion inhibitor as necessary.
Lines
Keep gaseous/liquid fuel injection lines, lines for urea solution and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
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.
Miscellaneous
Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P2) when work-
ing on exhaust components. Wear protective gloves and goggles for protection against acidic condensate.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
Only install them after painting the engine or mask them prior to painting.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). 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 after performing assembly, maintenance, and repair work

Before barring the engine, make sure that nobody is standing in the danger zone of the product.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
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Check that all safety equipment has been installed and that all tools and loose parts have been removed
(especially the barring tool).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
MS150120/02E 2017-08 | Safety | 11

Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld-
ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-
cants.
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 can induce interfering voltages in the wiring harnesses which may damage the electrical sys-
tem.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.
Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-
ces for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines which are under pressure.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
Working with batteries

Observe the safety instructions of the manufacturer when working on batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow battery acids to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. The battery may explode and spray
acid if the battery terminals are connected incorrectly.
Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing assembly, maintenance, and repair
work or switching off any part of the electronic system required to do so.
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De-energize the appropriate areas prior to working on assemblies.

ESD: Work on electrostatically endangered components which could be damaged by electrostatic discharge
(ESD) must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically con-
ductive work surfaces or antistatic wristbands.
Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-
ing operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
12 | Safety | MS150120/02E 2017-08

Do not secure cables on lines carrying fluids.
Do not use cable ties to secure lines.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to functional testing on completion of all repair work. The emergen-
cy stop function must be tested in particular.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil (as necessary)
Working with laser equipment

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to type
and application.
Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
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MS150120/02E 2017-08 | Safety | 13

1.6 Fire prevention and environmental protection, fluids and
lubricants, indirect materials
Fire prevention and safety
Flames, naked light and smoking are prohibited.
Ensure the area is well ventilated when working with combustible fluids and lubricants (e.g. cleaning agents).
The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires so keep the product
clean at all times. Do not leave rags saturated with fluids and lubricants on the product. Do not store com-
bustible materials near the product.
Clean welding points with a non-flammable fluid before welding. Do not carry out welding work on pipes and
components carrying oil or fuel.
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 cable from the external power source to the
ground cable of the engine or to the ground terminal of the starter.
Ensure that suitable extinguishing agents (fire extinguisher) are always available and that personnel are famil-
iar with their correct handling.
Toxic substances may be present following a fire. Always wear protective gloves and other appropriate per-
sonal protective equipment when handling components.
Noise
Wear ear protectors in work areas with a sound pressure level in excess of 85dB (A).
Noise can lead to an increased risk of accident if audible signals, warning shouts or noises indicating danger
are drowned.
Environmental protection and disposal

Dispose of used fluids, lubricants and components in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
cled.
Indirect materials, fluids and lubricants

Indirect materials, fluids and lubricants may be hazardous or contain toxic substances. Observe the informa-
tion provided in the safety data sheet for the product when using indirect materials and other chemical sub-
stances. The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Only use fluids and lubricants which have been approved by the manufacture and are specified in the Fluids
and Lubricants Specifications. Request the latest version from the manufacturer.
Contamination of fluids and lubricants with aqueous urea solution (e.g. AdBlue®, DEF): Store fluids and lubri-
cants in separate containers and use different drip trays. Even tiny amounts of aqueous urea solution can
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contaminate sensors and other components leading to malfunction.

Used oil contains harmful combustion residue.
Always wear protective gloves when handling used oil.
Wash relevant areas after contact with used oil.
REACH regulation (Registration, Evaluation, Authorisation and restriction of

CHemicals)
Any Substances of Very High Concern used in our products are listed under:
14 | Safety | MS150120/02E 2017-08

http://www.mtu-online.com/mtu/technical-info → SVHC acc. REACH in MTU products
Compressed air
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing off workpieces or blowing away chips.
• 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 level in the compressed air network or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Relieve residual pressure before removing compressed-air equipment from the supply line. To depressu-
rize compressed-air lines, shut off the lines first, then release the residual pressure.
• Perform leak testing in accordance with instructions.
Paints and lacquers

• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray booths provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• Avoid open flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• 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 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/alkaline solutions/urea (e.g. AdBlue®, DEF)

• When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and protec-
tive clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• Wash affected body areas with plenty of water after skin contact.
• Rinse eyes immediately with eyedrops or clean tap water after eye contact. Seek medical attention as
soon as possible.
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Contamination of aqueous urea solution with other fluids and lubricants: Store aqueous urea solution in
separate containers and use different drip trays. Even the slightest contamination may cause the exhaust
gas aftertreatment system to malfunction.
MS150120/02E 2017-08 | Safety | 15

1.7 Standards for warning notices in the text and highlighted
information
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Warning notices
1. This manual with all safety instructions and warning notices must be issued to all personnel involved in oper-
ation, maintenance, repair, assembly, installation, or transportation.
2. The highest level warning notice is used if several hazards apply at the same time. Warnings related to per-
sonal injury shall be considered to include a warning of potential damage.
Highlighted information
Important
This field contains product information which is important or useful for the user.
This information must not refer to hazards related to personal injury or material damage.
TIM-ID: 0000040578 - 006
16 | Safety | MS150120/02E 2017-08

2 Transport
2.1 Transportation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Crossbeam T80092360 1
DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Transportation
1. Install the engine mount locking devices and the engine shipping lock prior to transportation (→ Page 19).
2. Transport the engine by the lifting eyes provided (→ Page 18).
3. Use suitable transport and lifting gear only.
4. Transport the engine in the installation position only: maximum admissible diagonal pull is 10°, see engine
installation/arrangement drawings (→ Page 18).
5. Remove any loose parts on the engine.
6. Raise and lower the engine slowly. Lifting cables/chains must not touch the engine or any of its component
parts when lifting. Readjust lifting gear as necessary.
7. For special packaging with aluminum foil: Suspend the engine by the lifting eyes on the bearing pedestal or
transport by means of handling equipment (forklift truck) capable of bearing the load.
8. Secure the engine against tilting during transportation. Secure such as to preclude slipping and tipping when
driving up or down inclines and ramps.
Setting down after transport

1. Set engine down on a firm, level surface only.
2. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
3. Never set the engine down on its oil pan unless expressly authorized to do so by MTU in the case of the
particular engine concerned.
TIM-ID: 0000065149 - 002
MS150120/02E 2017-08 | Transport | 17

2.2 Lifting requirements
Lifting requirements
DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
This overview applies analogously to 12V and 16V engines.
1 Max. admissible diagonal 2 Center of gravity

pull 10°
Note engine center of gravity

See engine installation/arrangement drawings for details of engine center of gravity.
TIM-ID: 0000065869 - 002
18 | Transport | MS150120/02E 2017-08

2.3 Crankshaft transport locking device
Torque wrench, 10–60 Nm F30452769 1
Engine oil
Transport locking device

Note: The locking device protects the crankshaft bearings from possible shocks and vibration damage during en-
gine transport.
For installation and removal of the transport locking device, observe the following instructions:
• The transport locking device must remain installed as long as possible during engine installation in order
to avoid damage.
• Starting or barring the engine is allowed only with the transport locking device removed. If the generator/
gearbox is flanged on, make sure that the transport locking device of the generator/gearbox is removed
as well.
• The transport locking device must be reinstalled according to the instructions prior to every engine trans-
port.
• If the generator/gearbox is flanged on and is also going to be moved, install the transport locking device
of the generator/gearbox as well.
Removing the transport locking
device from driving end (KS),
version A
1. Remove parts (1) to (8) from engine. Spacer
sleeves (5) are optional.
2. Store the removed parts of the transport
locking device carefully for possible reuse.
TIM-ID: 0000027593 - 005
MS150120/02E 2017-08 | Transport | 19

Installing the transport locking
device on driving end (KS), ver-
sion A
1. Screw holder (4) with spacer sleeves (5) and
screws (6) onto crankshaft. Spacer sleeves
(5) are optional.
2. Tighten screws (6) with torque wrench to specified tightening torque.

Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 160 Nm +16 Nm
3. Screw nut (3) with washer (2) onto holder (4).

4. Fit carrier (1) with washer (7) and nut (8) and tighten to the specified tightening torque using the torque
wrench.
Nut M24 Tightening torque (Engine oil) 100 Nm +10 Nm
5. Lock with nut (3).

6. Mark the engine as "Fitted with transportation locking device".
Removing the transport locking

device from driving end (KS),
version B
1. Release locknuts (3) on both sides of the fly-
wheel housing, remove screws (4) and take
off the two holders (1).
2. Remove screws (6) with washers (5), label (7)
and plates (2).
3. Store the removed parts carefully for possible
reuse.
TIM-ID: 0000027593 - 005
20 | Transport | MS150120/02E 2017-08

Note: Use only the screws supplied with or re-
moved from the guard plates to secure the
guard plates.
4. Install guard plates (3), washers (2) and
screws (1) on both sides.
5. Tighten screws (1).
Fitting the transport locking de-

vice on driving end (KS), version
B
1. Remove screws (1) with washers (2) and take
off guard plates (3).
2. Store the removed parts carefully for possible
reuse.
TIM-ID: 0000027593 - 005
MS150120/02E 2017-08 | Transport | 21

Note: Only screw on the transport locking device with the screws supplied with or removed from the transport
locking device.
3. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel housing
and tighten to the specified tightening torque.
4. Screw nut (3) onto screws (4) up to the end of the thread.
5. Fit the holders (1) through the openings of plates (2) and fasten with the screws (4).
6. Tighten screws (4) alternately with torque wrench to the specified tightening torque.
7. Screw on nuts (3) of both screws (4) at plates (2) and secure.
8. Fit label (7) to mark the engine as "Fitted with transport locking device".
TIM-ID: 0000027593 - 005
22 | Transport | MS150120/02E 2017-08

3 General Information
3.1 Engine side and cylinder designations
1 Left engine side (A-side) 3 Right engine side (B-side)

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-
hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of
each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 014
MS150120/02E 2017-08 | General Information | 23

3.2 Engine – Overview
Engine overview, driving end – 12V
The overviews depicted here may vary from the actual engine.
1 EGR cooler 8 Cylinder head 15 Flywheel

2 Charge-air cooler (low pres- 9 Oil pan 16 Exhaust gas recirculation
sure) 10 Bypass flap (EGR)
3 Exhaust turbocharger (high 11 Oil dipstick 17 Charge-air cooler (high-
pressure) 12 Oil filler neck pressure)
4 Exhaust turbocharger (low- 13 Engine lifting equipment 18 Safety Function Box (option-
pressure) 14 Emergency-air shutoff flap al)
5 Exhaust outlet (optional) 19 Coolant pipework after EGR
6 Engine oil heat exchanger cooler
7 Air intake KS Driving end
TIM-ID: 0000045672 - 005
24 | General Information | MS150120/02E 2017-08

Engine overview, free end – 12V
1 HT coolant line after cylin- 7 Fuel filter 13 Battery-charging generator

der head 8 Fuel priming pump 14 Centrifugal oil filter
2 Engine governor (ECU) 9 Engine oil filter 15 Crankcase breather
3 Emergency-air shutoff flap 10 HP fuel pump KGS Free end
(optional) 11 Engine mounting
4 Charge-air pipework 12 Vibration damper
5 Starter
6 Additional fuel filter
TIM-ID: 0000045672 - 005

Engine overview, driving end – 16V
1 EGR cooler 8 Cylinder head 15 Flywheel

2 Charge-air cooler (low pres- 9 Oil pan 16 Exhaust gas recirculation
sure) 10 Bypass flap (EGR)
3 Exhaust turbocharger (high 11 Engine lifting equipment 17 Charge-air cooler (high-
pressure) 12 Oil dipstick pressure)
4 Exhaust turbocharger (low- 13 Oil filler neck 18 Safety Function Box (option-
pressure) 14 Emergency-air shutoff flap al)
5 Exhaust outlet (optional) 19 Coolant pipework after EGR
6 Engine oil heat exchanger cooler
7 Air intake
TIM-ID: 0000045672 - 005

Engine overview, free end – 16V
1 HT coolant line after cylin- 6 Additional fuel filter 11 Engine oil filter
der head 7 Fuel filter 12 Vibration damper
2 Engine governor (ECU) 8 Fuel priming pump 13 Battery-charging generator
3 Emergency-air shutoff flap 9 HP fuel pump 14 Centrifugal oil filter
(optional) 10 Engine mounting 15 Crankcase breather
4 Charge-air pipework
5 Starter
Engine model designation

Explanation of engine model designation 12/16V4000T95/T95L/T95R
12, 16 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
T Application: Oil&Gas (onshore)
9 Application segment: High performance (Hydro Frac)
5 Design status
TIM-ID: 0000045672 - 005
L L (enhanced power / speed)

R R (power / speed reduction)

3.3 Back Pack – Overview
Back Pack – Overview
Only applies to 12V4000T95 and 12V4000T95x.
1 Exhaust silencer 4 Air filter 7 Air intake elbow

2 Rain cap 5 Service indicator 8 Exhaust bellows
3 Air filter 6 Combined support for air/
exhaust system
TIM-ID: 0000057595 - 002

3.4 Sensors and actuators – Overview
Illustrations are also valid for 16V4000T95 engines.
1 Y12T5 – Adaption emergen- 2 Y12T4 – Adaption emergen- 3 B13 – Crankshaft speed

cy-air shutoff flap with SFS cy-air shutoff flap without
(optional) SFS (optional)
TIM-ID: 0000054363 - 003

1 M52 – Bypass flap 5 B91.3 – Exhaust gas pres- 9 B97B1–B6 Pressure ESD
2 B44.2 – Turbocharger B sure 10 B10.2 – Charge-air pres-
speed 6 B50 – Crankcase pressure sure, B side
3 B88.2 – NOx Lambda B side 7 B16 – Coolant pressure
4 B90 – Intake air humidity 8 XM2 – Lube oil pump adap-
(pressure, temperature) tion
TIM-ID: 0000054363 - 003

1 B88.1 – NOx Lambda A side 8 A19 – EIL 15 B34.2 – Fuel pressure be-
2 B44.3 – Turbocharger A+B 9 B9 – Charge-air tempera- fore filter
speed ture 16 B33 3 – Fuel temperature
3 B4 – Exhaust gas tempera- 10 XF70 – Water level in fuel 17 B34.1 – Fuel pressure after
ture filter filter
4 M55 – Donor cylinder flap A 11 XF57 – Charge-air coolant 18 F46 – Leak fuel level
5 B98 – Exhaust pressure af- leak level 19 B5.3 – Lube oil pressure be-
ter cylinder head 12 XF33 – Engine coolant level fore filter
6 B10.1 – Charge-air pressure 13 B97A1–A6 – Pressure ESD 20 B7 – Lube oil temperature
A 14 B34.3 – Fuel pressure be-
7 M53 – EGR shutoff flap fore opt. filter
TIM-ID: 0000054363 - 003

1 Y44.1 – Fan control 5 Y44.2 – Fan control, exter- 9 B43 – Charge-air coolant
2 B89 – Lambda probe nal pressure
3 B44.1 – Turbocharger A 6 B48 – Pressure in HP fuel 10 B26 – Charge-air coolant
speed system temperature
4 B5.1 – Lube oil pressure af- 7 M8 – HP fuel pump 11 B6 – Engine coolant temper-
ter filter 8 B1 – Camshaft speed ature
TIM-ID: 0000054363 - 003

4 Technical Data
4.1 Product data 12V4000T95R 12V4000T95 12V4000T95L
16V4000T95
Legend
DL Reference value: Continuous power. continuously attainable power at standard conditions
BL Reference value: Fuel stop power. Maximum engine power. not continuously attainable in some appli-
cations (margin for load fluctuations)
A Design value. Value required to design an external system (plant)
R Guideline value. Typical average value for information, only partially suitable for design purposes
L Limit value. Value which must not be violated (lower limit value, min. value / upper limit value, max.
value), not suitable for design purposes
N Not yet defined value. Value has not yet been defined or will not be defined
- Not applicable. Module does not apply to this product type
X Applicable. Module applies to this product type
> Actual value must be higher than the specified value
< Actual value must be lower than the specified value
* Value not adequately verified (tolerance +/- 10%)
** Value not adequately verified (tolerance +/- 5%)
Iden- Product type Application Speed List perform-

tifier ance
1 12V4000T95R Oil & Gas / mechani- 1900 rpm 1680 kW Ref. 25 °C/45 °C
cal drive O&G 2253 bhp EPA Nonroad T4
4D, continuous opera- (40CFR1039)
tion, variable
2 12V4000T95 Oil & Gas / mechani- 1900 rpm 1865 kW Ref. 25 °C/45 °C
tion, variable
3 12V4000T95L Oil & Gas / mechani- 1900 rpm 1939 kW Ref. 25 °C/45 °C
tion, variable
4 16V4000T95 Oil & Gas / mechani- 1900 rpm 2240 kW Ref. 25 °C/45 °C
tion, variable
Reference conditions
TIM-ID: 0000054790 - 003
Identifier 1 2 3 4
Intake air temperature °C 25 25 25 25
Charge-air coolant temperature °C 45 45 45 45
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
MS150120/02E 2017-08 | Technical Data | 33

Performance data
Identifier 1 2 3 4
Rated engine speed A rpm 1900 1900 1900 1900
Effective power (w/o fan) (fuel stop pow- A kW 1680 1865 1939 2240
er ISO 3046)
General conditions (for max. power)

Identifier 1 2 3 4
Intake depression (new filter) (total pres- A mbar 15 15 15 15
sure referenced to atmosphere)
Intake depression , max. (total pressure L mbar 50 50 50 50
referenced to atmosphere)
Exhaust gas overpressure (total pressure A mbar 30 30 30 30
referenced to atmosphere)
Exhaust gas overpressure, max. (total L mbar 85 85 85 85
pressure referenced to atmosphere)
Model related data (basic design)

Identifier 1 2 3 4
Engine with exhaust turbocharging (ETC) - X X X X
and charge-air cooling (CAC)
Uncooled exhaust lines - X X X X
Number of cylinders - 12 12 12 16
Cylinder arrangement: V angle De- 90 90 90 90
grees (°)
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Displacement of a cylinder Liters 4.77 4.77 4.77 4.77
Total displacement Liters 57.2 57.2 57.2 76.3
Compression ratio - 15.5 15.5 15.5 15.5
Number of inlet valves per cylinder - 2 2 2 2
Number of exhaust valves per cylinder - 2 2 2 2
Standard housing connection flange (en- SAE 00 00 00 00
gine driving end)
Combustion air / exhaust gas

Identifier 1 2 3 4
TIM-ID: 0000054790 - 003
Charge-air pressure before cylinder R bar abs 4.2 4.6 4.8 4.4
Exhaust temperature before turbocharg- R °C 550 568 574 584
er
Exhaust temperature after exhaust turbo- R °C 368 374 373 387
charger
Exhaust gas temperature downstream of L °C 358 364 366 370
engine, max. (exhaust turbocharger)
34 | Technical Data | MS150120/02E 2017-08

Coolant system (high-temperature circuit)
Identifier 1 2 3 4
Coolant temperature at ambient temper- A °C 105 105 105 105
ature up to 40 °C (at engine connection:
outlet to cooling system)
Coolant temperature after engine, limit 1 L °C 112 112 112 107
Coolant temperature after engine, limit 2 L °C 114 114 114 109
Coolant antifreeze content, max. L % 50 50 50 50
Pressure loss in off-engine cooling sys- L bar 1 1 1 1
tem, max. without thermostat
Thermostat: Starts to open R °C 79 79 79 79
Thermostat: Fully open R °C 92 92 92 92
Coolant system (low-temperature circuit)

Identifier 1 2 3 4
Coolant temperature (at engine connec- R °C 56 * 58 56 * 56 *
tion: outlet to cooling system)
Coolant temperature before charge-air L °C 82 82 82 82
cooler, limit 1
Coolant temperature before charge-air L °C 85 85 85 85
cooler, limit 2
Coolant antifreeze content, max. L % 50 50 50 50
Coolant pump: Inlet pressure, min. L bar 0.5 0.5 0.5 0.5
Coolant pump: Inlet pressure, max. L bar 2.5 2.5 2.5 2.5
Breather valve (expansion tank) opening R bar 1.0 1.0 1.0 1.0
pressure at overpressure
Breather valve (expansion tank) opening R bar 0,1 0.1 0.1 0.1
pressure at vacuum pressure
Pressure in cooling system, max. L bar 3.0 3.0 3.0 3.0
Cooling system: Operating pressure A bar 2.5 2.5 2.5 2.5
Thermostat: Starts to open R °C 38 38 38 38
Thermostat: Fully open R °C 51 51 51 51
Lube oil system

Identifier 1 2 3 4
Lube oil operating temperature before R °C 80 80 80 80
engine, from
Lube oil operating temperature before R °C 95 95 95 95
TIM-ID: 0000054790 - 003
engine, to
Lube oil temperature before engine, limit L °C 106 106 106 106
1
Lube oil temperature before engine, limit L °C 108 108 108 108
2
Lube oil operating pressure before en- R bar 5.5 5.5 5.5 5.5 *
gine, from
Lube oil operating pressure before en- R bar 6.8 6.8 6.8 6.9
gine, to

Fuel system
Identifier 1 2 3 4
Fuel pressure at engine inlet connection, L bar -0.3 -0.3 -0.3 -0.3
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
General operating data

Identifier 1 2 3 4
Cold start capability: air temperature R °C -10 -10 -10 -10
(w/o start aid, w/o preheating) - (case A)
Coolant preheating: Preheating tempera- L °C 40 40 40 40
ture (min.)
Firing speed, from R rpm 60 60 60 60
Inclinations – standard oil system (reference: waterline)

Identifier 1 2 3 4
Longitudinal inclination, continuous max. L De- 10 10 10 10
driving end down (option: max. operating grees (°)
inclinations)
Longitudinal inclination, continuous max. L De- 10 10 10 10
driving end up (option: max. operating in- grees (°)
clinations)
Transverse inclination, continuous max. L De- 10 10 10 10
(option: max. operating inclinations) grees (°)
Capacities
Identifier 1 2 3 4
Engine coolant capacity, engine side R Liters 220 220 220 270 *
(without cooling equipment)
Charge-air coolant, engine side R Liters 69 69 69 80 *
Total engine oil capacity, initial filling R Liters 250 250 250 310 *
(standard oil system) (option: max. oper-
ating inclinations)
Oil change quantity, max. (standard oil R Liters 195 195 195 240 *
system) (option: max. operating inclina-
tions)
Oil pan capacity at dipstick mark “min.” L Liters 155 155 155 225 *
TIM-ID: 0000054790 - 003
ating inclinations)
Oil pan capacity at dipstick mark “max.” L Liters 195 195 195 255 *
ating inclinations)
Weights / main dimensions

Identifier 1 2 3 4
Engine mass, dry (standard scope of sup- R kg 8320 ** 8320 ** 8320 ** 9975
ply)

Noise
Identifier 1 2 3 4
Exhaust noise, unsilenced – BL (free-field R dB(A) 110 111 111 111
sound pressure level Lp, 1 m distance,
ISO 6798, +3 dB(A) tolerance)
Exhaust noise, unsilenced - BL (sound R dB(A) 123 123 124 124
power level LW, ISO 6798, +3 dB(A) tol-
erance)
Engine surface noise with attenuated in- R dB(A) 105 109 110 109
take noise (filter) – BL (free-field sound
pressure level Lp, 1 m distance, ISO
6798, +2 dB(A) tolerance)
Engine surface noise with attenuated in- R dB(A) 124 128 129 128
take noise (filter) – BL (sound power level
LW, ISO 6798, +2 dB (A) tolerance)
TIM-ID: 0000054790 - 003

4.2 Firing order
Firing order
Number of cylinders Firing order
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
TIM-ID: 0000062692 - 001

4.3 Engine – Main dimensions
Item Dimensions (12V) Dimensions (16V)

Length (A) approx. 2650 mm approx. 3208 mm
Width (B) approx. 1635 mm approx. 1635 mm
Height (C) approx. 1948 mm approx. 2030 mm
TIM-ID: 0000054364 - 002

5 Operation
5.1 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.
WARNING
In case of out-of-service periods of more than one week: Possible corrosion of components carrying air
or exhaust gas due to weather conditions, e.g. rain or snow.
Risk of injury by flying debris when putting the engine into operation!
• Check the components carrying air and exhaust for corrosion.
• Do not put the engine in operation if corrosion was detected.
Putting into operation after extended out-of-service periods (>3 months)

Item Action
Engine Depreserve (→ MTU Preservation and Represervation Specifications
A001070/..).
Valve gear Lubricate valve gear every ≥ 6 months (→ Page 135).
Engine oil system Check engine oil level (→ Page 190).
Crank engine using starting system (→ Page 127).
Fuel prefilter Fill with fuel (if fitted, see manufacturer's documentation).
Coolant system If standstill for more than one year:
• Change engine coolant (→ Page 202).
• Change charge-air coolant (→ Page 212).
Coolant system Check engine coolant level (→ Page 200);
Check charge-air coolant level (→ Page 211).
Coolant system Preheat coolant with coolant preheating unit (if fitted, see manufacturer's
documentation).
Engine governor Check electrical connections (→ Page 229).
HP fuel pump Only for engines without oil priming pump:
Fill HP fuel pump with fresh engine oil (→ Page 145).
TIM-ID: 0000002200 - 007
40 | Operation | MS150120/02E 2017-08

5.2 Putting the engine into operation after scheduled out-of-
service period
Preconditions
WARNING
In case of out-of-service periods of more than one week: Possible corrosion of components carrying air
or exhaust gas due to weather conditions, e.g. rain or snow.
Risk of injury by flying debris when putting the engine into operation!
• Check the components carrying air and exhaust for corrosion.
• Do not put the engine in operation if corrosion was detected.
Putting into operation

Item Measure
Engine oil system Check engine oil level (→ Page 190).
Coolant circuit Check engine coolant level (→ Page 200);
Check charge-air coolant level (→ Page 211).
Coolant circuit Heat coolant with coolant preheater (if available; see manufacturer's docu-
mentation).
Engine control system Put into operation (see manufacturer's documentation).
TIM-ID: 0000002683 - 007
MS150120/02E 2017-08 | Operation | 41

5.3 Operational monitoring
DANGER
Emergency-air shutoff flaps cannot close and will not stop the engine at overspeed.
Danger to life due to the destruction of the engine!
• Obtain information on how the manufacturer displays the status of the safety feature, e.g. signal
lamp.
• Observe the safety function status.
• Notify the responsible management staff if a fault in the safety feature is signaled.
• Perform possible emergency measures after consultation with the responsible management staff,
e.g. emergency stop.
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
Operational monitoring
Item Measure
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine oil Check engine oil level (→ Page 190).
Engine operation Visually inspect engine for leaks and general condition.
Check engine for abnormal running noises, exhaust color and vibrations.
Air filter Check signal ring position of service indicator on air filter (if fitted)
(→ Page 175).
Battery-charging generator Check battery-charging generator for contamination, clean as necessary
(→ Page 221).
Exhaust system Check exhaust color (→ Page 55).
Fuel prefilter Drain water and contaminants at the drain cock of the fuel prefilter, if fitted
(→ Page 158).
Exhaust silencer Check condensate drain of silencer (→ Page 234).
Back Pack securing screws Visually check for damage (→ Page 235).
TIM-ID: 0000075043 - 001
42 | Operation | MS150120/02E 2017-08

5.4 Operating statuses of the Safety Function System (SFS)
DANGER
Emergency-air shutoff flaps cannot close and will not stop the engine at overspeed.
Danger to life due to the destruction of the engine!
• Obtain information on how the manufacturer displays the status of the safety feature, e.g. signal
lamp.
• Observe the safety function status.
• Notify the responsible management staff if a fault in the safety feature is signaled.
• Perform possible emergency measures after consultation with the responsible management staff,
e.g. emergency stop.
DANGER
WARNING
Operating statuses of the SFS in normal operation

Operating status SFS status signal- SFB * fault LED SFB *Power Comment
of SFS * ing On* LED
Normal operating Active (High) Orange Green System fully functional
mode
Uncritical system Active (High) Flashing code No. Green Fault report to ECU
error 2 or No. 3 Safety function of the SFS is
Orange operable
Critical system er- Inactive (Low) Flashing code No. Green Fault report to ECU
ror 4 Safety function of the SFS
Orange has failed
* SFS: Safety Function System
* SFB: Safety Function Box
Table 2: Operating statuses of the SFS in normal operation

Important information
A safety function meets the requirements of safety integrity level (SIL) 1 in accordance with
[IEC61508-2010].
TIM-ID: 0000077767 - 001
The safe state is a stationary engine.
MS150120/02E 2017-08 | Operation | 43

Operating statuses of the SFS with activated emergency-air shutoff flaps /
overspeed test
Operating status of SFS SFS status sig- SFB fault LED SFB *Power Comment
naling On* LED
Overspeed test active Inactive (Low) Off Green At engine speed >0 rpm, the
with engine running overspeed limit is set to an
overspeed test limit and sys-
tem validation can be car-
ried out.
Overspeed test active Inactive (Low) Off Green At an engine speed of
with the engine at a 0 rpm, all activated emer-
standstill gency-air shutoff flaps are
closed.
Engine emergency stop Inactive (Low) Off Green All activated emergency-air
(overspeed limit exceed- shutoff flaps are closed by
ed or emergency stop in- the SFS.
put active)
Table 3: Operating statuses of the SFS with activated emergency-air shutoff flaps / overspeed test
The SFB carries out a system reset automatically after 40 days of operation.
The automatic system reset is not carried out if the prescribed functional check takes place regularly.
Flashing codes from fault LED
TIM-ID: 0000077767 - 001
44 | Operation | MS150120/02E 2017-08

Flashing codes from fault LED
A: Fault LED lights Meaning Comment
up orange
Flashing code No.
1 Ready for operation Device is ready for operation.
2 Fault in the CAN da- Uncritical system error
ta transmission
3 Fault at an I/O Uncritical system error
4 Fault in the Safety Critical system error
Function System Safety functions of the devices are not guaranteed.
Automatic engine shutdown is not guaranteed.
5 Engine stop Engine stop was tripped because the overspeed limit was ex-
ceeded or due to external emergency stop activation.
Table 4: Flashing codes from fault LED
Response to fault messages

Target Measure
Making Safety Function Box (SFB) Acknowledgment of SFB fault message:
ready for operation 1. Switch off SFS_IGI.
2. Wait 5 seconds.
3. Switch on SFS_IGI.
Reaction to emergency engine 1. Deactivate the emergency-stop switch.
stop 2. Switches SFB off.
(Emergency-stop switch active, 3. Open emergency-air shutoff flaps.
overspeed limit reached) 4. Switches SFB on.
The device is ready for operation when the SFS status is active.
Resetting alarms 1. Identify fault in SFS.
2. Switches SFB off.
3. Rectify fault in SFS.
4. Switches SFB on.
The fault has been corrected if the fault LED is on permanently and the
SFS status is active.
Resetting overspeed test status • If emergency-air shutoff flaps are opened:
u Deactivate overspeed test via the SFB or ECU.
Device is ready for operation if the SFB status is active and the fault
LED is on permanently.
• If emergency-air shutoff flaps are closed:
1. Deactivate overspeed test via the SFB or ECU.
2. Switches SFB off.
3. Open emergency-air shutoff flaps.
4. Switches SFB on.
Device is ready for operation if the SFB status is active and the
TIM-ID: 0000077767 - 001
fault LED is on permanently.
Table 5: Response to fault messages
MS150120/02E 2017-08 | Operation | 45

Reaction to failure of the safety function
Signal Measure
Critical or uncritical system Have repaired by authorized Service personnel.
errors Operation of the engine with a faulty SFS reduces safety and is not permit-
(see above) ted.
If the engine is operated nevertheless, this is the sole responsibility of the
oeprating company.
The operator must decide whether engine operation is necessary to achieve
further safety targets and, if necessary, must introduce suitable measures to
reduce the risk.
This decision must be documented.
Table 6: Reaction to failure of the safety function

The SFS can be parameterized such that engine can be stopped via the ECU in the event of a failure of the
safety function. This engine-stop function is not an element of the safety function.
TIM-ID: 0000077767 - 001
46 | Operation | MS150120/02E 2017-08

5.5 Emission label – Check
Emission label – Check

Note: If there are any irregularities, notify your MTU contact person/service partner without delay.
1. Check that emission labels are present (there can be more than one).
2. Check emission label for intactness.
3. Check that emission label is fully legible.
4. Check content of emission label:
• Does the label on the engine match the label document in the Business Portal/Equipment?
• Does the engine number on the emission label match the engine identification plate?
• Does the Manufacturing Date match the year of manufacture on the identification plate?
TIM-ID: 0000063752 - 002
MS150120/02E 2017-08 | Operation | 47

5.6 Engine – Starting in manual mode
Preconditions
☑ Engine is not under load.
☑ External start interlock is not activated.
DANGER
Rotating and moving engine parts.
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
WARNING
Preparation
Item Action
Coolant preheater Switch on (if available; see manufacturer's documentation).
Starting the engine

Item Action
Control cabinet, operator 1. If there is a coolant preheater, make sure that the coolant temperature >
station etc. (depending on 40 °C (see manufacturer's documentation).
manufacturer) 2. Press the start key (see plant documentation).
• Automatic starting sequence is executed.
• Engine speed instrument indicates increasing speed.
• After the starting sequence is completed, engine runs at idle speed.
TIM-ID: 0000042871 - 003
48 | Operation | MS150120/02E 2017-08

5.7 Engine – Stopping in manual mode
Preconditions
☑ Engine is not under load.
☑ Engine is running in manual mode.
NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress-
es.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant
levels are indicated.
Preparation
Item Action
Engine Operate engine at idling speed for approx. 5 minutes.
Stopping the engine

Item Action
Control cabinet, operator Press the stop key (see plant documentation).
station etc. (depending on • Automatic stopping sequence is executed.
manufacturer)
TIM-ID: 0000042873 - 002
MS150120/02E 2017-08 | Operation | 49

5.8 Emergency engine stop
CAUTION
Shutting down from full-load operation may cause hot water to escape from the expansion tank.
Risk of scalding!
• Allow engine to cool down.
• Wear protective clothing, protective gloves, and safety goggles / safety mask.
NOTICE
An emergency stop subjects the engine system to an extremely high load.
Risk of overheating, damage to components!
• Trigger an emergency stop only in emergency situations.
Emergency engine stop

Item Measure
Emergency-stop button Press the emergency-stop button.
• Engine is stopped by disconnecting the power supply to the ECU;
• Emergency-air shutoff flaps close (if applicable);
• Signaling (e.g. by horn, flashing lamp) is tripped.
Safety Function System (if Automatic engine emergency stop when engine overspeed is detected.
fitted) • Emergency-air shutoff flaps close (if fitted).
After emergency engine stop

Item Measure
Switch cabinet, operator Press pushbutton for alarm acknowledgment.
panel, etc. (depending on • Audible and visual signalization stops.
manufacturer)
Engine Manually open emergency-air shutoff flaps (if fitted).
• Switch on ECU power supply
• Engine is ready for starting.
TIM-ID: 0000077607 - 001
50 | Operation | MS150120/02E 2017-08

5.9 After stopping the engine – Putting the engine out of
operation
Preconditions
☑ MTU Preservation and Represervation Specifications (A001070/..) are available.
NOTICE
Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at
temperatures below 0 °C.
Risk of sensor damage!
• Remove pressure sensors and shake off residual water.
After stopping the engine

Item Measure
Coolant circuit Drain engine coolant (→ Page 203) and
Drain charge-air coolant (→ Page 213) if
• freezing temperatures are expected, 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 tempera-
ture.
• the antifreeze concentration is 50% and the engine room temperature is
below -40 °C.
Engine control system Switch off (see manufacturer's documentation).
Air intake and exhaust sys- If the equipment is to remain out of service for more than one week, seal the
tem engine's air and exhaust sides. Otherwise, components carrying air or ex-
haust gas are at risk of corrosion.
If the equipment is to remain out of service for more than one month, pre-
serve the engine (→ MTU Preservation and Represervation Specifications
A001070/..).
TIM-ID: 0000002709 - 010
MS150120/02E 2017-08 | Operation | 51

5.10 Plant – Cleaning
Preconditions
☑ No operating voltage applied.

High-pressure cleaner (→ Tools Catalog) 1
Cleaner (Hakupur 50/136) X00056700 1
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Water jet from high-pressure cleaning unit.
Risk of eye injury, risk of scalding!
• Do not direct water jet at persons.
• Wear protective clothing, protective gloves, and goggles/safety mask.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors or
ECUs.
Cleaning the plant

1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec-
tion).
2. Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning
units carefully and observe the safety precautions.
3. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 034
• The temperature of the cleaning medium must not exceed 80 °C.

4. For external cleaning with high-pressure jet, use a fan jet nozzle only.
Note: Never direct compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use high-pressure jet to remove loosened dirt.
e) Dry engine with compressed air.
52 | Operation | MS150120/02E 2017-08

6 Maintenance
6.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option
Task Maintenance tasks
W0500 Check engine oil level. (→ Page 42)

W0501 Visually inspect engine for leaks and general condition. (→ Page 42)
W0503 X Check service indicator of air filter. (→ Page 42)
W0505 Check relief bores of coolant pump(s). (→ Page 208)
(→ Page 219)
W0506 Check engine for abnormal running noises, exhaust color and vibrations. (→ Page 42)
W0507 Drain water and contaminants from fuel prefilter. (→ Page 42)
W0525 X Check battery-charging generator for contamination, clean as necessa- (→ Page 42)
ry.
W0800 Check emissions label. (→ Page 47)
W1001 Replace fuel filter or fuel filter element. (→ Page 156)
W1005 X Replace air filter. (→ Page 174)
W1006 Replace fuel injectors. (→ Page 147)
W1008 Replace engine oil filter when changing engine oil, or when the interval (→ Page 195)
(years) is reached, at the latest.
W1009 Check layer thickness of the oil residue, clean out and replace filter (→ Page 197)
sleeve, accomplish together with every oil change, at the latest.
W1011 Perform endoscopic examination. (→ Page 129)
W1024 X Check (electric) function of emergency-air shutoff flaps. (→ Page 176)
W1046 Replace filter or filter element. (→ Page 133)
W1207 Check valve clearance, adjust if necessary. IMPORTANT! First adjust- (→ Page 140)
ment after 1,000 operating hours on a new engine, and after 1,000 op-
erating hours following each cylinder head overhaul.
W1241 X Check condition of belt drive and replace if necessary; adjust belt ten- (→ Page 220)
sion.
W1296 X Replace valve. (→ Page 210)
W1481 Replace intermediate fuel filter or intermediate fuel filter element. (→ Page 157)
TIM-ID: 0000054512 - 005
W1525 Replace sensor. (→ Page 230)

W1526 Replace sensor. (→ Page 232)
W1551 Check operability of exhaust flap actuator. (→ Page 183)
W1575 Check general condition of trunnion mounts (visual inspection). (→ Page 224)
W1577 Check turbine housing externally for cracks, perform endoscopic exami- (→ Page 161)
nation to check it internally for cracks, replace if necessary.
W1610 Check securing screws of trunnion mounts for secure seating. (→ Page 224)
W1636 Reset drift correction parameters (CDC) and enter injector codes (IIG). (→ Page 148)
MS150120/02E 2017-08 | Maintenance | 53

Option
Task Maintenance tasks
W1675 Replace fuel prefilter or fuel prefilter element. (→ Page 159)

W1689 Measure valve protrusion. (→ Page 136)
W1817 Check coupling rods of EGR flaps for play. (→ Page 183)
W8644 X Visually check for damage. (→ Page 42)
W8645 X Check for firm seating. (→ Page 236)
W8646 X Check exhaust silencer condensate drain. (→ Page 42)
Table 7: Maintenance task reference table [QL1]
TIM-ID: 0000054512 - 005
54 | Maintenance | MS150120/02E 2017-08

7 Troubleshooting
7.1 Troubleshooting
Engine does not turn when starter is actuated
Cause Corrective action
Battery/UltraCaps low or faulty u Charge or replace (→ manufacturer's documentation)
Cable connections faulty u Check cable connections for secure seating (→ manufacturer's
documentation)
Starter: Engine cabling, POM or u Check if cable connections are properly secured , contact Service
starter defective
Engine wiring defective. u Check (→ Page 225)
Engine / generator control: u Perform visual inspection (→ manufacturer's documentation)
Assemblies or connectors
possibly loose
Engine governor: Plug-in u Check plug-in connections (→ Page 229)
connections loose
Running gear blocked (engine u Contact Service
cannot be barred manually)
Engine turns on starting but does not fire

Engine: Too cold u Preheat (40 °C)
Poor rotation by starter: Battery/ u Charge or replace battery/UltraCaps (→ manufacturer's
UltraCaps low or faulty documentation)
Engine wiring faulty. u Check (→ Page 225)
Air in fuel system u Vent fuel system (→ Page 155)
Engine governor defective u Contact Service
Engine fires unevenly

Injector defective u Check, replace as necessary (→ Page 148)
TIM-ID: 0000055274 - 004
MS150120/02E 2017-08 | Troubleshooting | 55

Engine does not reach nominal speed
Fuel prefilter clogged u Replace (→ manufacturer's documentation)
Fuel filter clogged u Replace (→ Page 156)
Additional fuel filter clogged u Replace (→ Page 157)
Air filter clogged u Check, replace as necessary (→ manufacturer's documentation)
Engine: Overload u Contact Service
Engine speed not steady

Speed transmitter defective u Contact Service
Charge-air temperature too high

Incorrect coolant concentration u Check (→ MTU test kit)
Charge-air cooler dirty u Contact Service
Engine room: Air-intake u Check fans and air supply/exhaust ducts
temperature too high
Charge-air pressure too low

Air filter clogged u Check, clean as necessary (→ manufacturer's documentation)
Charge-air cooler dirty u Contact Service
Exhaust turbocharger defective u Contact Service
Emergency-air shutoff flaps are not closed

Emergency-stop switch faulty u Check emergency-stop switch (check for correct resistor circuitry)
(→ Electronics documentation E532445/..).
Cable between Safety Function u Check cable between Safety Function Box and emergency-stop
TIM-ID: 0000055274 - 004
Box and emergency-stop switch switch

defective
Cable between Safety Function u Check cable between Safety Function Box, relay and emergency-air
Box, relay and emergency-air shutoff flap
shutoff flap defective
Relay defective u Replace relay (→ Electronics documentation E532445/..).
Emergency-air shutoff flap u Replace emergency-air shutoff flap (→ Instructions for Exchange of
defective Sub-assemblies).
56 | Troubleshooting | MS150120/02E 2017-08

Coolant discharge at charge-air cooler
Charge-air cooler: Leaking, major u Contact Service
coolant discharge
Blue exhaust gas

Too much engine oil in the engine u Drain engine oil (→ Page 191)
Oil separator of crankcase u Replace filter (→ Page 133)
breather contaminated
Exhaust turbocharger, cylinder u Contact Service
head, piston rings or cylinder liner
defective
White exhaust gas

Engine is not at operating u Preheat/run up to operating temperature
temperature
Water in fuel u Check fuel system at fuel prefilter (→ manufacturer's
documentation)
Drain water from fuel prefilter (→ manufacturer's documentation)
Charge-air cooler u Contact Service
TIM-ID: 0000055274 - 004

7.2 Fault messages 12V- and 16V4000T95
Possible engine responses to yellow alarm:
Warning, power limitation/reduction, speed limitation, engine stop
Possible engine responses to red alarm:

Engine stop, power limitation/reduction, speed limitation, warning
3 – HI T-Fuel
The fuel temperature at sensor 1. Reduce power.
B33 exceeded limit value 1. Fuel 2. Check fuel cooling system (if fitted).
temperature is too high. 3. Contact Service.
4 – SS T-Fuel
The fuel temperature at sensor 1. Reduce power.
B33 exceeded limit value 2. Fuel 2. Check fuel cooling system (if fitted).
temperature is too high. 3. Contact Service.
5 – HI T-Charge Air
The charge-air temperature at 1. Reduce power.
sensor B9 exceeded limit value 1. 2. Check whether alarms 9 and 10 are signaled.
Charge-air temperature is too 3. Contact Service.
high.
6 – SS T-Charge Air
The charge-air temperature at 1. Reduce power.
sensor B9 exceeded limit value 2. 2. Check whether alarms 9 and 10 are signaled.
Charge-air temperature is too 3. Contact Service.
high.
9 – HI T-Coolant Intercooler
The charge-air cooler coolant 1. Reduce power.
TIM-ID: 0000075358 - 001
temperature at sensor B26 2. Check whether alarm 23 is signaled.

exceeded limit value 1. The 3. Check cooler (plant) for contamination.
coolant temperature in the 4. Check fan operation (plant).
charge-air cooler is too high. 5. Contact Service.

10 – SS T-Coolant Intercooler
The charge-air cooler coolant 1. Reduce power.
temperature at sensor B26 2. Check whether alarm 23 is signaled.
exceeded limit value 2. The 3. Check cooler (plant) for contamination.
coolant temperature in the 4. Check fan operation (plant).
charge-air cooler is too high. 5. Contact Service.
15 – LO P-Lube Oil
The lube oil pressure at sensor 1. Check engine oil level (→ Page 190).
B5.1 undershot limit value 1. Lube 2. Contact Service.
oil pressure is too low.
16 – SS P-Lube Oil
The lube oil pressure at sensor 1. Check engine oil level (→ Page 190).
B5.1 undershot limit value 2. Lube 2. Contact Service.
oil pressure is too low.
19 – HI T-Exhaust A
The exhaust gas temperature at u Run injector test according to DiaSys description. Contact Service
sensor B4 exceeded limit value 1. if no DiaSys is available.
Exhaust temperature is too high.
20 – SS T-Exhaust A
The exhaust gas temperature at u Run injector test according to DiaSys description. Contact Service
sensor B4 exceeded limit value 2. if no DiaSys is available.
Exhaust temperature is too high.
23 – LO Coolant Level
Coolant level at level switch F33 1. Check engine coolant level (→ Page 200).
in HT circuit is too low. 2. Check relief bore of engine coolant pump (→ Page 208).
3. Check cooling circuit visually for leaks.
4. Contact Service.
TIM-ID: 0000075358 - 001
25 – HI P-Diff-Lube Oil
The differential oil pressure at 1. Replace engine oil filter (→ Page 195).
sensors B5.1 and B5.3 exceeded 2. Contact Service.
limit value 1. The differential oil
pressure is too high.

26 – SS P-Diff-Lube Oil
The differential oil pressure at 1. Replace engine oil filter (→ Page 195).
sensors B5.1 and B5.3 exceeded 2. Contact Service.
limit value 2. The differential oil
27 – HI Level Leakage Fuel

Switch F46 in the collecting tank u Contact Service.
has been tripped. The HP fuel
system is leaking.
30 – SS Engine Overspeed
The engine speed exceeded the 1. Restart the engine if the emergency stop was tripped by the engine
upper limit or the engine overspeed test.
overspeed test was tripped. An 2. Contact Service if the emergency stop was tripped by the engine.
emergency engine shutdown has
been initiated.
31 – HI ETC1 Overspeed
The speed of the A side LP 1. Reduce power.
turbocharger at sensor B44.1 2. Contact Service.
exceeded limit value 1.
Turbocharger speed is too high.
Cause: Fault or malfunction of
another turbocharger.
32 – SS ETC1 Overspeed
The speed of the A side LP 1. Reduce power.
TIM-ID: 0000075358 - 001
33 – HI P-Diff-Fuel
The differential pressure at 1. Replace fuel filter (→ Page 156).
sensors B34.1 and B34.2 has 2. Contact Service.
violated upper limit value 1. The
differential pressure is too high.

34 – SS P-Diff-Fuel
The differential pressure at 1. Replace fuel filter (→ Page 156).
sensors B34.1 and B34.2 has 2. Contact Service.
violated upper limit value 2. The
differential pressure is too high.
The speed of the B side LP 1. Reduce power.
The speed of the B side LP 1. Reduce power.
44 – LO Coolant Level Intercooler

Coolant level in LT circuit at 1. Check charge-air coolant level (→ Page 211).
switch F57 is too low. 2. Check relief bore of charge-air coolant pump (→ Page 219).
3. Check cooling circuit visually for leaks.
4. Contact Service.
51 – HI T-Lube Oil
The lube oil temperature at sensor 1. Reduce power.
B7 exceeded limit value 1. Lube 2. Check operation of cooler and fan (plant).
oil temperature is too high. 3. Check engine coolant level (→ Page 200).
4. Contact Service.
TIM-ID: 0000075358 - 001
52 – SS T-Lube Oil
The lube oil temperature at sensor 1. Check operation of cooler and fan (plant).
B7 exceeded limit value 2. Lube 2. Check engine coolant level (→ Page 200).
oil temperature is too high. 3. Contact Service.

57 – LO P-Coolant
Coolant pressure at sensor B16 1. Check relief bore of engine coolant pump (→ Page 208).
undershot limit value 1. Coolant 2. Check engine coolant level (→ Page 200).
pressure is too low. 3. Contact Service.
58 – SS P-Coolant
Coolant pressure at sensor B16 1. Check relief bore of engine coolant pump (→ Page 208).
undershot limit value 2. Coolant 2. Check engine coolant level (→ Page 200).
pressure is too low. 3. Contact Service.
63 – HI P-Crank Case
The crankcase pressure at sensor 1. Stop engine.
B50 exceeded limit value 1. The 2. Contact Service.
crankcase pressure is too high.
64 – SS P-Crank Case
The crankcase pressure at sensor 1. Stop engine.
B50 exceeded limit value 2. The 2. Contact Service.
crankcase pressure is too high.
65 – LO P-Fuel
The fuel pressure at sensor B34.1 1. Replace additional fuel filter (→ Page 157).
undershot limit value 1. Fuel 2. Replace fuel filter (→ Page 156).
pressure is too low. 3. Replace fuel prefilter (→ Page 159).
4. Contact Service.
66 – SS P-Fuel
The fuel pressure at sensor B34.1 1. Replace additional fuel filter (→ Page 157).
undershot limit value 2. Fuel 2. Replace fuel filter (→ Page 156).
pressure is too low. 3. Replace fuel prefilter (→ Page 159).
4. Contact Service.
TIM-ID: 0000075358 - 001
67 – HI T-Coolant
The coolant temperature at 1. Reduce power.
sensor B6 exceeded limit value 1. 2. Check operation of cooler and fan (plant).
Coolant temperature is too high. 3. Check engine coolant level (→ Page 200).
4. Contact Service.

68 – SS T-Coolant
The coolant temperature at 1. Check operation of cooler and fan (plant).
sensor B6 exceeded limit value 2. 2. Check engine coolant level (→ Page 200).
Coolant temperature is too high. 3. Contact Service.
82 – HI P-Fuel (Common Rail)

The fuel pressure at sensor B48 u Contact Service.
exceeded the limit value. Fuel
83 – LO P-Fuel (Common Rail)

The fuel pressure at sensor B48 u Contact Service.
went below the limit value. Fuel
pressure is too low.
89 – SS Engine Speed too low

The engine speed has undershot 1. Acknowledge alarm.
the limit value. An emergency 2. Observe any other messages.
engine shutdown has been 3. Contact Service.
initiated.
90 – SS Idle Speed Not Reached

The engine has failed to reach idle 1. Check pressure supply (plant) of starter.
speed within the defined time 2. Check additional fuel filter, replace as necessary (→ Page 157).
after reaching starter 3. Check fuel filter, replace as necessary (→ Page 156).
disengagement speed. 4. Check fuel prefilter, replace as necessary (→ Page 159).
5. Observe any other messages.
6. Contact Service.
91 – SS Release Speed Not Reached

The engine has failed to reach 1. Check pressure supply (plant) of starter.
starter disengagement speed 2. Observe any other messages.
TIM-ID: 0000075358 - 001
within the defined time after 3. Contact Service.

reaching starter speed.
92 – SS Starter Speed Not Reached

The engine has failed to reach the 1. Check pressure supply (plant) of starter.
defined speed threshold within 2. Observe any other messages.
the defined time. 3. Contact Service.

93 – SS T-Preheat
The engine coolant temperature u Contact Service.
has failed to reach the defined
limit value 2. Preheater is out of
order. Start interlock.
94 – LO T-Preheat
The engine coolant temperature u Contact Service.
has failed to reach the defined
limit value 1. Preheater is out of
order.
102 – AL Fuel Cons. Counter Defect

The fuel consumption calculated u Contact Service.
by the ECU and stored on
stopping the engine cannot be
read out properly on restarting the
engine.
104 – AL Eng Hours Counter Defect

The operating hours calculated by u Contact Service.
the ECU and stored on stopping
the engine cannot be read out
properly on restarting the engine.
118 – LO ECU Power Supply Voltage

The ECU supply voltage undershot 1. Check condition of batteries (plant).
the defined limit value 1. 2. Check plug connections to engine governor (→ Page 229).
3. Check battery-charging generator (→ Page 221).
4. Contact Service.
119 – LOLO ECU Power Supply Voltage

TIM-ID: 0000075358 - 001
The ECU supply voltage undershot 1. Check condition of batteries (plant).

the defined limit value 2. 2. Check plug connections to engine governor (→ Page 229).
4. Contact Service.

120 – HI ECU Power Supply Voltage
ECU supply voltage exceeded limit 1. Check condition of batteries (plant).
value 1. 2. Check plug connections to engine governor (→ Page 229).
4. Contact Service.
121 – HIHI ECU Power Supply Voltage

ECU supply voltage exceeded limit 1. Check condition of batteries (plant).
value 2. 2. Check plug connections to engine governor (→ Page 229).
4. Contact Service.
122 – HI T-ECU
The temperature at the sensor 1. Disconnect power supply.
inside the ECU exceeded the limit 2. Check power supply (plant).
value. The temperature inside the 3. Contact Service.
housing is too high.
180 – AL CAN1 Node Lost

Connection or communication 1. Check engine cabling (→ Page 225).
with a node on CAN bus 1 has 2. Disconnect power supply, then reconnect.
failed 3. Contact Service.

Connection or communication 1. Check engine cabling (→ Page 225).
with a node on CAN bus 2 has 2. Disconnect power supply, then reconnect.
failed 3. Contact Service.
186 – AL CAN1 Bus Off

CAN bus 1 for MTU Automation 1. Check plug connections to engine governor (→ Page 229).
(e.g. ECU/MAU/SAM) disrupted 2. Contact Service.
or faulty.
TIM-ID: 0000075358 - 001
187 – AL CAN1 Error Passive

CAN bus 1 for MTU Automation 1. Check plug connections to engine governor (→ Page 229).
(e.g. ECU/MAU/SAM) disrupted 2. Contact Service.
or faulty.

CAN bus 2 to plant-side 1. Check connection between plant automation system and MTU
automation (e.g. Murphy Display) automation system.
interrupted or faulty. 2. Contact Service.
201 – SD T-Coolant
The signal from the coolant 1. Check engine cabling (→ Page 225).
temperature sensor (B6) on the 2. Contact Service.
coolant distribution housing is
faulty or missing.
202 – SD T-Fuel
The signal from the fuel 1. Check engine cabling (→ Page 225).
temperature sensor (B33) on the 2. Contact Service.
HP distributor is faulty or missing.
203 – SD T-Charge Air

The signal from the A side charge- 1. Check engine cabling (→ Page 225).
air temperature sensor (B9) is 2. Contact Service.
faulty or missing.
205 – SD T-Coolant Intercooler

The signal from the charge-air 1. Check engine cabling (→ Page 225).
coolant temperature sensor (B26) 2. Contact Service.
after engine inlet is faulty or
missing.
206 – SD T-Exhaust A
The signal from the exhaust gas 1. Check engine cabling (→ Page 225).
temperature sensor (B4) in the A 2. Contact Service.
side exhaust pipe is faulty or
missing.
TIM-ID: 0000075358 - 001
208 – SD P-Charge Air

The signal from the charge-air 1. Check engine cabling (→ Page 225).
temperature sensor (B10.1) after 2. Contact Service.
the A side charge-air cooler is
faulty or missing.

211 – SD P-Lube Oil
The signal from the lube oil 1. Check engine cabling (→ Page 225).
pressure sensor after filter (B5.1) 2. Contact Service.
is faulty or missing.
212 – SD P-Coolant
The coolant pressure sensor after 1. Check engine cabling (→ Page 225).
coolant pump (B16) delivers 2. Contact Service.
incorrect or no signal.
213 – SD P-Coolant charge-air cooler

The coolant pressure sensor (B43) 1. Check engine cabling (→ Page 225).
delivers incorrect or no signal. 2. Contact Service.
214 – SD P-CrankCase
The signal from the crankcase 1. Check engine cabling (→ Page 225).
pressure sensor (B50) is faulty or 2. Contact Service.
missing.
215 – SD P-HD
The signal from the rail pressure 1. Check engine cabling (→ Page 225).
sensor (B48) is faulty or missing. 2. Contact Service.
216 – SD T-Lube Oil

The signal from the lube oil 1. Check engine cabling (→ Page 225).
temperature sensor (B7) is faulty 2. Contact Service.
or missing.
220 – SD Level Coolant Water

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The signal from the coolant level 1. Check engine cabling (→ Page 225).
sensor (F33) is faulty or missing. 2. Contact Service.
221 – SD P-Diff Lube Oil

The signals from lube oil pressure 1. Check engine cabling (→ Page 225).
sensors B5.3 and/or B5.1 are 2. Contact Service.
faulty or missing.

222 – SD Level Leakage Fuel
The signal from the fuel leakage 1. Check engine cabling (→ Page 225).
sensor (F46) is faulty or missing. 2. Contact Service.
227 – SD P-Lube Oil before Filter

The signal from the oil pressure 1. Check engine cabling (→ Page 225).
sensor before filter (B5.3) is faulty 2. Contact Service.
or missing.
228 – SD P-Fuel before Filter

The HP fuel sensor before the 1. Check engine cabling (→ Page 225).
main fuel filter (B34.2) supplies a 2. Contact Service.
faulty signal or no signal.
229 – AL Stop Camshaft Sensor Defect

Emergency engine stop following u Contact Service.
failure of the crankshaft sensor
and camshaft sensor.
230 – SD Crankshaft Speed

The signal from the crankshaft 1. Check engine cabling (→ Page 225).
speed sensor (B13) is faulty or 2. Contact Service.
missing.
231 – SD Camshaft Speed

The signal from the camshaft 1. Check engine cabling (→ Page 225).
missing.
232 – SD Charger 1 Speed

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The signal from the A side ETC 1. Check engine cabling (→ Page 225).
speed sensor (B44.1) is faulty or 2. Contact Service.
missing.

The signal from the B side ETC 1. Check engine cabling (→ Page 225).
speed sensor (B44.2) is faulty or 2. Contact Service.
missing.
239 – SD P-Diff Fuel

The pressure sensors B34.1 1. Check engine cabling (→ Page 225).
and/or B34.2 supply a faulty 2. Contact Service.
signal or no signal.
240 – SD P-Fuel
The signal from the fuel pressure 1. Check engine cabling (→ Page 225).
sensor after main fuel filter 2. Contact Service.
(B34.1) is faulty or missing.
245 – SD ECU Power Supply Voltage

The signal from the internal 1. Check engine cabling (→ Page 225).
voltage sensor in the ECU is faulty 2. Contact Service.
or missing.
266 – SD Speed Demand

The analog nominal speed setting 1. Switch on plant automation.
signal is missing. 2. Contact Service.
321 – AL Wiring Cylinder A1

Short circuit fault in the injector 1. Check wiring of affected injector (→ Page 225).
wiring for cylinder A1 or injector 2. Replace injector (→ Page 147).
defective. 3. Contact Service.

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331 – AL Wiring Cylinder B1

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wiring for cylinder B1 or injector 2. Replace injector (→ Page 147).







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341 – AL Open Load Cylinder A1
Open load in injector wiring for 1. Check wiring of affected injector (→ Page 225).
cylinder A1. 2. Contact Service.







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Open load in injector wiring 1. Check wiring of affected injector (→ Page 225).

351 – AL Open Load Cylinder B1
cylinder B1. 2. Contact Service.







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Open load in injector wiring 1. Check wiring of affected injector (→ Page 225).

361 – AL Power Stage Low
The output stage voltage to 1. Check power supply (plant).
control the injectors is too low. 2. Contact Service.
362 – AL Power Stage High

control the injectors is too high. 2. Contact Service.
363 – AL Stop Power Stage

control the injectors is too low. 2. Contact Service.
Engine stop
365 – AL Stop MV-Wiring Ground

Short circuit of injector positive 1. Check cabling (→ Page 225).
connection to ground of one or 2. Restart engine.
more injectors. 3. Contact Service.
Short circuit of negative
connection of one or more
injectors to ground.
381 – AL Wiring TOP 1

Short circuit or wire break at 1. Check cabling (→ Page 225).
transistor output 1 plant side (TOP 2. Contact Service.
1).

2).
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3).

4).
400 – AL Open Load Digital Input 1

Open load detected at digital 1. Check cabling (→ Page 225).
input 1 of the ECU. 2. Contact Service.





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408 – AL Open Load Emerg. Stop Input ESI

Open load detected at the 1. Check cabling (→ Page 225).
emergency stop input. 2. Contact Service.
410 – LO U-PDU
The ECU voltage to control the 1. Check power supply (plant).
injectors undershot limit value 1. 2. Check cabling (→ Page 225).
3. Contact Service.
411 – LOLO U-PDU

injectors undershot limit value 2. 2. Check cabling (→ Page 225).
3. Contact Service.
412 – HI U-PDU
injectors exceeded limit value 1. 2. Check cabling (→ Page 225).
3. Contact Service.
413 – HIHI U-PDU

injectors exceeded limit value 2. 2. Check cabling (→ Page 225).
3. Contact Service.
415 – LO P-Coolant Intercooler

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The charge-air coolant pressure in 1. Check relief bore of charge-air coolant pump (→ Page 219);
the charge-air cooler at sensor 2. Check charge-air cooler for coolant discharge (→ Page 173).
B43 has undershot the limit value 3. Contact Service.
1. Charge-air coolant pressure is
too low.

416 – SS P-Coolant Intercooler
The charge-air coolant pressure in 1. Check relief bore of charge-air coolant pump (→ Page 219);
the charge-air cooler at sensor 2. Check charge-air cooler for coolant discharge (→ Page 173).
B43 has undershot the limit value 3. Contact Service.
2. Charge-air coolant pressure is
too low.
440 – AL L1 P-Aux 1
The pressure measurement u Contact Service.
sensor at the pressure
measurement channel has
violated lower limit value 1. The
pressure value at the pressure
measurement channel is too low.
442 – AL L2 P-Aux 1
The pressure measurement u Contact Service.
sensor at the pressure
measurement channel has
violated lower limit value 2. The
pressure value at the pressure
measurement channel is too low.
444 – SD U-PDU
Fault in the internal supply voltage u Contact Service.
for the injector output stage.
445 – SD P-Ambient Air

The signal from the ambient u Contact Service.
pressure sensor in the ECU is
faulty or missing.
454 – SS Power Reduction Active

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Power reduction activated. A main 1. Observe any other messages.
alarm activating power reduction 2. Contact Service.
has been tripped.

470 – SD T-ECU
The signal from the temperature u Contact Service.
sensor in the ECU is faulty or
missing.
480 – AL Ext. Engine Protection

The external engine protection 1. Check plant signal.
function is active. 2. Contact Service.

The speed of the HP turbocharger 1. Reduce power.
at sensor B44.3 exceeded limit 2. Contact Service.
value 1. Turbocharger speed is
too high. Cause: Fault or
malfunction of another
turbocharger.

The speed of the HP turbocharger 1. Reduce power.
at sensor B44.3 exceeded limit 2. Contact Service.
value 2. Turbocharger speed is
too high. Cause: Fault or
malfunction of another
turbocharger.
536 – AL Wiring PWM_CM1

HP fuel control block M8 of the 1. Check engine cabling (→ Page 225).
HP fuel pump cannot be activated. 2. Contact Service.
549 – AL Power Cut-Off detected

The ECU operating voltage was 1. Check engine wiring if the power supply was not disconnected
switched off while the engine was manually (→ Page 225).
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running. Do not disconnect the 2. Contact Service.

power supply until the engine is at
standstill.

551 – SS Engine Overspeed Camshaft
The engine speed measured at u Contact Service.
camshaft sensor B1 exceeded
limit value 2 or the engine
overspeed test was tripped. An
emergency engine shutdown has
been initiated.

The emergency-air shutoff flaps 1. Check wiring to emergency-air shutoff flaps (→ Page 225).
cannot be activated. 2. Contact Service.
582 – AL Emergency Stop Failed

This alarm is raised if the engine u Contact Service.
fails to come to a standstill within
a defined time following an
emergency stop signal.

Open circuit or short circuit in 1. Check engine cabling (→ Page 225).
wiring to fan control Y44.2 2. Contact Service.

Open circuit or short circuit in 1. Check engine cabling (→ Page 225).
wiring to fan oil priming pump M2. 2. Contact Service.

Wire break or short circuit in the 1. Check engine cabling (→ Page 225).
power supply for the TriCAN (B90) 2. Contact Service.
or NOx sensor (B88.1 or B88.2).
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614 – AL L1 P-Fuel Add.sec.fuelfilt. Diff.

The differential pressure across 1. Replace additional fuel filter (→ Page 157).
the additional fuel filter at sensors 2. Replace fuel filter (→ Page 156).
B34.2 and B34.3 has exceeded 3. Replace fuel prefilter (→ Page 159).
limit value 1. The differential 4. Contact Service.

615 – AL EIL Protection
The engine number in the EIL 1. Check engine cabling (→ Page 225).
does not match the number 2. Contact Service.
stored in the ECU.
616 – AL EIL Fault

The ECU is unable to detect the u Contact Service.
EIL.
625 – SD P-Fuel bef. Add.sec.fuelfilter

Signal from fuel pressure sensor 1. Check engine cabling (→ Page 225).
(B34.3) before additional filter 2. Contact Service.
faulty or missing.

Disruption or short circuit in the 1. Check engine cabling (→ Page 225).
wiring of the servomotor for 2. Contact Service.
bypass flap M52.

wiring of the servomotor for 2. Contact Service.
dispenser flap M55.

wiring of the servomotor for EGR 2. Contact Service.
shutoff flap M53.
629 – AL Flap Egr A Defect

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The EGR shutoff flap (M53) is 1. Check operation of the EGR shutoff flap (→ Page 183).
faulty. 2. Contact Service.
631 – AL Flap Bypass Defect

The bypass flap (M52) is faulty. 1. Check operation of the bypass flap (→ Page 183).
2. Contact Service.

632 – AL Flap Dispenser Defect
The dispenser flap (M55) is faulty. 1. Check operation of the dispenser flap (→ Page 183).
2. Contact Service.
633 – SD P-Ambient Air (HDT2800)

The signal from the air pressure u Contact Service.
sensor (B90) is missing.
634 – SD T0-Ambient Air (HDT2800)

The signal from the temperature u Contact Service.
635 – SD Air Humidity (HDT2800)

The signal from the humidity u Contact Service.
647 – SD P-Exhaust Lambda

pressure sensor (B91.3) is faulty 2. Contact Service.
or missing.
648 – SD P-Charge Air B

Signal from charge-air pressure 1. Check engine cabling (→ Page 225).
sensor (B10.2) after charge-air 2. Contact Service.
cooler on B side faulty or missing.
727 – AL L1 Delta T-NT Intercooler

The differential temperature at 1. Check cooler (plant) for contamination.
sensors B26 and B90 exceeded 2. Check fan operation (plant).
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limit value 1. Based on the 3. Contact Service.

ambient air temperature, the LT
coolant inlet temperature is too
high.

728 – AL L2 Delta T-NT Intercooler
The differential temperature at 1. Check cooler (plant) for contamination.
sensors B26 and B90 exceeded 2. Check fan operation (plant).
limit value 2. Based on the 3. Contact Service.
ambient air temperature, the LT
coolant inlet temperature is too
high.
754 – SD Bosch LSU Lambda Sensor

The signal from the lambda sensor 1. Check lambda sensor, replace as necessary (→ Page 232).
(B89) is faulty or missing. 2. Contact Service.
763 – AL OL ASO Flap Feedback B

Open circuit in cabling of 1. Check wiring of emergency-air shutoff flap on B-side (→ Page 225).
emergency-air shutoff flap on B- 2. Contact Service.
side.
764 – AL ASO Flap B closed, A failed

After activating the emergency-air 1. Check wiring of emergency-air shutoff flap on A-side (→ Page 225).
shutoff flaps (test / overspeed), 2. Contact Service.
the one on B-side closed while A-
side remained open.
765 – AL OL ASO Flap Feedback A

Open circuit in cabling of 1. Check wiring of emergency-air shutoff flap on A-side (→ Page 225).
emergency-air shutoff flap on A- 2. Contact Service.
side.
766 – AL ASO Flap A closed, B failed

After activating the emergency-air 1. Check wiring of emergency-air shutoff flap on B-side (→ Page 225).
shutoff flaps (test / overspeed), 2. Contact Service.
the one on A-side closed while B-
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side remained open.
767 – AL ASO Flaps closed

Emergency-air shutoff flaps on A- 1. Set emergency-air shutoff flaps to "ON" (→ Page 176).
side and B-side are closed. 2. Contact Service.

778 – AL ASO Flaps open / failed to close
After activating the emergency-air 1. Check power supply (plant).
shutoff flaps (test / overspeed), 2. Check wiring of emergency-air shutoff flaps (→ Page 225).
the A-side and B-side flaps 3. Contact Service.
remained open.

The signal from the speed sensor 1. Check engine cabling (→ Page 225).
(B44.3) C-ETC (high pressure) is 2. Contact Service.
faulty or missing.
833 – AL Emission Warning

Summary emission fault alarm. 1. Observe any other messages.
2. Contact Service.
834 – AL Gas Path Warning

2. Contact Service.
835 – AL Gas Path Fault

2. Contact Service.
836 – AL Speed Demand Failure

The ECU is unable to receive a 1. Switch on plant automation.
speed demand signal via the CAN 2. Contact Service.
bus. Alarm 266 is signaled
simultaneously.
839 – AL ASO Flap A Not Closed by ECU

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The emergency-air shutoff flap on 1. Check engine cabling (→ Page 225).
B-side is closed without having 2. Contact Service.
been activated by the ECU. With
the engine running, the signal also
activates the B-side flap to close
(if open).

840 – AL ASO Flap B Not Closed by ECU
The emergency-air shutoff flap on 1. Check engine cabling (→ Page 225).
B-side is closed without having 2. Contact Service.
been activated by the ECU. With
the engine running, the signal also
activates the A-side flap to close
(if open).
857 – AL NOx ATO1 Sensor Defect

The signal from the NOx sensor 1. Check engine cabling (→ Page 225).
(B88.1) in the exhaust pipe after 2. Check NOx sensor, replace as necessary (→ Page 230).
the LP turbocharger A side is 3. Contact Service.
faulty or missing.
871 – AL NOx ATO1 Communication Lost

The ECU cannot detect the NOx 1. Check engine cabling (→ Page 225).
sensor (B88.1) after LP 2. Check NOx sensor, replace as necessary (→ Page 230).
turbocharger A side on the bus. 3. Contact Service.
872 – AL EGR FlpA Wear Limit3

Abnormal fast homing of the EGR 1. Check condition of batteries (plant).
shutoff flap (M53) (performed 2. Check operation of the EGR shutoff flap (→ Page 183).
every time the ECU is restarted). 3. Contact Service.
877 – AL Bypass FlpA Wear Limit3

Abnormal fast homing of the 1. Check condition of batteries (plant).
bypass flap (M52) (performed 2. Check operation of the bypass flap (→ Page 183).
879 – AL Dispenser Flp Wear Limit3

dispenser flap (M55) (performed 2. Check operation of the dispenser flap (→ Page 183).
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898 – AL Trican Communication Lost

The ECU is no longer able to 1. Check engine cabling (→ Page 225).
detect the TriCAN sensor (B90) on 2. Contact Service.
the bus.

947 – AL Invalid LSI Channel Config
Incorrect LSI channel u Contact Service.
configuration.
953 – AL Lambda value invalid

Status information from the 1. Acknowledge alarm.
lambda sensor (B89), generated in 2. Replace lambda sensor (→ Page 232).
case of temporary implausible 3. Contact Service.
measured values or a lambda
sensor fault.
954 – AL NOx value invalid

Status information from the NOx 1. Acknowledge alarm.
sensor (B88), generated in case of 2. Replace NOx sensor (→ Page 230).
temporary implausible measured 3. Contact Service.
values or an NOx sensor fault.
956 – AL p5 ctrlvar limit min active

The charge-air pressure controller 1. Check operation of the bypass flap (→ Page 183).
is attempting to adjust its set 2. Contact Service.
value, but has reached its lower
limit. The bypass flap (M52) is
fully open.
957 – AL p5 ctrlvar max BOI min active

Emission-related alarm. 1. Check air filter (plant side) for contamination.
The charge-air pressure controller 2. Check operation of the bypass flap (→ Page 183).
is attempting to adjust its set 3. Check exhaust turbocharger (LP) – turbine housing (→ Page 168).
value, but has reached its upper 4. Check exhaust turbocharger (HP) – turbine housing (→ Page 162).
limit. The bypass flap (M52) is 5. Contact Service.
fully closed.
Delayed injection timing has
reached the maximum value.
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958 – AL Lambda ctrlvar limit min active

The lambda controller is 1. Check operation of the dispenser flap (→ Page 183).
attempting to adjust its set value, 2. Contact Service.
but has reached its lower limit.
The EGR shutoff flap (M53) is fully
closed. The dispenser flap (M55)
is fully open.

959 – AL Lambda ctrlvar max BOI min act
Emission-related alarm. 1. Check operation of the EGR shutoff flap and the dispenser flap
This fault message probably (→ Page 183).
indicates a heavily sooted EGR 2. Contact Service.
cooler. A mechanical fault in the
exhaust flap before the cooler
and/or the dispenser flap (broken
linkage, but servomotor electrics
OK) is another possible cause. A
faulty signal from the lambda
sensor may also cause this alarm.
960 – AL NOx p5 min BOI max active

Emission-related alarm. 1. Check operation of the bypass flap (→ Page 183).
The charge-air pressure has 2. Contact Service.
reached the minimum value
defined in the performance map.
Advanced injection timing has
961 – AL NOx p5 max BOI min active

Emission-related alarm. u Contact Service.
This fault message probably
indicates a heavily sooted EGR
cooler.
The charge-air pressure has
reached the maximum value
defined in the performance map.
Delayed injection timing has
962 – AL GPS Lambda ctrlvar max active

This fault message indicates a 1. Check operation of the EGR shutoff flap, dispenser flap and bypass
heavily sooted EGR cooler. flap (→ Page 183).
The lambda controller is 2. Contact Service.
attempting to adjust its set value,
but has reached its upper limit.
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The EGR shutoff flap (M53) is fully

open. The dispenser flap (M55) is
fully closed.

963 – AL GPS p5 ctrlvar max active
The necessary charging pressure 1. Check air filter (plant side) for contamination.
could not be reached. 2. Check operation of the bypass flap (→ Page 183).
3. Check exhaust turbocharger (LP) – turbine housing (→ Page 168).
4. Check exhaust turbocharger (HP) – turbine housing (→ Page 162).
5. Contact Service.
964 – AL GPS p5 ctrlvar min active

The necessary charging pressure 1. Check operation of the bypass flap (→ Page 183).
could not be reached. 2. Contact Service.
970 – SD P-Exhaust
pressure sensor (B91.3) is faulty 2. Contact Service.
or missing.
973 – AL Check Sum IIG

The IIG value entered does not 1. Check the IIG input in DiaSys, repeat as necessary.
match the defined input format. 2. Contact Service.

The first engine CAN (CAN 3) for 1. Check engine cabling (→ Page 225).
engine sensors/actuators is 2. Contact Service.
disconnected or faulty.

The first engine CAN (CAN 3) for 1. Check engine cabling (→ Page 225).
engine sensors/actuators is 2. Contact Service.
disrupted.

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The second engine CAN (CAN 4) 1. Check engine cabling (→ Page 225).
for engine sensors/actuators is 2. Contact Service.
disconnected or faulty.

The second engine CAN (CAN 4) 1. Check engine cabling (→ Page 225).
for engine sensors/actuators is 2. Contact Service.
disrupted.
983 – AL Stop on Trigger Crashrecorder

This alarm indicates that the u Contact Service.
Crash Recorder has been tripped
and a start interlock activated as
a result.
984 – AL NOx ATO2 Sensor Defect

The signal from the NOx sensor 1. Check engine cabling (→ Page 225).
(B88.2) in the exhaust pipe after 2. Check NOx sensor, replace as necessary (→ Page 230).
the turbocharger B side is faulty 3. Contact Service.
or missing.
985 – AL NOx ATO2 Communication Lost

The ECU cannot detect the NOx 1. Check engine cabling (→ Page 225).
sensor (B88.2) after LP 2. Check NOx sensor, replace as necessary (→ Page 230).
turbocharger B side on the bus. 3. Contact Service.
1015 – AL Total breakdown NOx sensors

Both NOx sensors (B88.1 and 1. Replace NOx sensors (→ Page 230).
B88.2) indicate sensor defect or 2. Contact Service.
an invalid value.
1026 – AL IAP Communication Lost

The maximum number of 1. Check engine cabling (→ Page 225).
unsuccessful connection attempts 2. Contact Service.
with the EXU was exceeded.
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1027 – AL Engine Cold Active

This fault is signaled and the 1. Switch on preheater.
“Engine Cold” function initiated if 2. Check preheater, overhaul as necessary (see manufacturer's
one of the temperature values is documentation).
below the defined limit. 3. Contact Service.

1032 – AL Inj. Drift Limit 1 Cyl. A1
The drift correction for u Schedule an injector replacement.
energization (start and duration)
of injector A1 has exceeded limit
1. The injector has soon reached
its maximum drift limit.




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1042 – AL Inj. Drift Limit 1 Cyl. B1

of injector B1 has exceeded limit


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The drift correction for u Replace injector (→ Page 147).
2. The injector has reached its
maximum drift limit.
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TIM-ID: 0000075358 - 001






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1097 – AL Act Egr A Communication Lost

detect the EGR shutoff flap (M53) 2. Contact Service.
on the bus.
1098 – AL Act Egr A Temperature Warning

The internal servomotor u Contact Service.
electronics of the EGR shutoff flap
(M53) signal increased
temperature.
1099 – AL Act Egr A Targetposition

The servomotor of the EGR u Contact Service.
shutoff flap (M53) has failed to
reach its target position with the
defined time.
1103 – AL Flap BypassA Communication Lost

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detect the bypass flap (M52) on 2. Contact Service.
the bus.

1104 – AL Act BypasA Temperature Warning
electronics of the bypass flap
temperature.
1105 – AL Act Bypass A Targetposition

The servomotor of the bypass flap u Contact Service.
(M52) has failed to reach its
target position with the defined
time.
1109 – AL Act Dispens Communication Lost

detect the dispenser flap (M55) 2. Contact Service.
on the bus.
1110 – AL Act Dispens Temperature Warning

electronics of the dispenser flap
temperature.
1111 – AL Act Dispenser Targetposition

The servomotor of the dispenser u Contact Service.
flap (M55) has failed to reach its
time.
1115 – AL Difference P0 P1 Intake Air L1

The difference in pressure 1. Check air filter (plant side) for contamination.
between sensor B90 and the 2. Contact Service.
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ambient air pressure sensor

integrated in the ECU has violated
limit value 1. The differential air
intake pressure is too high.

1116 – AL Difference P0 P1 Intake Air L2
The difference in pressure 1. Check air filter (plant side) for contamination.
between sensor B90 and the 2. Contact Service.
ambient air pressure sensor
integrated in the ECU has violated
limit value 2. The differential air
intake pressure is too high.
1120 – AL Flap Egr A Calibration Drive Err

The ECU has detected a u Contact Service.
calibration routine error at the
EGR shutoff flap (M53). Cause:
The range (angle) of rotation
taught during the calibration
routine is not plausible. The
taught angle is not between the
admissible minimum and
maximum angles.
1122 – AL Flap BypassA Calibr. Drive Err

bypass flap (M52). Cause: The
range (angle) of rotation taught
during the calibration routine is
not plausible. The taught angle is
not between the admissible
minimum and maximum angles.
1124 – AL Flap Dispenser Calibr Drive Err

dispenser flap (M55). Cause: The
range (angle) of rotation taught
during the calibration routine is
not plausible. The taught angle is
not between the admissible
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minimum and maximum angles.
1130 – AL Short Circuit Analog Out 1

Incorrect plant value at analog u Contact Service.
output 1 (e.g. moving-coil
instrument, output signal for HT
circuit fan control).

1131 – AL Short Circuit Analog Out 2
Incorrect plant value at analog u Contact Service.
output 2 (e.g. moving-coil
instrument, output signal for LT
circuit fan control).
1139 – AL Communication Error ECU - EXU

Communication error between 1. Check engine cabling (→ Page 225).
ECU and EXU. 2. Restart ECU.
3. Contact Service.
1142 – SFB Relay Interface Defect

Fault detected between SFB (A81) 1. Check condition of batteries (plant).
and relay control. 2. Check wiring harness of emergency-air shutoff flaps (→ Page 225).
3. Contact Service.
1143 – SFB Relay Voltage Level Low

The voltage level at relay KY12 1. Check condition of batteries (plant).
before the NO contact has fallen 2. Contact Service.
below 21 V with the engine
running.
1144 – SFB SpeedSensorRedundancyLost

Loss of one of the speed signals 1. Check wiring harness of emergency-air shutoff flaps (→ Page 225).
B13.4 at the SFB (A81). 2. Contact Service.
1145 – SFB Speed Sensor defect

Loss of both speed signals B13.4 1. Check wiring harness of emergency-air shutoff flaps (→ Page 225).
at the SFB (A81). 2. Contact Service.
1146 – SFB Flap Feedback Interface A

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Limit switch S12.1 of emergency- 1. Check wiring harness of emergency-air shutoff flaps (→ Page 225).
air shutoff flap XSY12.1 A side 2. Contact Service.
faulty or cable disrupted.

1147 – SFB Flap Feedback Interface B
Limit switch S12.2 of emergency 1. Check wiring harness of emergency-air shutoff flaps (→ Page 225).
air-shutoff flap XSY12.2 B side 2. Contact Service.
faulty or cable disrupted.
1148 – SFB ESS_H Interface defect

NO contacts (optional) of plant- 1. Check cabling and installation on the plant side.
side emergency-stop switch faulty 2. Contact Service.
or cable disrupted.
1149 – SFB SFS Interface defect

Channel for displaying SFS status 1. Check cabling and installation on the plant side.
faulty. 2. Contact Service.
1150 – SFB ECU_CAN Communication lost

CAN communication between 1. Check engine cabling (→ Page 225).
ECU and SFB (A81) faulty/ 2. Contact Service.
disrupted.
1151 – SFB SFB_CAN_CommunicationLost

CAN communication between SFB 1. Check engine cabling (→ Page 225).
(A81) and ECU faulty/disrupted. 2. Contact Service.
1152 – SFB Configuration Data failure

Configuration data detected as u Contact Service.
being implausible.
1153 – SFB SFB_Power Supply Out of Range

The voltage supply measured at 1. Check condition of batteries (plant).
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the internal voltage sensor of SFB 2. Contact Service.

(A81) is out of range <16V >32V.
1154 – SFB SFB_Defect

Internal fault in SFB (A81). u Contact Service.

1155 – SFB Emergency Stop
Emergency stop activated u Contact Service.
manually on plant-side. SFB (A81)
has consequently tripped the
emergency stop.
1156 – SFB Overspeed Emergency Stop

SFB (A81) has detected u Contact Service.
overspeeding and consequently
tripped the emergency stop.
1158 – SFB Flap A failed to close

Emergency-air shutoff flap A side 1. Check condition of batteries (plant).
Y12.1 was not tripped by the 2. Check wiring harness of emergency-air shutoff flaps (→ Page 225).
solenoid/linkage, or was tripped 3. Contact Service.
but failed to close fully.
1159 – SFB Flap B failed to close

Emergency-air shutoff flap B side 1. Check condition of batteries (plant).
Y12.2 was not tripped by the 2. Check wiring harness of emergency-air shutoff flaps (→ Page 225).
solenoid/linkage, or was tripped 3. Contact Service.
but failed to close fully.
1160 – SFB Overspeed Test Emergency Stop

SFB (A81) has tripped the u Contact Service.
emergency stop in the course of
an overspeed test.
1161 – SFB Flap A not closed by SFB

Emergency-air shutoff flap A side 1. Check cause:
Y12.1 has closed without having 2. Flap was closed before the supply voltage was switched on, ->
been tripped by SFB (A81), or was open emergency-air shutoff flap by hand (set pointer to "OPEN").
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already closed before the SFB 3. Flap mechanism tripped automatically,-> contact Service.
power supply was switched on.

1162 – SFB Flap B not closed by SFB
Emergency air shutoff flap B side 1. Check cause:
Y12.2 has closed without having 2. Flap was closed before the supply voltage was switched on, ->
been tripped by SFB (A81), or was open emergency-air shutoff flap by hand (set pointer to "OPEN").
already closed before the SFB 3. Flap mechanism tripped automatically,-> contact Service.
power supply was switched on.
1163 – SFB Flap A closed

Emergency-air shutoff flap A side u No action required.
Y12.1 has tripped as intended.
1164 – SFB Flap B closed

Emergency-air shutoff flap B side u No action required.
Y12.2 has tripped as intended.
1165 – SFB SFS_Not available

The safety functions of SFB (A81) 1. Observe any other messages.
are no longer available. Summary 2. Contact Service.
alarm.
1166 – SFB SFB/ECU_Engine Speed deviation

SFB (A81) has detected that the u Contact Service.
speed measured at sensor B13.4
deviates from the ECU speed
(value determined from sensor B1
and B13).
1167 – AL Inplausible NOx High Limit1

NOx emissions too high. u Contact Service.
Cumulative NOx emissions from
the engine have violated limit
value 1.
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1168 – AL Inplausible NOx Low Limit1

NOx emissions too low. u Contact Service.
value 1.

1172 – AL Inplausible NOx High Limit2
NOx emissions too high. u Contact Service.
value 2.
1173 – AL Inplausible NOx Low Limit2

NOx emissions too low. u Contact Service.
value 2.
1174 – HI T-Fuel f(T0)

The charge-air pressure at sensor 1. Reduce power.
B33 has violated upper limit value 2. Check fuel cooling system (if fitted).
1. Fuel temperature is too high. 3. Contact Service.
1175 – SS T-Fuel f(T0)

The charge-air pressure at sensor 1. Reduce power.
B33 has violated upper limit value 2. Check fuel cooling system (if fitted).
1. The fuel temperature has 3. Contact Service.
violated the critical upper limit
value.
1178 – AL J1939 Heartbeat1 Lost

No message via J1939 plant bus u Contact Service.
(CAN2).
1179 – AL J1939 Heartbeat2 Lost

No message via J1939 plant bus u Contact Service.
(CAN2).
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1180 – AL NOx 2 Sensor invalid

Status information of NOx sensor 1. Acknowledge alarm.
(B88.2), generated in case of 2. Replace NOx sensor (→ Page 230).
short-term implausible measured 3. Contact Service.
values or sensor defect.

1183 – AL Invalid Measurement Config
Selected measuring point not u Contact Service.
activated or configured
incorrectly.
1186 – AL EGR FlpA Wear Limit2

Abnormal fast homing of the EGR 1. Check condition of batteries (plant).
shutoff flap (M53) (performed 2. Check operation of the EGR shutoff flap (→ Page 183).
2nd limit value
1188 – AL Bypass FlpA Wear Limit2

bypass flap (M52) (performed 2. Check operation of the bypass flap (→ Page 183).
2nd limit value
1190 – AL Dispenser Flp Wear Limit2

dispenser flap (M55) (performed 2. Check operation of the dispenser flap (→ Page 183).
2nd limit value
1201 – AL Stop Start Low Power Supply Pow

Engine start is blocked because 1. Check condition of batteries (plant).
the supply voltage is too low. 2. Contact Service.
1368 – SD P-Abgas AGR A (P6)

pressure sensor (B98) after 2. Contact Service.
cylinder before dispenser flap is
faulty or missing.
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1372 – AL Exhaust gas inclusion
The pressure differential between u Contact Service.
exhaust gas pressure after
cylinder (P6) measured at sensor
B98, and charge-air pressure (P5)
measured at sensor B10.1, has
exceeded the limit. A fault has
occurred in the exhaust gas path.
1373 – AL P6 Sensor A Sooting

The ECU has not detected any u Contact Service.
variation in pressure at exhaust
gas pressure sensor B98. The
exhaust line to the sensor is
contaminated with soot.
1376 – AL Refdrive Impossibl Ubat Low

The ECU supply voltage is too low 1. Check condition of batteries (plant).
for successful homing of all flaps 2. Check plug connections to engine governor (→ Page 229).
even when the engine is running. 3. Contact Service.
1377 – AL Refdrive Impossibl Eng Op Point

Homing of one or more flaps 1. Run engine up to idling speed. Result: Homing is executed.
before engine start was not 2. Contact Service.
completed successfully. Homing
the affected flaps is no longer
possible.
1378 – AL Act Egr A Ref-Drv EngStop

This alarm is set in the fault 1. Check condition of batteries (plant).
memory if homing the EGR shutoff 2. Check plug connections to engine governor (→ Page 229).
flap (M53) was not successful 3. Contact Service.
when initiated with the engine at
standstill.
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1380 – AL Act Byp A Ref-Drv EngStop

memory if homing the bypass flap 2. Check plug connections to engine governor (→ Page 229).
(M52) was not successful when 3. Contact Service.
initiated with the engine at
standstill.

1382 – AL Act Dispenser Ref-Drv EngStop
memory if homing the dispenser 2. Check plug connections to engine governor (→ Page 229).
flap (M55) was not successful 3. Contact Service.
when initiated with the engine at
standstill.
1384 – AL Act Egr A Ref-Drv Eng Running

Homing the EGR shutoff flap 1. Check condition of batteries (plant).
(M53) could not be carried out. 2. Check plug connections to engine governor (→ Page 229).
3. Check engine cabling (→ Page 225).
4. Contact Service.
1386 – AL Act Byp A Ref-Drv Eng Running

Homing the bypass flap (M52) 1. Check condition of batteries (plant).
could not be carried out. 2. Check plug connections to engine governor (→ Page 229).
4. Contact Service.
1388 – AL Act Disp B Ref-Drv Eng Running

Homing the dispenser flap (M55) 1. Check condition of batteries (plant).
could not be carried out. 2. Check plug connections to engine governor (→ Page 229).
4. Contact Service.
1390 – AL Flap Egr A Wear Limit 1

The range of rotation on homing u Replace linkage rod at next scheduled maintenance interval
the EGR shutoff flap (M53) has (→ Page 185).
exceeded limit 1. The flap
mechanism is beginning to wear.
1392 – AL Flap Byp A Wear Limit 1

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the bypass flap (M52) has (→ Page 185).

1394 – AL Flap Disp Wear Limit 1
the dispenser flap (M55) has (→ Page 185).
1396 – AL Flap Egr A Wear Limit 2

The range of rotation on homing u Replace linkage rod (→ Page 185).
the EGR shutoff flap (M53) has
mechanism is significantly worn.
1398 – AL Flap Byp A Wear Limit 2

the bypass flap (M52) has
1400 – AL Flap Disp Wear Limit 2

the dispenser flap (M55) has
1402 – AL Flap Egr A linkage failure

The range of rotation on homing 1. Check exhaust flap for damage (→ Page 180).
the EGR shutoff flap (M53) has 2. Replace the linkage rod if it is damaged (→ Page 180).
exceeded the limit. The flap 3. Contact Service on detecting any other damage at the exhaust
mechanism is faulty. flap.
1404 – AL Flap Byp A linkage failure

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the bypass flap (M52) has 2. Replace the linkage rod if it is damaged (→ Page 180).

1406 – AL Flap Dispenser linkage failure
the dispenser flap (M55) has 2. Replace the linkage rod if it is damaged (→ Page 180).
1408 – AL Flap Egr A restricted Limit 1

The range of rotation on homing 1. Check smooth operation of the exhaust flap mechanism.
the EGR shutoff flap (M53) has 2. Contact Service.
exceeded limit 1. Flap travel is
marginally restricted.
1410 – AL Flap Byp A restricted Limit 1

the bypass flap (M52) has 2. Contact Service.
1412 – AL Flap Disp restricted Limit 1

the dispenser flap (M55) has 2. Contact Service.
1414 – AL Flap Egr A restricted Limit 2

the EGR shutoff flap (M53) has 2. Contact Service.
restricted.
1416 – AL Flap Byp A restricted Limit 2

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the bypass flap (M52) has 2. Contact Service.

restricted.

1418 – AL Flap Disp restricted Limit 2
the dispenser flap (M55) has 2. Contact Service.
restricted.
1420 – AL Flap Egr A blocked drive

The mechanism of the EGR 1. Check smooth operation of the exhaust flap mechanism.
shutoff flap (M53) is blocked. 2. Contact Service.
1422 – AL Flap Bypass A blocked drive

The mechanism of the bypass flap 1. Check smooth operation of the exhaust flap mechanism.
(M52) is blocked. 2. Contact Service.
1424 – AL Flap Dispenser blocked drive

The mechanism of the dispenser 1. Check smooth operation of the exhaust flap mechanism.
flap (M55) is blocked. 2. Contact Service.
1430 – AL Act Agr A Temperature Alert

The internal servomotor 1. Check for high temperatures in the vicinity of the servomotor, e.g.
electronics of the EGR shutoff flap resulting from faulty insulation, defective seals, signs of sooting
(M53) signal excessively high (→ Page 180).
temperature. 2. Check coolant connections of servomotor for leaks and blockages
(→ Page 226).
3. Contact Service.
1432 – AL Act Byp A Temperature Alert

electronics of the bypass flap resulting from faulty insulation, defective seals, signs of sooting
(→ Page 226).
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3. Contact Service.

1434 – AL Act Dispenser Temperature Alert
electronics of the dispenser flap resulting from faulty insulation, defective seals, signs of sooting
(→ Page 226).
3. Contact Service.
1436 – AL Act Agr A Voltage Supply

The servomotor supply voltage for 1. Check condition of batteries (plant).
the EGR shutoff flap (M53) is 2. Check plug connections to engine governor (→ Page 229).
below 9V or above 32V. The 3. Contact Service.
servomotor assumes a safe
position.
1438 – AL Act Byp A Voltage Supply

the bypass flap (M52) is below 9V 2. Check plug connections to engine governor (→ Page 229).
or above 32V. The servomotor 3. Contact Service.
assumes a safe position.
1440 – AL Act Dispenser Voltage Supply

the dispenser flap (M55) is below 2. Check plug connections to engine governor (→ Page 229).
9V or above 32V. The servomotor 3. Contact Service.
assumes a safe position.
1448 – AL ECU Comm Lost to Act EGR A

detect the EGR shutoff flap (M53) 2. Contact Service.
on the CAN bus.
1450 – AL ECU Comm Lost to Act Byp A

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detect the bypass flap (M52) on 2. Contact Service.
the CAN bus.

1452 – AL ECU Comm Lost to Act Dispenser
detect the dispenser flap (M55) 2. Contact Service.
on the CAN bus.
1454 – AL Act EGR A Comm Lost to ECU

The servomotor of the EGR 1. Check engine cabling (→ Page 225).
shutoff flap (M53) receives no 2. Contact Service.
data from the ECU via the CAN
bus.
1456 – AL Act Byp A Comm Lost to ECU

The servomotor bypass flap (M52) 1. Check engine cabling (→ Page 225).
receives no data from the ECU via 2. Contact Service.
the CAN bus.
1458 – AL Act Dispenser Comm Lost to ECU

The servomotor of the dispenser 1. Check engine cabling (→ Page 225).
flap (M55) receives no data from 2. Contact Service.
the ECU via the CAN bus.
1550 – AL LSU Stop Cal Airmass

Calibration of lambda sensor 1. Execute manual lambda calibration via DiaSys® (→ Dialog system
failed. Engine coasting too short DiaSys® E531920/..).
2. Start engine (→ Page 48).
3. Shut down engine in accordance with specifications (→ Page 49).
4. Contact Service.
1551 – AL LSU Stop Cal Min Max

Calibration of lambda sensor 1. Replace lambda sensor (→ Page 232).
failed. Sensor defective. 2. Contact Service.
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1552 – AL LSU Stop Cal Delta Factor

Calibration of lambda sensor 1. Replace lambda sensor (→ Page 232).
failed. Sensor defective. 2. Contact Service.

1553 – AL Act Agr A Targetpos Blocked
The servomotor of the EGR u Contact Service.
shutoff flap (M53) has failed to
reach its target position with the
defined time.
1555 – AL Act Byp A Targetpos Blocked

The servomotor of the bypass flap u Contact Service.
(M52) has failed to reach its
time.
1557 – AL Act Disp Targetpos Blocked

The servomotor of the dispenser u Contact Service.
flap (M55) has failed to reach its
time.
5000 – AL Sensordefect T-EXU Device

Signal from EXU internal u Contact Service.
temperature sensor faulty or
missing.
5001 – AL HI T-EXU Device

The temperature limit measured u Contact Service.
at the device-internal temperature
sensor of the EXU was exceeded.
The temperature of the EXU
device is too high.
5002 – AL Sensordefect EXU Power Supply

Signal from EXU internal voltage u Contact Service.
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sensor faulty or missing.
5003 – AL LO EXU Supply Voltage

The supply voltage of the EXU has 1. Check condition of batteries (plant).
undershot limit value 1. 2. Check plug connection cables to the EXU (→ Page 229).
4. Contact Service.

5004 – AL LOLO EXU Supply Voltage
undershot limit value 2. 2. Check plug connection cables to the EXU (→ Page 229).
4. Contact Service.
5005 – AL HI EXU Supply Voltage

exceeded limit value 1. 2. Check plug connection cables to the EXU (→ Page 229).
4. Contact Service.
5006 – AL HIHI EXU Supply Voltage

exceeded limit value 2. 2. Check plug connection cables to the EXU (→ Page 229).
4. Contact Service.
5009 – AL EXU Device Defect

Fault in EXU. u Contact Service.
5011 – AL experimental parameter set

Test operation activated via u No actions required.
DiaSys.
5012 – AL CAN PU Data Flash Error

EXU device-internal memory u Contact Service.
module faulty.
5014 – AL incorrect parameter setting

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The ECU data record and the EXU 1. Check plug connection cables between ECU and EXU
data record are at variance (→ Page 229).
leading to deactivation of the 2. Restart ECU and EXU.
single accumulator pressure 3. Contact Service.
monitoring.

5018 – AL CAN1 error passive
CAN bus 1 for plant-side MTU u Contact Service.
automation (e.g. MAU/SAM)
faulty. Alarm 5019 follows if fault
persists.
5019 – AL CAN1 bus off

CAN bus 1 for plant-side MTU u Contact Service.
automation (e.g. MAU/SAM)
disrupted/failed.

CAN bus 2 to customer u Contact Service.
automation (e.g. Murphy display)
faulty. Alarm 5021 follows if fault
persists.

CAN bus 2 to customer u Contact Service.
automation (e.g. Murphy display)
disrupted/failed.

Connection to a node on CAN bus u Contact Service.
1 failed.

Connection to a node on CAN bus u Contact Service.
2 failed.
5024 – AL duplicate node failure CAN1 CAN2

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Connection to a node on CAN u Contact Service.
bus 1 and CAN bus 2 failed.

Communication with ECU (CAN 1. Check plug connection cables between ECU and EXU
bus 3) is out of order. (→ Page 229).
2. Contact Service.

Communication with ECU (CAN 1. Check plug connection cables between ECU and EXU
bus 3) disrupted/failed. (→ Page 229).
2. Contact Service.
5027 – AL SD Camshaft Speed

The signal from the camshaft 1. Check engine cabling (→ Page 225).
missing.
5028 – AL SD Crankshaft Speed

The signal from the crankshaft 1. Check engine cabling (→ Page 225).
missing.
5029 – AL Synchonization Lost

Unable to synchronize crankshaft 1. Check engine cabling (→ Page 225).
and camshaft. 2. Contact Service.
5030 – AL CAN3 communication lost

The EXU receives no data from 1. Check engine cabling (→ Page 225).
the ECU in spite of intact CAN 2. Contact Service.
bus.
5199 – AL IAP NotAvailable

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Faults have occurred that result in u Contact Service.
deactivation of the individual
accumulator pressure monitoring.
Occurs in conjunction with the
following other alarms: 5014,
5025, 5026, 5027, 5028, 5029,
5030.

5200 – AL Dev P_Rail ECU EXU
Excessive difference in pressure u Contact Service.
measured at sensor B48 in the
fuel distributor block and the
averaged pressure value of
sensors B97A1-Bx of the specified
limit. One of the pressure sensors
delivers an incorrect measured
value.
5201 – AL IAP Sensor Cyl A1 Defect

Signal from single accumulator u Contact Service.
pressure sensor (B97.A1) in
injector A1 faulty or missing.




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5211 – AL IAP Sensor Cyl B1 Defect

pressure sensor (B97.B1) in
injector B1 faulty or missing.




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5221 – AL No Injection Detected CylA1

The pressure variation measured 1. Check whether alarm 5201 is signaled. If so, contact Service.
at sensor B97A1 and evaluated by 2. Replace injector (→ Page 147).
the EXU indicates that despite 3. Contact Service.
correct energization no fuel is
being injected at cylinder A1.


TIM-ID: 0000075358 - 001






TIM-ID: 0000075358 - 001
5231 – AL No Injection Detected CylB1

at sensor B97B1 and evaluated by 2. Replace injector (→ Page 147).
being injected at cylinder B1.





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5241 – AL Implausible BOI CylA1

The beginning of injection u Contact Service.
measured by sensor B97A1 and
evaluated by the EXU is outside
the controllable tolerance.




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5251 – AL Implausible BOI CylB1

measured by sensor B97B1 and


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5261 – AL Implausible EOI CylA1

The end of injection measured by u Contact Service.
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sensor B97A1 and evaluated by

the EXU is outside the
controllable tolerance.






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5271 – AL Implausible EOI CylB1

sensor B97B1 and evaluated by




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8 Task Description
8.1 Engine
8.1.1 Engine – Barring manually
Preconditions

Barring gear F6792918 1
Barring gear F6555766 1
Ratchet with extension F30006212 1
DANGER
danger zone.
Barring engine manually – on

gear
1. Loosen screws (1) and remove end cover (2)
from flywheel housing.
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MS150120/02E 2017-08 | Task Description | 125

Note: Use barring gear F6555766.
2. Engage barring gear (2) in ring gear of fly-
wheel and mount on flywheel housing.
3. Fit ratchet (1) on barring gear.
Note: No resistance other than compression resist-
ance may be encountered.
4. Rotate crankshaft in engine direction of rota-
tion.
Result: If resistance other than the compression re-
sistance occurs, contact Service.
5. Barring gear is removed by same procedure
in reverse.
Barring engine manually –

through starter opening
1. Loosen screws (1) and remove end cover (2)
from flywheel housing.
Note: Use barring gear F6792918.

2. Engage barring gear (2) in ring gear and
mount on flywheel housing.
3. Fit ratchet (1) with socket onto barring
gear (2).
Note: No resistance other than compression resist-
ance may be encountered.
4. Rotate crankshaft in engine direction of rota-
tion.
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Result: If resistance other than the compression re-

sistance occurs, contact Service.
5. Barring gear is removed by same procedure
in reverse.
126 | Engine | MS150120/02E 2017-08

8.1.2 Engine – Barring with starting system
DANGER
• 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.
Engine – Barring with starting

system
1. Release latch (1) of connector X3 (2).
Note: Seal unused connectors with the supplied
protective cap.
2. Remove connector from engine governor.
3. Turn engine in unloaded condition: Press
START button.
4. Let the crankshaft rotate until oil pressure is
indicated.
5. Engine start is interrupted automatically after
the maximum permissible time.
6. Repeat this procedure after approximately
20 seconds if required.
7. Fit connector X3 (2) on engine governor and
close latch (1).
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MS150120/02E 2017-08 | Engine | 127

8.1.3 Engine – Test run
DANGER
danger zone.
WARNING
Engine – Test run

2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 42).
4. Stop engine (→ Page 49).
TIM-ID: 0000000870 - 008
128 | Engine | MS150120/02E 2017-08

8.2 Cylinder Liner
8.2.1 Cylinder liner – Endoscopic examination
Preconditions
☑ Engine is stopped and starting disabled

Barring tool F6555766 1
Ratchet with extension F30006212 1
Endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 143).
2. Remove injector (→ Page 148).
Positioning crankshaft at BDC

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

Findings Measure
• Thin carbon coating around carbon scraper ring No actions 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 examina-
• Beginning and end of the discoloration are not sharply defined and do tion required as part of mainte-
not cover the entire stroke area nance work.
• Dark areas in the upper section of the cooling bore, remaining circum-
ference are faultless
• Piston rings are faultless
• On the entire circumference, apart from light areas of discoloration (do Cylinder liner must be replaced,
TIM-ID: 0000003304 - 006
not impair operation) clearly darker stripes that start at the top piston contact Service.
ring
• Heat discoloration in the direction of stroke and honing pattern dam-
age
• Heat discoloration of piston rings
MS150120/02E 2017-08 | Cylinder Liner | 129

1. Compile endoscopic report using the table.
2. Use technical terms to describe the liner surface (→ Page 131).
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 148).
2. Install cylinder head cover (→ Page 143).
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130 | Cylinder Liner | MS150120/02E 2017-08

8.2.2 Cylinder liner – Instructions and comments on endoscopic and visual
examination
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina-
tion report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). 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 honing 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.
Polished area Polished areas are on the running surface but almost the whole honing pattern is
still visible. Polished areas appear brighter and more shiny than the surrounding
running surface.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from the honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from moisture (condensate) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a preliminary stage of burn marks. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark These are caused by a disturbance in the liner / ring tribo system. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
TIM-ID: 0000000014 - 016
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks starting in TDC ring 1 have to be replaced.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.
Table 8: Endoscopic examination – Terms used
MS150120/02E 2017-08 | Cylinder Liner | 131

Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and burn marks are similar. A thorough investigation
and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary
disassembly work, it is recommended that another inspection be carried out after further operation of the
engine.
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132 | Cylinder Liner | MS150120/02E 2017-08

8.3 Crankcase Breather
8.3.1 Oil mist fine separator – Replacement
Preconditions

Engine oil
Oil mist fine separator (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)
Locknut (→ Spare Parts Catalog)
Washer (→ Spare Parts Catalog)
WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Replacing oil mist fine separator

1. Remove lines (1).
2. Undo screws (3) on vent lines (2) and remove
vent lines with O-rings.
3. Remove screws (4) with washers.
4. Remove diaphragm housing (5).
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5. Unscrew nut (2) remove together with wash-
ers.
6. Remove cover (1) and sealing ring.
7. Replace filter element (3).
8. Replace seal ring as necessary.
9. Install sealing ring and cover (1).
10. Screw on new nut (2) with new washers and tighten nut (2) to specified torque using a torque wrench.
Nut Tightening torque 10 Nm ±2 Nm
11. Replace other oil mist fine separators in the same way.
12. Install diaphragm housing and lines.
TIM-ID: 0000054365 - 007
134 | Crankcase Breather | MS150120/02E 2017-08

8.4 Valve Drive
8.4.1 Valve gear – Lubrication
Preconditions

Engine oil
Valve gear – Lubrication

1. Remove cylinder head upper section
(→ Page 143).
2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjusting
screws with oil.
4. Install cylinder head upper section
(→ Page 143).
TIM-ID: 0000055644 - 001
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8.4.2 Valve protrusion – Measurement
Preconditions

Measuring jig 1 Y4350009 1
Measuring jig 2, optional Y4350010 1
Depth gauge, 200 mm Y20000918 1
Preparatory steps
1. Remove cylinder head covers (→ Page 143).
2. Install barring tool (→ Page 125).
3. Using the barring tool, turn crankshaft in di-
rection of engine rotation until TDC mark on
the rear side of the flywheel and pointer (1).
Calibrating measuring jigs 1 and

2
1. Place measuring unit (2) on calibration
plate (3).
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136 | Valve Drive | MS150120/02E 2017-08

2. Turn measuring unit screws (1) into the threads and tighten to specified torque using a torque wrench.
Screw M10 Tightening torque 20 Nm
3. Set all dial gauges to 0.

4. Unscrew measuring unit (2) from calibration plate (3).
Step 1: Measure valve protrusion at the valve head with measuring jig 1
1. Check TDC position of piston in cylinder A1:
• If rocker arms on cylinder A1 are unloaded, the piston is in firing TDC.
• If rocker arms on cylinder A1 are loaded, the piston is in overlap TDC.
2. Measure valve stem end to cylinder head top distance for each valve in two crankshaft positions (firing TDC
and overlap TDC) according to the diagram. Diagram (→ Page 140).
3. Place measuring unit 1 (2) on the cylinder
head (3).
4. Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specified
torque using a torque wrench.
5. Determine the values with all dial gages.

• The valve protrusion value must be ≤ 1.5 mm.
• If the value is > 1.5 mm, measure with a depth gauge or optionally with measuring jig 2.
6. Unscrew measuring unit (2) from cylinder head (3).
Step 2: Measure valve protrusion at the valve stem with a depth gauge
TIM-ID: 0000076183 - 001

MS150120/02E 2017-08 | Valve Drive | 137

3. Release adjusting screw (1) and remove valve
bridge. Do not remove rocker arm (2).
4. Measure distance (A) between valve stem

end and cylinder head top at the injector
bore with depth gauge.
• The specified value for a new cylinder
head: 93.8 mm.
• Admissible wear: 2 mm.
• Have the affected cylinder head replaced
by expert personnel ahead of schedule if
the measured value is > 95.8 mm.
5. Install valve bridge.
6. Adjusting valve clearance (→ Page 140)
Step 2 optional: Measure valve protrusion at the valve stem with measuring
jig 2
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138 | Valve Drive | MS150120/02E 2017-08

Note: Do not remove rocker arm (2).
3. Release adjusting screw (1) and remove valve
bridge.
4. Place measuring unit 2 (2) on the cylinder

head (3).
5. Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specified
torque using a torque wrench.
6. Determine the values with all dial gauges.

• The valve protrusion value must be ≤ 2 mm.
• Have the affected cylinder head replaced by expert personnel if the value is > 2 mm.
7. Unscrew measuring unit (2) from cylinder head (3).
TIM-ID: 0000076183 - 001
8. Install valve bridge.

9. Adjusting valve clearance (→ Page 140)
Final steps
1. Remove barring tool (→ Page 125).
MS150120/02E 2017-08 | Valve Drive | 139

8.4.3 Valve clearance – Check and adjustment
Preconditions
☑ Coolant temperature is max. 40 °C.
☑ Valves are closed.

Feeler gage Y20098771 1
Allen key F30002815 1
Socket wrench, 24 mm F30039526 1
Engine oil
Preparatory steps
1. Remove cylinder head upper section (→ Page 143).
2. Install barring gear (→ Page 125).
3. The OT/A1 mark (1) on the outer circumfer-
ence of the flywheel (if applicable) must not
be used for reference.
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Note: The pointer (1) is in the lower opening of the
flywheel housing (arrow).
4. Use barring gear to turn crankshaft in engine
direction of rotation until marking OT/A1 on
the rear side of the flywheel and pointer (1)
are aligned.
Diagram 12V (two crankshaft

positions)
Diagram for 16V engines (two

crankshaft positions)
TIM-ID: 0000055645 - 004
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Checking valve clearance at two crankshaft positions
• The piston is in firing TDC when the rocker arms on cylinder A1 are unloaded.
• The piston is in overlap TDC when the rocker arms on cylinder A1 are loaded.
2. Check valve clearance with cold engine:
• Inlet valves (long rocker arm) = 0.2 mm ± 0.05 mm
• Exhaust valves (short rocker arm) = 0.5 mm ± 0.05 mm
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per
diagram:
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
4. Use feeler gage to determine the distance between valve bridge and rocker arm.
5. If the deviation from the set value exceeds 0.1 mm, adjust valve clearance.
Adjusting valve clearance

1. Release locknut (1).
2. Insert feeler gage (3) between valve bridge
and rocker arm.
Note: Replace or free up tight adjusting screws
and/or locknuts.
3. Using Allen key, set adjusting screw (2) so
that the specified valve clearance is provided.
Note: Feeler gage must just pass through the gap.
4. Insert feeler gage (3) between valve bridge
and rocker arm.
Note: Counter adjusting screw (2).

5. Tighten locknut (1) to specified torque using a torque wrench.
Locknut M16x1.5 Tightening torque (Engine oil) 90 Nm +9 Nm
6. Check valve clearance, adjust as necessary.
Final steps
1. Remove barring gear (→ Page 125).
2. Install cylinder head upper section (→ Page 143).
3. Enable engine start.
TIM-ID: 0000055645 - 004
142 | Valve Drive | MS150120/02E 2017-08

8.4.4 Cylinder head cover – Removal and installation
Preconditions

Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Gasket (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
Removing cylinder head cover

1. Clean very dirty cylinder head cover upper
section (2) prior to removal.
2. Remove screws (4, 5) with washers (3, 6).
3. Remove cylinder head cover upper sec-
tion (2) with gasket (1) from cylinder head
cover lower section (7).
4. Screw out ESD connector (8) from cylinder
head cover lower section (7).
5. Remove screws (4, 5) with washers (3, 6).

6. Remove cylinder head cover lower section (2)
with gasket (1) from cylinder head.
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Installing cylinder head cover
1. Clean installation surface.
2. Check gasket (1) for damage, replace as nec-
essary.
3. Coat gasket (1) with assembly compound.
4. Place gasket (1) and cylinder head cover low-
er section (2) on cylinder head.
5. Install cylinder head cover lower section (2)
with screws (4, 5) and washers (3, 6).
Note: Ensure that O-ring is positioned correctly.

6. Screw in ESD connector (8) in cylinder head cover lower section (7) and tighten to specified torque using a
torque wrench.
Nut Tightening torque 6 Nm + 1 Nm
7. Install pressure sensor on ESD connector (8) and tighten bayonet lock to specified torque using a torque
wrench.
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Connector Tightening torque 1.2 Nm
8. Check gasket (1) for damage, replace as necessary.

9. Coat gasket (1) with assembly compound.
10. Place gasket (1) and cylinder head cover upper section (2) on cylinder head cover lower section (7).
11. Install cylinder head cover upper section (2) with screws (4, 5) and washers (3, 6).
144 | Valve Drive | MS150120/02E 2017-08

8.5 Injection Pump / HP Pump
8.5.1 HP fuel pump – Filling with engine oil
Preconditions
☑ HP pump is installed.

Fuel suction device F30378207 1
Engine oil
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Oils/oil vapors are combustible/explosive.
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.
NOTICE
HP fuel pump not filled with engine oil.
Damage to components, major material damage!
• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.
NOTICE
Contaminated components.
Risk of damage to component!
• Check components for special cleanliness and clean if necessary.
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Preparatory steps
u Loosen nut (2) and remove oil line (1) from
HP pump.
HP pump – Filling
1. Remove union (1).
Note: Excess engine oil runs into gear box.
2. Use fuel suction device to fill HP pump with
2 liters of clean engine oil.
3. Screw in union (1) and use torque wrench to tighten to specified tightening torque.
Union M16x1.5 Tightening torque 40 Nm
Final steps
u Install oil line.
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8.6 Injector
8.6.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Injector – Replacement
u Remove injector and install new one (→ Page 148).
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MS150120/02E 2017-08 | Injector | 147

8.6.2 Injector – Removal and installation
Preconditions

Installation/removal jig F6796646 1
Milling cutter F30452739 1
Assembly compound (Molykote P 37) 50564 1
Multi-purpose grease 40320 1
Engine oil
WARNING
• Do not smoke.
WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.
TIM-ID: 0000077696 - 001
WARNING
Internal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.
Risk of injury by ejected parts!
• Only use specified tools and devices.
• Wear goggles/facial protection.
NOTICE
Contamination of components.
Risk of damage to component!
• Seal off components with suitable covers.
• Check components for special cleanliness prior to installation/assembly and clean if necessary.
148 | Injector | MS150120/02E 2017-08

Label
u The nameplate contains the following infor-
mation:
1. DMC - Data Matrix Code
2. L'Orange part number
3. MTU part number
4. IIG-Code - Initial Injector Equalization
5. EMI-ID code
6. Serial number
7. Date of manufacture
Preparatory steps
1. Allow HP system to cool down.
2. Close off fuel supply to engine.
3. Remove cylinder head cover (→ Page 143).
Removing injector
Note: The cable connectors feature a latch, which
is released by pulling the black connector
housing backwards.
1. Disconnect connectors on injector (arrowed).
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MS150120/02E 2017-08 | Injector | 149

Note: Be aware of system pressure.
2. Slowly release union nuts (2, 5) and remove
HP line (3) from rail (4) and cylinder head.
Note: When the adapter is unscrewed, the stored
volume of the injector is emptied.
3. Provide suitable container to collect escaping
fuel.
4. Remove adapter (1).
5. Loosen union nuts and remove return line (6).
6. Remove screw (2) from hold-down clamp (1).
7. Install installation/removal jig (2) on cylinder

head.
8. Remove injector (1) and hold-down clamp
with installation/removal jig (2).
9. Remove installation/removal jig (2).
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Note: The sealing ring for sealing the combustion
chamber must only be used once.
10. Remove sealing ring from injector or use a
self-made wire hook or magnet to take it out
of the cylinder head and dispose of properly.
Note: For new assembly:
11. Close used injector with plug and cap of the
new injector and dispose of injector with in-
stalled O-rings.
Note: For repeated assembly:
12. Remove O-rings (2, 3) and damper ring from
injector.
13. Clean all mating and sealing surfaces.
14. If carbon residue is present, clean sealing
face on cylinder head and protective sleeve
with milling cutter.
15. Cover all connections and bores, or seal with
suitable plugs.
Installing injector
Note: • The new sealing ring is included in the
scope of supply of the injector (new part).
• A multi-purpose grease without solids con-
tent must be used.
1. Install new sealing ring (arrow) abutted to
(Multi-purpose grease) and ensure that instal-
lation position is correct.
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Note: Remove the seal plug of the HP line only be-
fore installing the adapter.
2. Remove plug.
3. Clean sealing face on cylinder head and pro-
tective sleeve by removing carbon deposits
with a milling cutter.
Note: The damper ring is already in place for new
assembly.
4. Fit damper ring on injector and coat with (As-
sembly compound (Molykote P 37)).
Note: The O-rings are already in place for new as-
sembly.
5. Fit new O-rings (3) on injector (2) and apply
(Assembly compound (Kluthe Hakuform
30-15)).
Note: Make sure that the sealing ring does not fall
into the water sleeve.
6. Ensure that the sealing ring is correctly seat-
ed.
7. Insert injector (1) together with hold-down
clamp into cylinder head, ensuring that the
high-pressure fuel line connection is aligned
correctly.
8. Press in injector (1) and hold-down clamp
with installation/removal jig (2).
9. Remove the installation/removal jig.
TIM-ID: 0000077696 - 001
152 | Injector | MS150120/02E 2017-08

10. Coat screw head mating face on hold-down
clamp (1) and screw head mating face and
thread of screw (2) with engine oil.
11. Insert screw (2) and tighten hand-tight.
Note: Ensure immaculate cleanliness.

12. Apply engine oil to thread, sealing taper and
thrust ring of adapter (1).
13. Apply (Assembly compound (Kluthe Haku-
form 30-15)) to O-rings on adapter (1).
14. Install adapter (1) and tighten hand-tight.
15. Tighten screw on hold-down clamp (→ Step 11) to specified torque using a torque wrench.
16. Tighten adapter (1) to specified torque using a torque wrench.

Adapter M18 Tightening torque (Engine oil) 100 Nm +10 Nm
TIM-ID: 0000077696 - 001
Note: Ensure particular cleanliness.

17. Apply engine oil to thread, sealing taper and thrust ring of HP line (3).
18. Coat O-rings with (Assembly compound (Kluthe Hakuform 30-15)).
19. Thread in HP line (3), ensuring that the sealing areas are not damaged.
MS150120/02E 2017-08 | Injector | 153

20. Tighten union nuts (2, 5) on HP line (3) to specified torque using a torque wrench according to the tightening
sequence. Tightening sequence:
1 Nut on adapter (2), counterhold on adapter (1)
2 Nut on rail (5)
Union nut / thrust M12 Tightening torque (Engine oil) 40 Nm +5 Nm
screw
Note: Do not hold in place by hand.

21. Release union nuts (2, 5) on HP line (3) approx. 45° angle of rotation while counterholding adapter (1) in
relation to injector.
22. Tighten union nuts (2, 5) on HP line (3) without interruption once again in the same sequence to specified
final tightening torque using a torque wrench. Tightening sequence:
1 Nut on adapter (2), counterhold on adapter (1)
2 Nut on rail (5)
Union nut / thrust M12 Tightening torque (Engine oil) 40 Nm +5 Nm
screw
23. Install return line (6) and tighten union nuts.

24. Fit connectors on injector (arrowed).
For new assembly: CDC parameters – Reset

Note: If the drift correction (CDC) is not reset, the emission certification becomes invalid.
u Reset drift compensation (CDC) using DiaSys® and enter injector code (IIG) (→ Dialog system DiaSys®
E531920/..). If DiaSys® is not available, contact Service.
TIM-ID: 0000077696 - 001
Final steps
2. Open fuel supply to engine.
154 | Injector | MS150120/02E 2017-08

8.7 Fuel System
8.7.1 Fuel system – Venting
Preconditions

Diesel fuel
WARNING
• Do not smoke.
Venting LP fuel system

1. Open threaded vent plug (2) and connect a
suitable hose.
fuel.
3. Operate the hand pump (1) as follows:
4. Operating principle:
a Hold sleeve (2). Turn handle (1) coun-
terclockwise until sleeve can be
moved back (arrowed).
b Operate pump with handle (1) until
bubble-free fuel emerges from thread-
ed vent plug.
TIM-ID: 0000064777 - 001
Close threaded vent plug.

c Slide sleeve (2) forwards and hold.
Turn handle (1) clockwise until both
parts are firmly screwed together by
hand.
5. Remove hose from vent valve.
6. Verify that fuel hand pump is properly locked:
Handle (1) must be tightened finger-tight.
MS150120/02E 2017-08 | Fuel System | 155

8.8 Fuel Filter
8.8.1 Fuel filter – Replacement
Preconditions

Filter wrench F30379104 1
Engine oil
Easy-change filter (→ Spare Parts Catalog) 2
WARNING
• Do not smoke.
Replacing fuel filter

fuel.
2. Remove easy-change filter (2) with filter
wrench.
3. Clean sealing surface on filter head (1).
4. Apply a thin coat of engine oil to seal (3) on
easy-change filter (2).
5. Screw on easy-change filter (2) by hand until
the seal makes contact with the filter head
and tighten manually.
6. Replace other easy-change filters in the same
way.
7. Vent fuel system (→ Page 155). TIM-ID: 0000064778 - 001
156 | Fuel Filter | MS150120/02E 2017-08

8.8.2 Additional fuel filter – Replacement
Preconditions

Filter wrench F30379104 1
Engine oil
Easy-change filter (→ Spare Parts Catalog) 4
WARNING
• Do not smoke.
Replacing additional fuel filter

fuel.
2. Remove easy-change filter (2) with filter
wrench.
3. Clean sealing surface on filter head (1).
4. Apply a thin coat of engine oil to seal on
easy-change filter (3).
5. Screw on easy-change filter (2) by hand until
the seal makes contact with the filter head
and tighten manually.
6. Replace other easy-change filters in the same
way.
7. Vent fuel system (→ Page 155).
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8.8.3 Fuel prefilter – Draining
Preconditions

Diesel fuel
WARNING
• Do not smoke.
Note: Only applies to 12V4000T95x
Preparatory steps
2. Provide suitable container to collect escaping fuel.
Draining fuel prefilter

1. Open threaded vent plug (1).
2. Open drain valve (2).
3. Drain water and dirt until clean fuel emerges.
4. Close drain valve (2).
5. Close threaded vent plug (1).
Final steps
u Open fuel supply to engine.
TIM-ID: 0000064780 - 002
158 | Fuel Filter | MS150120/02E 2017-08

8.8.4 Fuel prefilter – Filter element replacement
Preconditions

Diesel fuel
Filter element (→ Spare Parts Catalog) 1
WARNING
• Do not smoke.
WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
Note: Only applies to 12V4000T95x

Preparatory steps
fuel.
3. Open threaded vent plug (1).
4. Open drain valve (3).
5. Drain fuel until easy-change fuel filter (2) is
empty.
6. Close drain valve (3).
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Replacing filter element
1. Remove easy-change fuel filter (2).
2. Install new easy-change fuel filter (2).
Note: Prevent any dirt ingressing the filter.
3. Fill easy-change fuel filter (2) with pure fuel.
4. Close threaded vent plug (1).
5. Vent fuel system (→ Page 155).
TIM-ID: 0000064781 - 002
160 | Fuel Filter | MS150120/02E 2017-08

8.9 Exhaust Turbocharger
8.9.1 Exhaust turbocharger – Turbine housing check
Turbine housing (→ Spare Parts Catalog)
Exhaust turbocharger (low-pressure charger)

u Check turbine housing (→ Page 168).
Exhaust turbocharger (high pressure)

u Check turbine housing (→ Page 162).
TIM-ID: 0000026625 - 003
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8.9.2 Exhaust turbocharger (HP) – Turbine housing check
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Engine oil
WARNING
Risk of burns!
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Note: The procedure is only described for the exhaust turbocharger (HP). Checking of the exhaust turbocharger
turbine housing (LP) requires separate activities (→ Page 168).
Removing lashing plate and
heat shield
1. Unscrew screws (1) and remove them togeth-
er with spacer sleeves (3) and holders (4).
2. Take off lashing plate (2).
TIM-ID: 0000054792 - 003
162 | Exhaust Turbocharger | MS150120/02E 2017-08

3. Remove screws (1) and take off with hold-
er (2) and washers.
4. Remove screws (2) and take off with heat

shield (1) and washers.
Removing exhaust pipe insula-

tion
u Release clamps (1) and remove insulation (2).
TIM-ID: 0000054792 - 003

Removing exhaust pipe
u Release clamp (2) and take off with exhaust
pipe (3) and sealing ring (1) from turbine
housing.
Removing insulation of exhaust pipe bellows

u Release clamps (1) and remove insulation (2).
Checking turbine housing

Note: Cracks are only permissible in the direction
of circumference of the spiral.
u Check turbine housing from the inside for
cracks.
Result: If the crack is larger than the maximum per-
missible crack length (x = 30 mm) or if trans-
verse cracks are present, contact Service.
TIM-ID: 0000054792 - 003

Installing exhaust pipe
1. Install exhaust pipe (3) with clamp (2) and
sealing ring (1) on turbine housing.
2. Tighten nut of clamp (2) to specified torque using a torque wrench.

Nut Tightening torque (Assembly compound 27 Nm +2 Nm
(Molykote P 37))
Installing exhaust pipe insula-

tion
u Install insulation (2) on exhaust pipe, secure with clamps (1) and tighten to specified tightening torque.
Nut Tightening torque 5 Nm +0.5 Nm
TIM-ID: 0000054792 - 003

Installing heat shield
1. Install heat shield (1) with washers and screws (2) and tighten to specified tightening torque.
Screws Tightening torque (Engine oil) 42 Nm +4 Nm
2. Install holder (2) with washers and screws (1)

and washers and tighten.
TIM-ID: 0000054792 - 003

3. Install holders (4) and lashing plate (2).
4. Install spacer sleeves (3) and screws (1) and
tighten.
TIM-ID: 0000054792 - 003

8.9.3 Exhaust turbocharger (LP) – Turbine housing check
Preconditions

Engine oil
Sealing ring (→ Spare Parts Catalog) 8
Gasket (→ Spare Parts Catalog) 2
WARNING
Risk of burns!
WARNING
Note: The following activity steps are only described for one exhaust turbocharger (LP). The description applies in-
versely to the other side. Checking of the turbine housing of the HP exhaust turbocharger requires separate
activities (→ Page 162).
Removing lashing plate and
heat shield
1. Undo screws (1) with spacer sleeves (3).
2. Remove lashing plate (2) with holders (4).
TIM-ID: 0000054791 - 002

3. Undo screws (1) and remove holder (2).
4. Undo screws (3) and remove holder (4).
5. Undo screws (2, 3) and remove heat

shield (1).
Removing exhaust elbow

Note: Mark position of clamp (5).
1. Remove screws (6) with spacer sleeves (7)
from mounting bracket.
2. Loosen clamp (5).
3. Remove exhaust elbow (1) with sealing rings
(2), collar ring (3) and gasket (4) from turbine
housing.
TIM-ID: 0000054791 - 002

Checking turbine housing
Note: Cracks are only permissible in the direction
of circumference of the spiral.
u Check turbine housing from the inside for
cracks.
Result: If the crack is larger than the maximum per-
missible crack length (x = 30 mm) or if trans-
verse cracks are present, contact Service.
Installing exhaust elbow

Note: Two sealing rings per groove.
1. Fit new sealing rings in exhaust elbow
grooves.
2. Replace gasket (4) in collar ring (3).
3. Slide collar ring (3) onto exhaust elbow (1).
4. Coat thread of screws (6) with assembly
compound.
5. Coat screws and V-band- seat of clamp (5)
with assembly compound prior to assembly.
6. Loosely pre-assemble exhaust elbow with
screws (6) and spacer sleeves (7) on mount-
ing bracket.
7. Connect collar ring (3) to exhaust turbocharg-
er with clamp (5).
8. Align clamp and tighten to specified tightening torque.

V clamp Tightening torque (Assembly compound 27 Nm +2 Nm
(Molykote P 37))
9. Tighten screws (6) to specified tightening torque.

Hex bolts M12x70 Tightening torque (Assembly compound 54 Nm +6 Nm
TIM-ID: 0000054791 - 002
(Molykote P 37))

Installing heat shield
1. Install heat shield (1) with washers and screws (2, 3) and tighten to specified tightening torque.
Screws Tightening torque (Engine oil) 42 Nm +4 Nm
2. Install holder (4) with screws (3) and wash-

ers.
3. Install holder (2) with screws (1) and wash-
ers.
TIM-ID: 0000054791 - 002

4. Install lashing plate (2) and holders (4) with
screws (1) and spacer sleeves (3).
TIM-ID: 0000054791 - 002

8.10 Charge-Air Cooling
8.10.1 Charge-air cooler – Leak check
DANGER
WARNING
WARNING
WARNING
Condensation contains acid.
Risk of chemical burns!
• Wear protective goggles.
• Wear protective gloves.
Charge-air cooler leak check

1. With the engine at standstill, open the plug
screws in the charge-air elbows on the left
and right engine sides on driving end (ar-
rows).
2. If necessary, use a suitable tool to remove
obstructions and check the openings for
coolant discharge.
Result: If a large amount of coolant is discharged,
contact Service.
TIM-ID: 0000018644 - 007
Emergency measures prior to engine start with a leaking charge-air cooler

1. Remove injector (→ Page 148).
2. Bar engine manually (→ Page 125).
3. Bar engine with starting system to blow out combustion chambers (→ Page 127).
Note: Install injectors in their original fitting position.
4. Install injector (→ Page 148).
MS150120/02E 2017-08 | Charge-Air Cooling | 173

8.11 Air Filter
8.11.1 Air filter – Replacement
Preconditions
Note: Only applies to 12V4000T95 and 12V4000T95x.

Replacing air filter
1. Release closures (1).
2. Remove cover (2).
3. Remove filter insert (3) and filter element (4).
4. Wipe out filter housing (5) and cover (2) with
a damp cloth.
5. Insert new filter element (4) and filter in-
sert (3).
6. Installation is in reverse sequence of removal.
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174 | Air Filter | MS150120/02E 2017-08

8.12 Air Intake
8.12.1 Service indicator – Signal ring position check
Preconditions
Checking signal ring position

Note: The contamination indicator is located at the
outlet of the air filter (3) (→ Page 28)
1. If the signal ring is completely visible in the
viewing window (2), replace air filter
(→ Page 174).
2. After installation of new filter, press reset
button (1).
Result: Engaged plunger with signal ring returns to
initial position.
TIM-ID: 0000075404 - 001
MS150120/02E 2017-08 | Air Intake | 175

8.12.2 Overspeed test – Emergency-air shutoff flap functional check
DANGER
danger zone.
WARNING
Risk of burns!
WARNING
Air flaps close abruptly.
Risk of injury!
• Before actuating, ensure that nobody is in the danger zone.
WARNING
Option 1: Checking function while engine is running

1. Check both emergency-air shutoff flaps and their wiring for mechanical damage.
TIM-ID: 0000054667 - 003
176 | Air Intake | MS150120/02E 2017-08

2. Make sure that the pointers (1) of both emer-
gency-air shutoff flaps are pointing to
OPEN / ON and the emergency-air shutoff
flaps are open.
3. Start the engine.(→ Page 48)
4. Activate overspeed test via the SFS input
OS_Test. Alternatively, the overspeed test
can be activated via a DI of the ECU or PV
2.2510.020. If the overspeed test is activat-
ed at an engine speed of >0 rpm, the over-
speed limit is set to the overspeed test value
of the Safety Function Box. In this operating
status, system validation of the Safety Func-
tion System SFS can be carried out
5. Run up the engine without a load.
6. Check the following functions:
• Close both emergency-air shutoff flaps, at
latest when a speed of 835 rpm is
reached.
• The emergency-air shutoff flaps are com-
pletely closed and the pointers (1) point to
CLOSED / OFF.
Result: If one or both emergency-air shutoff flaps do
not completely close or do not close at all,
shut the engine down and notify Service. If
necessary, observe the fault message (error
log).
7. After the functional check, open the emer-
gency-air shutoff flaps by hand so that the
pointers (1) point to OPEN/ON.(→ Page 179)
8. Reactivate overspeed test to return to normal
operating mode.
Option 2: Checking function while engine is stopped

1. Check both emergency-air shutoff flaps and their wiring for mechanical damage.
TIM-ID: 0000054667 - 003
MS150120/02E 2017-08 | Air Intake | 177

2. Make sure that the pointers (1) of both emer-
gency-air shutoff flaps are pointing to
OPEN / ON and the emergency-air shutoff
flaps are open.
3. Activate overspeed test via the SFS input
OS_Test. Alternatively, the overspeed test
can be activated via a DI of the ECU or PV
2.2510.020. If the overspeed test is activat-
ed at engine standstill (engine speed 0 rpm),
the emergency-air shutoff flaps are activated
immediately and closed
4. Check the following functions:
• Both emergency-air shutoff flaps close im-
mediately when triggered.
• The emergency-air shutoff flaps are com-
pletely closed and the pointers (1) point to
CLOSED / OFF.
Result: If one or both emergency-air shutoff flaps do
not completely close or do not close at all,
shut the engine down and notify Service. If
necessary, observe the fault message (error
log).
5. Before starting the engine, open the emer-
gency-air shutoff flaps so that the pointer (1)
points to OPEN/ON.(→ Page 179)
6. Reactivate overspeed test to return to normal
operating mode.
TIM-ID: 0000054667 - 003
178 | Air Intake | MS150120/02E 2017-08

8.12.3 Emergency-air shutoff flaps – Manual opening
WARNING
Risk of burns!
WARNING
Air flaps close abruptly.
Risk of injury!
• Before actuating, ensure that nobody is in the danger zone.
Manual opening of emergency-

air shutoff flaps
u Open closed emergency-air shutoff flaps with
an open-end wrench (17 A/F) via the nut on
the emergency-air shutoff flap shaft so that
the pointer (1) is at OPEN/ON.
TIM-ID: 0000073637 - 001
MS150120/02E 2017-08 | Air Intake | 179

8.13 Exhaust Gas Recirculation
8.13.1 Exhaust flaps overview ‒ 12V and 16V
Exhaust flaps overview ‒ 12V
1 Dispenser cylinder flap 2 EGR shutoff flap
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180 | Exhaust Gas Recirculation | MS150120/02E 2017-08

1 Bypass flap
Exhaust flaps overview ‒ 16V

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1 Dispenser cylinder flap 2 EGR shutoff flap
MS150120/02E 2017-08 | Exhaust Gas Recirculation | 181

1 Bypass flap
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8.13.2 Exhaust flaps – Checking coupling rod clearance and function
Preconditions
WARNING
Actuation mechanism in the exhaust and intake area closes automatically.
Risk of crushing hands!
• To carry out the teach-in routine, keep clear of the safety zone of the actuation mechanism in the
intake and exhaust area.
• Switch off the operating voltage of the engine governor before starting the mechanical test.
WARNING
Risk of burns!
Checking coupling rods (bypass and EGR flap) – mechanical

Note: For installation position of exhaust flaps, refer to overview (→ Page 180).
1. Remove guard plates of exhaust flaps (→ Page 185).
2. Check operability and ease of movement of
coupling rod (1) by moving it at the specified
points (arrows) and make sure that there is
no excessive play.
Result: Replace coupling rod (1) if it is jamming, slug-
gish or features excessive play (→ Page 185).
3. Check whether the internal spring pulls the
flap into the F-position:
• Fail-safe position for bypass flap and EGR
shutoff flap: opened.
• Fail-safe position for donor cylinder flap:
closed.
Result: If the bypass flap/EGR shutoff flap is closed
or the donor cylinder flap is opened, contact
Service.
Checking coupling rod (donor cylinder flap) – mechanical

TIM-ID: 0000060224 - 001
1. Remove guard plates of exhaust flaps.

2. Check operability and ease of movement of
coupling rod (1) by moving it at the specified
points (arrows) and make sure that there is
no excessive play.
Result: Replace coupling rod (1) if it is jamming, slug-
gish or features excessive play (→ Page 185).
TIM-ID: 0000060224 - 001

8.13.3 Exhaust flaps – Coupling rod replacement
Preconditions

Ratchet adapter F30027340 1
Assembly paste (Ultra-Therm MTU) 50547
Coupling rod (→ Spare Parts Catalog) 1
Coupling rod (→ Spare Parts Catalog) 2
Locknut (→ Spare Parts Catalog)
Locking screw (→ Spare Parts Catalog)
Washer (→ Spare Parts Catalog)
WARNING
WARNING
Risk of burns!
Removing coupling rods (bypass

and EGR shutoff flaps)
Note: For installation position of exhaust flaps, re-
fer to overview (→ Page 180).
1. Unscrew screws (1, 3) and remove guard
plate (2) for exhaust flaps.
2. Remove spacer sleeves (4).
TIM-ID: 0000060174 - 001

3. Unscrew locknuts (3) with washers.
4. Unscrew locknut (1) with washer.
Result: Lever detached from actuator output shaft.
5. Remove coupling rod (4) and lever (2).
6. Remove washers.
Installing coupling rods (bypass and EGR shutoff flaps)

1. Insert coupling rod (4) and washers.
2. Tighten lever (2) with locknut (1) on output shaft to the specified tightening torque.
Nut Tightening torque (Assembly paste (Ul- 16 Nm ±2 Nm
tra-Therm MTU))
3. Tighten washers and locknuts (3) to the specified tightening torque.

tra-Therm MTU))
4. Mount guard plate (2).
TIM-ID: 0000060174 - 001
5. Tighten securing screws (1) to the specified tightening torque.

Screw Tightening torque (Assembly paste (Ul- 35 Nm ±2 Nm
tra-Therm MTU))

6. Tighten screws (3) with spacer sleeves (4) to the specified tightening torque.
Screw Tightening torque (Assembly paste (Ul- 10 Nm ±1 Nm
tra-Therm MTU))
Note: After every change to the exhaust gas recirculation mechanical system, the DiaSys® must be used to carry
out an actuator test (learning run) (→ Dialog system E531920/..).
Removing coupling rod (donor

cylinder flap)
Note: For installation position of exhaust flaps, re-
fer to overview drawing (→ Page 180).
1. Unscrew locknuts (2) with washers.
2. Unscrew locknut (3).
Result: Lever detached from actuator output shaft.
3. Remove coupling rod (4) and lever (1).
4. Remove washers.
Installing coupling rod (donor cylinder flap)

1. Insert coupling rod (4) and washers.
2. Tighten lever (1) with locknut (3) on output shaft to the specified tightening torque.
tra-Therm MTU))
3. Tighten locknuts (2) with washers to the specified tightening torque.

tra-Therm MTU))
Note: After every change to the exhaust gas recirculation mechanical system, the DiaSys® must be used to carry
out an actuator test (learning run) (→ Dialog system E531920/..).
TIM-ID: 0000060174 - 001

8.14 Starting Equipment
8.14.1 Starter – Condition check
Preconditions
Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 225).
TIM-ID: 0000000905 - 018
188 | Starting Equipment | MS150120/02E 2017-08

8.15 Lube Oil System, Lube Oil Circuit
8.15.1 Engine oil level – Check at sight glass
Preconditions
Engine oil level check at sight

glass
1. Make a preliminary visual check of oil lev-
el (2) at the sight glass (1).
2. A proper engine oil level check must always
be carried out using the oil dipstick
(→ Page 190).
TIM-ID: 0000038098 - 002
MS150120/02E 2017-08 | Lube Oil System, Lube Oil Circuit | 189

8.15.2 Engine oil – Level check with oil dipstick
Checking oil level prior to en-

gine start
1. Pull out dipstick from guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop,
pull out after approx. 10 seconds. Check oil
level on oil dipstick side marked "5 Min. after
Stop".
Note: After extended out-of-service periods, the oil
level may be up to 2 cm above the "max."
mark. This might be caused by engine oil
flowing from oil filter and heat exchanger
back into the oil pan.
3. The oil level must reach the "max." mark or
exceed it by up to 2 cm.
4. If necessary, top up to "max." mark
(→ Page 191).
5. Insert oil dipstick into guide tube up to the
stop.
Checking engine oil level with the engine running

1. After the engine has run for approx. 10 minutes at a constant speed of 600 to 900 rpm, pull out oil dipstick
from guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, pull out after approx. 10 seconds. Check oil level on the dip-
stick side marked "IDLE".
3. Oil level must not be lower than the "min" mark.
4. If necessary, top up to "max." mark (→ Page 191).
Checking oil level after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, pull out after approx. 10 seconds. Check oil level on oil dipstick
side marked "5 Min. after Stop".
3. Oil level must be between “min.” and “max.” marks.
4. If necessary, top up to "max." mark (→ Page 191).
5. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000026776 - 005
190 | Lube Oil System, Lube Oil Circuit | MS150120/02E 2017-08

8.15.3 Engine oil – Change
Preconditions
☑ Engine is at operating temperature.

Ratchet bit F30027341 1
Engine oil
WARNING
Oil is hot.
Oil change without semirotary hand pump: Draining engine oil at drain
plug(s) on oil pan
1. Provide a suitable container in which to collect the engine oil.
2. Remove drain plugs (1) on driving and free
end and drain engine oil.
3. Fit drain plugs (1) on driving and free end and
with new sealing ring.
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Oil change using semirotary hand pump: Extracting engine oil
1. Provide a suitable container in which to collect the engine oil.
2. Extract all engine oil from oil pan using the semirotary hand pump.
Draining residual oil from equip-

ment carrier (only with un-
scheduled engine oil change)
1. Provide a suitable container in which to col-
lect the engine oil.
2. Remove drain plug (1) and drain engine oil
from engine oil heat exchanger and from en-
gine oil filter.
3. Remove drain plugs (2, 3, 4) and drain engine
oil.
4. Replace engine oil filter (→ Page 195).
Note: Screw in drain plugs with new sealing ring.

5. Screw in drain plug (1) and tighten to specified torque using a torque wrench.
Screw M18x1.5 Tightening torque (Engine oil) 50 Nm +10 Nm
6. Screw in drain plugs (2, 4) and tighten to specified torque using a torque wrench.
7. Screw in drain plug (3) and tighten to specified torque using a torque wrench.
Filling with new engine oil

1. Open cover (1) on filler neck (2).
2. Pour engine oil in at filler neck (2) up to
“max.” mark at oil dipstick.
3. Close cover (1) on filler neck (2).
4. Check engine oil level (→ Page 190).
TIM-ID: 0000037912 - 006

8.15.4 Engine oil – Sample extraction and analysis
Preconditions

Test kit F6798833 1
DANGER
WARNING
Oil is hot.
WARNING
Engine oil sample extraction

and analysis (12V)
1. With the engine running at operating temper-
ature, open screw on flange of centrifugal oil
filter by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw (arrowed).
5. Using the equipment and chemicals of the
MTU test kit, examine the engine oil for:
• Dispersancy (spot test)
• Proportion of water
TIM-ID: 0000075406 - 001
• Fuel dilution

Engine oil sample extraction
and analysis (16V)
1. With the engine running at operating temper-
ature, open screw (1) on flange of centrifugal
oil filter by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw (1).
5. Using the equipment and chemicals of the
MTU test kit, examine the engine oil for:
• Dispersancy (spot test)
• Proportion of water
• Fuel dilution
TIM-ID: 0000075406 - 001

8.16 Oil Filtration / Cooling
8.16.1 Engine oil filter – Replacement
Preconditions
☑ Run engine to reach operating temperature.

Filter wrench F30379104
Engine oil
Oil filter (→ Spare Parts Catalog)
WARNING
Oil is hot.
Replacing engine oil filter

1. Stop engine and disable engine start.
2. After warning up and directly stopping the en-
gine, open the vent plug (1) on the oil heat
exchanger.
3. Wait 5 minutes until the oil system is vented
and the oil has drained off.
Note: Always use a new sealing ring for the vent
plug.
4. Screw the vent plug (1) back in.
TIM-ID: 0000028834 - 007
MS150120/02E 2017-08 | Oil Filtration / Cooling | 195

5. Remove engine oil filter using the filter
wrench.
6. Clean sealing surface on connecting piece.
Note: Only install engine oil filter with an integrated
safety valve.
7. Check condition of the new oil filter sealing
ring and coat it with engine oil.
8. Screw the engine oil filter on and tighten by
hand.
9. Replace other engine oil filters in the same
way.
10. Bar the engine using the starting system
(→ Page 127).
11. Check engine oil level (→ Page 190).
TIM-ID: 0000028834 - 007
196 | Oil Filtration / Cooling | MS150120/02E 2017-08

8.16.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement
Preconditions

Cold cleaner (Hakutex 60) X00070585 1
Filter sleeve (→ Spare Parts Catalog)
Filter sleeve (→ Spare Parts Catalog)
WARNING
Oil is hot.
WARNING
TIM-ID: 0000071290 - 002

Centrifugal oil filter, cleaning
and filter-sleeve replacement on
12V engines
1. Release screw (1) and remove.
2. Remove clamp (3) and take off hood (2).
3. Carefully remove rotor assembly (5) from
housing.
4. Hold rotor assembly (5) firmly in position with
filter wrench and undo knurled nut (7).
5. Take off rotor cap (8).
6. Take off filter sleeve (9), stiffener plate (10 )
and sealing ring (11).
7. Measure thickness of oil residue on filter
sleeve.
8. Shorten maintenance interval if maximum
layer thickness of oil residues ex-
ceeds 30 mm.
9. Remove standpipe (12) from lower rotor sec-
tion (13).
10. Wash out cover (2), rotor cap (8), stiffener
plate (10), stand pipe (12), base (13) and noz-
zles (14) with cleaner and blow out with com-
pressed air. Do not use sharp objects for
cleaning.
11. Check nozzles (14) for obstructions.
12. Press standpipe (12) onto rotor lower sec-
tion (13).
13. Insert new filter sleeve (9) with stiffener
plate (10) into rotor cap (8), ensuring that
smooth surface of filter sleeve (9) faces rotor
cap (8).
14. Check sealing ring (11), replace if necessary.
Coat sealing ring with grease and insert in
groove of rotor cap (8).
15. Place rotor cap (8) onto standpipe (12).
16. Hold rotor assembly (5) firmly in position with
filter wrench and tighten knurled nut (7).
17. Lubricate bearings of rotor assembly (5), in-
sert into housing (6) and check for ease of
movement.
18. Check sealing ring (4), replace if necessary.
Fit sealing ring on housing (6).
19. Fit hood (2).
20. Tighten screw (1) by hand.
21. Install clamp (3) and tighten to specified torque using a torque wrench:
TIM-ID: 0000071290 - 002

Clamp Tightening torque 8 to 9 Nm
22. Tighten screw (1) to specified torque using a torque wrench:

Screw Tightening torque 5 Nm to 7 Nm
198 | Oil Filtration / Cooling | MS150120/02E 2017-08

Centrifugal oil filter, cleaning
and filter-sleeve replacement on
16V engines
1. Remove clamp (17).
2. Release cover screw (2) and remove cov-
er (1).
3. Carefully lift rotor (14), allow oil to drain and
remove from housing.
4. Holding the rotor (14) firmly, release rotor
cover nut (3).
5. Take off rotor cover (3).
6. Remove filter sleeve (6).
7. Measure layer thickness of oil residues on fil-
ter sleeve (6).
Result: If the oil residue exceeds the maximum layer
thickness of 45 mm, shorten the mainte-
nance interval.
8. Disassemble rotor tube (7), conical disk (8)
and rotor base (13).
1. Wash rotor cover (3), rotor tube (7), conical disk (8) and rotor base (13) with cold cleaner.
2. Blow out with compressed air.
3. Check sealing rings (9, 10, 12) and replace if necessary.
4. Coat sealing rings (9, 10) with assembly compound and insert in grooves on bearing shaft (11).
5. Assemble rotor tube (7), conical disk (8) and rotor base (13) with sealing ring (12).
Note: Observe markings and information on paper element!
6. Insert new filter sleeve (6) in rotor tube (7) with the smooth paper surface facing the outer wall.
7. Check sealing rings (4, 5) and replace if necessary.
8. Insert sealing ring (5) in rotor tube (7) and sealing ring (4) in rotor cover (3).
9. Install rotor cap (3) tighten nut for rotor cover (3) with torque wrench to specified tightening torque.
Nut M12 Tightening torque 80 Nm ±12 Nm
10. Place rotor (14) in housing (15) and check for ease of movement.
11. Check sealing ring (16), replace as necessary.
12. Fit sealing ring (16) on housing (15).
13. Fit hood (1).
14. Tighten cover screw (2) by hand.
15. Install clamp (17) and tighten to specified torque using a torque wrench.
Clamp Tightening torque 20 Nm ±3 Nm
TIM-ID: 0000071290 - 002
16. Tighten cover nut (2) to specified torque using a torque wrench.
Screw Tightening torque 7 Nm ±1 Nm

8.17 High-Temperature Circuit
8.17.1 Engine coolant – Level check
Preconditions
WARNING
Checking coolant level at filler neck:

1. Turn cap on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.
2. Continue to turn cap counterclockwise and remove.
3. Check engine coolant level (engine coolant must be visible at bottom edge of cast-in eye of filler neck).
Checking coolant level at exter-

nal cooler:
Note: Engine coolant must be visible at marker
plate.
1. Check engine coolant level.
2. Top up engine coolant as necessary
(→ Page 205).
3. Check and clean cap.
4. Place cap on filler neck and close.
Checking coolant level with level sensor:

Note: Engine coolant level is automatically monitored by the engine control system.
1. Switch on engine control system and check readings on the display.
2. Top up engine coolant as necessary (→ Page 205).
TIM-ID: 0000000937 - 015
200 | High-Temperature Circuit | MS150120/02E 2017-08

Checking engine coolant level at
sight glass
1. Check coolant level (coolant level must be
between “min.” and “max.” mark).
2. Top up coolant if necessary (→ Page 205).
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MS150120/02E 2017-08 | High-Temperature Circuit | 201

8.17.2 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 203).
2. Fill with engine coolant (→ Page 205).
TIM-ID: 0000000036 - 031

8.17.3 Engine coolant – Draining
Preconditions

Torque wrench 10–60 Nm F30452769 1
WARNING
Coolant is hot and highly pressurized.
Risk of injury! Risk of scalding!
Preparatory steps
1. Provide a suitable container to collect the coolant.
2. Switch off preheating unit (external).
Engine coolant – Draining

1. Provide a suitable container to collect the coolant.
2. Turn cover on coolant expansion tank counterclockwise until the first stop and allow pressure to escape.
3. Continue to turn cover counterclockwise and remove.
4. Extract remaining engine coolant in the coolant expansion tank via the filler neck.
5. Drain engine coolant at preheating unit (ex-
ternal).
6. Open drain valve (2) and drain engine coolant
at elbow on engine coolant pump.
7. Open drain valves (1) on A and B side of
crankcase and drain engine coolant.
Note: With the air compressor (optional) installed at
the drain point (A side), the drain valve is in-
accessible.
8. Open supply hose at air compressor.
TIM-ID: 0000030760 - 006

9. Drain remaining engine coolant at EGR cool-
er, A and B side (arrow).
Final steps
1. Tighten all open drain valves to specified torque using a torque wrench.
Spindle 11A/F Tightening torque 12 Nm
2. Fit cover on filler neck and close it.
TIM-ID: 0000030760 - 006

8.17.4 Engine coolant – Filling
Preconditions

Torque wrench 10-60 Nm F30452769 1
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. Turn cover (1) of coolant expansion tank (ex-
ternal) counterclockwise until the first stop
and allow pressure to escape.
2. Continue to turn cover (1) counterclockwise
and remove.
TIM-ID: 0000054694 - 003

Filling with engine coolant using
pump
1. Connect appropriate pump with hose to drain
valve (1).
2. Open vent points on EGR cooler (1, 8), dis-

tributors (2, 5), exhaust turbochargers (3, 4,
7) and oil heat exchanger (6).
3. Open drain valve and pump coolant into en-
gine at 0.5 bar minimum.
Result: When coolant emerges from the vent points,
close vent points one by one, proceeding
from the lowest point upwards.
4. Fill expansion tank until overflow edge is
reached.
5. Tighten drain valve to specified torque using a torque wrench.

Spindle 11A/F Tightening torque 12 Nm
6. Check satisfactory condition of cover and clean sealing faces if required.

8. Start engine (→ Page 48) and shut down after 10 second of operation without load (→ Page 48).
10. Check engine coolant level (→ Page 200) and top up coolant as necessary:
TIM-ID: 0000054694 - 003
a) Fill in coolant in expansion tank until the coolant level at top edge of filler neck remains constant.
b) Fit cover on filler neck and close it.
c) Repeat the steps from “Start engine” (→ Step 8) until no more engine coolant needs to be topped up.
d) Disconnect pump and hose.

Alternatively: Filling with cool-
ant through filler neck
1. Open vent points on EGR cooler (1, 8), dis-
tributors (2, 5), exhaust turbochargers (3, 4,
7) and oil heat exchanger (6).
2. Fill engine coolant in expansion tank via filler
neck until coolant level at top edge of filler
neck remains constant.
Result: When coolant emerges from the vent points,
close vent points one by one, proceeding
from the lowest point upwards.
3. Check satisfactory condition of cover and
clean sealing faces if required.
4. Place cover onto filler neck and close until
first stop is reached.
5. Start engine (→ Page 48) and shut down after
10 second of operation without load
(→ Page 49).
6. Turn cover counterclockwise and remove.
7. Check engine coolant level (→ Page 200) and
top up coolant as necessary:
a) Repeat the steps from “Start engine”
(→ Step 5) until no more engine coolant
needs to be topped up.
b) Check satisfactory condition of cover and
c) Fit cover on filler neck and close it.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check engine coolant level (→ Page 200) and top up coolant as necessary.
TIM-ID: 0000054694 - 003

8.17.5 Engine coolant pump – Relief bore check
DANGER
WARNING
Engine coolant pump, relief bore

check
1. Check relief bore (arrow) for oil and coolant
discharge.
Note: Observe safety regulations when carrying out
maintenance and repair work (→ Page 10).
2. Shut down engine (→ Page 49) and disable
engine start.
3. Clean the relief bore with a wire if it is dirty.
• Permissible coolant discharge: up to
10 drops per hour
• Permissible oil discharge: up to 5 drops
per hour
Result: If discharge is greater, contact Service.
TIM-ID: 0000037916 - 006

8.17.6 Engine coolant – Sample extraction and analysis
Preconditions

Test kit F6798833 1
DANGER
WARNING
WARNING
Engine coolant – Sample extrac-

tion and analysis
1. With the engine running, open drain valve (1).
2. Drain off approx. 1 liter of engine coolant.
Result: Drain point is rinsed.
3. Drain approx. 1 liter coolant into a clean con-
tainer.
TIM-ID: 0000037917 - 005
4. Tighten drain valve (1) to specified tightening using a torque wrench.

Spindle 11 A/F Tightening torque 12 Nm
5. Using the equipment and chemicals of the MTU test kit, examine engine coolant for:
• Concentration of engine coolant additives
• pH value
6. Engine coolant change intervals (→ MTU Fluids and Lubricants Specifications (A001061/..)).

8.17.7 Valve cover – Replacement
Preconditions

Valve cover (→ Spare Parts Catalog) 1
WARNING
Preparatory steps
u Switch off preheater.
Replacing valve cover

Note: Schematic diagram. Design may deviate.
1. Turn valve cover (1) on coolant expansion
tank counterclockwise until the first stop and
release pressure.
2. Continue to turn valve cover counterclock-
wise and remove.
3. Remove chain with screw (4) and washer (3).
4. Draw off separated corrosion inhibitor oil in
expansion tank via filler neck (2).
5. Fit new valve cover and close it.
6. Install chain.
TIM-ID: 0000065495 - 004

8.18 Low-Temperature Circuit
8.18.1 Charge-air coolant – Level check
Preconditions
WARNING
Checking charge-air coolant level at filler neck:

1. Turn cap on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.
2. Continue to turn cap counterclockwise and remove.
Note: Charge-air coolant must be visible at marker
plate.
3. Check charge-air coolant level.
4. Top up charge-air coolant as necessary
(→ Page 216).
5. Check that cap is in serviceable condition.
6. Clean sealing surfaces as necessary.
7. Fit cap and close tight.
Checking charge-air coolant level by means of level sensor:

Note: Coolant level is automatically monitored by engine control system.
1. Switch on engine control system and check readings on the display.
2. Top up charge-air coolant as necessary (→ Page 216).
TIM-ID: 0000000042 - 008
MS150120/02E 2017-08 | Low-Temperature Circuit | 211

8.18.2 Charge-air coolant – Change
Coolant
Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 213).
2. Fill with charge-air coolant (→ Page 216).
TIM-ID: 0000000041 - 011
212 | Low-Temperature Circuit | MS150120/02E 2017-08

8.18.3 Charge-air coolant – Draining
Preconditions
☑ Operating voltage is not applied.

WARNING
Risk of burns!
WARNING
Draining charge-air coolant

1. Provide a suitable container in which to collect the charge-air coolant.
4. Extract remaining charge-air coolant in the coolant expansion tank via the filler neck.
5. Open drain valve (2) and drain charge-air
coolant at charge-air coolant pump.
6. Unscrew drain screw (1) and drain charge-air
coolant at thermostat housing.
TIM-ID: 0000026956 - 008

7. Drain remaining charge-air coolant at charge-
air cooler (high pressure) (arrowed).

air cooler (low pressure) A side (arrowed).

air cooler (low pressure) B side (arrowed). TIM-ID: 0000026956 - 008

Note: • The procedure is only described for one
exhaust flap, but also applies to the re-
maining exhaust flaps. Exhaust flap over-
view (→ Page 180).
• Collect emerging engine coolant in a suita-
ble container.
10. Loosen the union nut (4) of the lower coolant
line (3).
11. Carefully pull the coolant line (3) out of the
union.
12. Loosen the union nut (1) of the upper coolant
line (2).
13. Pull the coolant line (2) a little out of the un-
ion.
Note: Wait until no more coolant comes out of the
lines.
14. Tighten the union nuts (1, 4) of the coolant
lines (2, 3) again.
Final steps
1. Screw in all drain plugs with new sealing rings.
2. Tighten all drain valves to specified tightening torque using a torque wrench.
Spindle 11 A/F Tightening torque 12 Nm
3. Fit cap on filler neck and close it.

TIM-ID: 0000026956 - 008

8.18.4 Charge-air coolant – Filling
Preconditions

Torque wrench 10-60 Nm F30452769 1
Charge-air 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. Turn cover (1) of coolant expansion tank (ex-
ternal) counterclockwise until the first stop
and allow pressure to escape.
2. Continue to turn cover (1) counterclockwise
and remove.
TIM-ID: 0000054692 - 003

Filling with charge-air coolant
through filler neck
1. Open vent points at intercooler (high pres-
sure) (4), intercooler (low pressure) (1, 3) and
distributor (2, ).
2. Fill in charge-air coolant at expansion tank via
filler neck until coolant level at top edge of
filler neck remains constant.
3. Check satisfactory condition of cover and
4. Place cover onto filler neck and close until
first stop is reached.
6. After 10 seconds of running the engine with-
out load, shut down the engine (→ Page 49).
7. Turn cover counterclockwise and remove.
8. Check charge-air coolant level (→ Page 211)
and top up if required:
a) Repeat the steps from “Start engine”
(→ Step 5) until charge-air coolant no lon-
ger needs to be topped up.
b) Check satisfactory condition of cover and
c) Fit cover on filler neck and close it.
Alternatively: Filling with

charge-air coolant using pump
1. Connect suitable pump with a hose to one of
the drain valves (1, 2).
TIM-ID: 0000054692 - 003

2. Open vent points at intercooler (high pres-
sure) (4), intercooler (low pressure) (1, 3) and
distributor (2, ).
3. Open drain valve and pump charge-air cool-
ant into engine at 0.5 bar minimum.
4. Fill expansion tank until overflow edge is
reached.
5. Tighten drain valve to specified torque using a torque wrench.

Spindle SW11 Tightening torque 12 Nm
6. Check satisfactory condition of cover and clean sealing faces if required.

9. After 10 seconds of running the engine without load, shut down the engine (→ Page 49).
12. Check charge-air coolant level (→ Page 211) and top up if required:
a) Fill charge-air coolant into expansion tank until the coolant level at top edge of filler neck remains con-
stant.
b) Fit cover on filler neck and close it.
c) Repeat the steps from “Start engine” (→ Step 8) until charge-air coolant no longer needs to be topped
up.
d) Disconnect pump and hose.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check charge-air coolant level (→ Page 211) and top up if required.
TIM-ID: 0000054692 - 003

8.18.5 Charge-air coolant pump – Relief bore check
DANGER
WARNING
Charge-air coolant pump, relief

bore check
1. Check pressure relief port (arrow) for oil and
coolant discharge.
Note: Observe safety regulations when carrying out
maintenance and repair work (→ Page 10).
2. Shut down engine (→ Page 49) and disable
engine start.
3. Clean the relief bore with a wire if it is dirty.
• Permissible coolant discharge: up to
10 drops per hour
• Permissible oil discharge: up to 5 drops
per hour
Result: If discharge is greater, contact Service.
TIM-ID: 0000026960 - 011

8.19 Belt Drive
8.19.1 Drive belt – Condition check
Preconditions
☑ Protective cover is removed.
Drive belt – Condition check
Item Findings Measure

Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Replace (→ Page 223)
Drive belt C Chunking
Drive belt Belt is oily, shows signs of over-
heating
TIM-ID: 0000000920 - 012
220 | Belt Drive | MS150120/02E 2017-08

8.20 Battery-Charging Generator
8.20.1 Battery-charging generator – Check
Preconditions
WARNING
Checking battery-charging generator

Item Findings Action
Ventilation area (arrowed) Clean None
Ventilation area (arrowed) Contaminated Clean
Cleaning battery-charging generator

Note: Dry-clean battery-charging generator only. Do not insert sharp objects into the ventilation holes.
1. Remove coarse dirt from battery-charging generator.
2. Blow out ventilation area (arrowed) with compressed air until all dust is cleared.
TIM-ID: 0000065117 - 001
MS150120/02E 2017-08 | Battery-Charging Generator | 221

8.20.2 Battery-charging generator – Drive belt tension adjustment
Preconditions

WARNING
Belt tensioner spring is pretensioned.
Risk of hands being crushed!
• Lock belt tensioner in position.
Adjusting belt tension

1. Slacken screws (1) and (2) by half a turn.
Result: Belt tensioner moves against the drive belt
and tensions it.
2. Tighten screw (2) to specified torque using a torque wrench.

Screw M10 Tightening torque 60 Nm +5 Nm
3. Tighten screw (1) with a torque wrench.

TIM-ID: 0000071474 - 002
222 | Battery-Charging Generator | MS150120/02E 2017-08

8.20.3 Battery-charging generator drive – Drive belt replacement
Preconditions

Drive belt (→ Spare Parts Catalog)
WARNING
Belt tensioner spring is pretensioned.
Risk of hands being crushed!
• Lock belt tensioner in position.
Battery-charging generator drive – Drive belt replacement

1. Remove protective cover.
2. Loosen screws (2) and (3) by half a turn.
3. Mount socket or box wrench on screw (1)
and press belt tensioner in direction of arrow
as far as the stop.
4. Tighten screw (3).
5. Remove the used drive belt.
6. Fit new drive belt.
7. Loosen screw (3) by half a turn.
Result: Belt tensioner moves against the drive belt
and tensions it.
8. Tighten screw (3) with torque wrench to specified tightening torque.

TIM-ID: 0000022970 - 007
Screw M10 Tightening torque 60 Nm +5 Nm
9. Tighten screw (2).

10. Install protective cover.
11. Readjust drive belt tension after 30 minutes and after 8 hours engine runtime (→ Page 222).
MS150120/02E 2017-08 | Battery-Charging Generator | 223

8.21 Engine Mounting / Support
8.21.1 Engine mounting – Check
Preconditions
☑ Engine is stopped and starting disabled

Engine oil
Checking general condition

Item Findings Action
Visually inspect resilient mounts. • Damage Replace (→ Contact Service.)
• Brittleness
• Deformation
• Crack formation
• Swelling
visible
Checking securing screws for

firm seating
1. Check securing screws (1, 2) for firm seating.
2. Tighten loose threaded connections to specified torque using a torque wrench.

TIM-ID: 0000037198 - 004
Screw M16 Control torque (Engine oil) 250 Nm +25 Nm
224 | Engine Mounting / Support | MS150120/02E 2017-08

8.22 Wiring (General) for Engine/Gearbox/Unit
8.22.1 Engine cabling – Check
Preconditions

Solvent (isopropyl alcohol) X00058037 1
Engine cabling – Check

1. Check securing screws of cable clamps on engine and tighten loose screw connections.
2. Ensure that cables are securely seated in clamps and cannot move freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check cable clamps for secure fit, tighten loose clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical components for damage:
• Connector housings
• Contacts
• Plug connectors
• Cables and terminals
• Plug-in contacts
Result: If cable conductors are damaged, contact Service.
Note: Close connectors that are not plugged in with the protective cap supplied.
8. Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts.
9. Ensure that all connecting plugs of the sensors are correctly engaged.
TIM-ID: 0000000029 - 025
MS150120/02E 2017-08 | Wiring (General) for Engine/Gearbox/Unit | 225

8.23 Accessories for (Electronic) Engine Governor / Control System
8.23.1 Actuators – Visual inspection and test
Preconditions
WARNING
WARNING
Risk of burns!
NOTICE
Carry out the calibration learning run for a functional check of the servomotor. Overwriting of stop val-
ues through already existing wear.
Exceeding of emission values and engine damage are possible!
• Only carry out the calibration learning run if the servomotor of the flap is connected to the ECU for
the first time or a coupling rod was been replaced.
Checking actuators visually

Note
Actuators must not be interchanged or exchanged from other engines - even for test purposes. Always use
new actuators.
TIM-ID: 0000044543 - 007
226 | Accessories for (Electronic) Engine Governor / Control System | MS150120/02E 2017-08
Corrugated pipe (1) Damaged, holes or cracks. Replace
Coolant connections (2, 3) Traces of coolant leaks. Replace
Output shaft (4) Damaged Replace

Connector (1) Damaged Replace actuator.
Actuator cable connection (2) Damaged Replace actuator.
Protective cap not correctly Mount protective cap correctly.
mounted.
Actuator general condition Heavily contaminated by black ex- Replace actuator.
haust.
Checking actuators with DiaSys®

1. Switch on ECU.
Note: A learning run must not be carried out for a functional test of the servomotor because this would result in
malfunction of the wear detection of the flap.
2. For a function test, move the flap via DiaSys® in manual mode into different positions (→ Dialog system
E531920/..). If no DiaSys® is available, contact Service.
TIM-ID: 0000044543 - 007
MS150120/02E 2017-08 | Accessories for (Electronic) Engine Governor / Control System | 227
8.23.2 Engine governor and connector – Cleaning
Preconditions

Solvent (isopropyl alcohol) X00058037 1
NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.
Engine governor and connector – Cleaning

1. Use isopropyl alcohol to remove coarse dirt from housing surface.
2. Use isopropyl alcohol to remove dirt from the connector and cable surfaces.
3. Check legibility of cable labels. Clean or replace illegible labels.
Heavily contaminated connectors on engine governor – Cleaning

Note: Close connectors that are not plugged in with the protective cap supplied.
1. Release latches of connectors and withdraw connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and latch them.
TIM-ID: 0000000047 - 014
8.23.3 Engine governor plug connections – Check
Preconditions
☑ Engine stopped and starting disabled.
☑ Electronic engine management system is de-energized.
NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.
Checking plug connections at engine governor

1. Check all plug connections for secure seating.
2. Lock loose connectors.
3. Check dust cap on ECU and EXU connectors for damage and correct seating.
TIM-ID: 0000000048 - 009
8.23.4 NOx sensor – Replacement
Preconditions
☑ Power supply to engine electronics is switched off.

NOx sensor (→ Spare Parts Catalog) 1
WARNING
Risk of burns!
NOTICE
High voltage.
Risk of damage to components!
• Switch off ignition before replacing components.
NOTICE
Ceramic cell breakage due to shock or impact.
• Avoid shocks and impacts.
• Exercise extreme care when handling sensors.
Removing NOx sensor

Note: Observe arrangement and position of sensor
(→ Page 29).
1. Disconnect and remove male connector (2)
from control unit (1).
2. Unscrew control unit (1) at the eyelets.
3. Remove sensor (3).
TIM-ID: 0000025205 - 017
Installing NOx sensor
Note: Note the following:
• If the sensor (3) was subjected to shock or
impact load, it is considered to be defec-
tive and may not be used.
• Always replace NOx sensor (3) together
with control unit (1).
1. Screw on control unit (1) at the eyelets and
tighten screws.
2. Remove protective cap on thread of sen-
sor (3) only just before installation.
Note: Do not wipe off thread grease of manufactur-
er.
3. Coat sensor (3) thread with specified assem-
bly compound as required.
4. Screw in sensor (3) by hand.
5. Use torque wrench to tighten nut (3) to the specified tightening torque.
Nut M20 Tightening torque (Assembly compound 40 Nm +4 Nm
(Molykote P 37))
6. Fit male connector (2) and latch it.

TIM-ID: 0000025205 - 017
8.23.5 Lambda sensor – Replacement
Preconditions
☑ Power supply to electronic engine management system is switched off.

Lambda sensor (→ Spare Parts Catalog) 1
WARNING
Risk of burns!
NOTICE
Ceramic cell breakage due to shock or impact.
• Avoid shocks and impacts.
• Exercise extreme care when handling sensors.
NOTICE
High voltage.
• Switch off ignition before replacing components.
Removing Lambda sensor

1. Observe the following general information:
• Layout and position of sensor (→ Page 29).
2. Unplug and remove male connector (1).
3. Remove sensor (2).
TIM-ID: 0000025194 - 017
Installing Lambda sensor
Note: When the sensor was subjected to shock or
impact load, it is deemed to be defective and
may not be used.
1. Remove protective cap on thread only just
before installation.
Note: Do not wipe off the thread lubricant applied
by the manufacturer.
2. Apply specified assembly compound to sen-
sor thread if required.
3. Screw in sensor by hand.
4. Tighten nut (2) to specified torque using a torque wrench.

Nut M18 x 1.5 Tightening torque (Assembly compound 40 Nm +4 Nm
(Molykote P 37))
5. Fit male connector (1) and latch it.

6. Reset Lambda sensor calibration with DiaSys® (→ Dialog system DiaSys® E531920/..). If no DiaSys® is
available, contact Service.
TIM-ID: 0000025194 - 017
8.24 Exhaust System
8.24.1 Exhaust silencer – Condensate drain check
Preconditions
Exhaust silencer – Condensate

drain check
1. Provide a suitable container to collect the
condensate.
2. Open drain plug (1).
3. Allow the condensate to drain off.
4. Close drain plug (1).
5. If the drain point is connected to a perma-
nently installed waste-water line, check the
line for obstructions, clean it if necessary.
TIM-ID: 0000057594 - 001
234 | Exhaust System | MS150120/02E 2017-08

8.24.2 Back Pack – Visual inspection of securing screws
Preconditions
Back Pack – Visual inspection of securing screws

Check securing screws for damage and de- Damaged, deformation visi- Replace
formation. ble.
TIM-ID: 0000057596 - 001
MS150120/02E 2017-08 | Exhaust System | 235

8.24.3 Back Pack – Checking securing screws for firm seating
Preconditions

Check securing screws for firm

seating
1. Check-tighten securing screws (1).

Screw M12x75 Tightening torque 137 Nm
TIM-ID: 0000057599 - 001
236 | Exhaust System | MS150120/02E 2017-08

2. Check-tighten securing screws (1).
Screw M10x50 Tightening torque 79 Nm
TIM-ID: 0000057599 - 001
MS150120/02E 2017-08 | Exhaust System | 237

9 Appendix A
9.1 List of abbreviations
Abbre- Meaning Explanation
viation
ADEC Advanced Diesel Engine Controller Engine management system
AET Außenerprobungsträger Field trials unit
AGN Abgasnachbehandlung Exhaust gas aftertreatment
AGR Abgasrückführung Exhaust gas recirculation
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger
BDM Backup Data Module Data backup module
BR Baureihe Series
BV Betriebsstoffvorschrift MTU Publication No. A001061/..
CAD Computer-Aided Design –
CAN Controller Area Network Data bus system, bus standard
CCS Compatibility Check System –
CPP Controllable Pitch Propeller –
cpsi cells per square inch –
CR Common Rail –
CSMF Coated Sintered Metal Filter –
DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards (“Deutsche In-
dustrie-Norm”)
DIS Display Unit Display panel
DL Default Lost Alarm: Default CAN bus failure
DOC Diesel Oxidation Catalyst –
DPF Diesel Particulate Filter –
ECS Engine Control System Engine management system
ECU Engine Control Unit –
EDM Engine Data Module Memory module for engine data
EIL Engine Ident Label –
EMU Engine Monitoring Unit –
TIM-ID: 0000002045 - 022
ETK Ersatzteilkatalog Spare parts catalog

FPP Fixed Pitch Propeller –
GCU Gear Control Unit –
GMU Gear Monitoring Unit –
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
value
HT High Temperature –
238 | Appendix A | MS150120/02E 2017-08

viation
ICFN ISO – Continuous rating – Fuel stop power Power specification in accordance with DIN-ISO
– Net 3046-7
IDM Interface Data Module Memory module for interface data
IGI Ignition Input Binary input for ignition
IMO International Maritime Organization –
ISO International Organization for Standardiza- International umbrella organization of all standardi-
tion zation institutes
KGS Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204
KS Kupplungsseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal Device Liquid crystal display
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode –
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
value
LOLO Low Low Alarm: Measured value lower than 2nd minimum lim-
it value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station Local operating station
LPU Lubricating Oil Pump Control Unit –
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 Control panel
PAU Power Automation Unit Module for monitoring, control and plant-related sys-
tem integration of peripheral components
PCU Propeller Control Unit Propeller controller
PIM Peripheral Interface Module –
UPS Unit Pump System –
POM Power Output Module Module to control starter and battery-charging gen-
erator
PPC Priming Pump Control Oil priming pump
RCS Remote Control System –
TIM-ID: 0000002045 - 022
RL Redundancy Lost Alarm: Redundant CAN bus failure

rpm revolutions per minute –
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps –
SFB Safety Function Box Control unit
SFS Safety Function System Control system
SMF Sintered Metal Filter (uncoated) –
SS Safety System Safety system alarm
MS150120/02E 2017-08 | Appendix A | 239

viation
SSK Schnellschlussklappe(n) Emergency air-shutoff flaps
SUE- Steuerungs- und Überwachungseinrichtung Control and monitoring unit for oil priming pump
VSP Vorschmierpumpe
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Deviation in transmitter values
UPS Uninterrupted Power Supply –
BDC Bottom Dead Center –
VS Voith Schneider Voith-Schneider drive
VSP Vorschmierpumpe Oil priming pump
WJ WaterJet Waterjet drive
WZK Werkzeugkatalog –
TIM-ID: 0000002045 - 022
240 | Appendix A | MS150120/02E 2017-08

9.2 MTU Contact/Service Partners
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-
er service centers ensure fast and direct support on site and ensure 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 high flexibility, we're your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare Parts Service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse at
headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
TIM-ID: 0000000873 - 016
MS150120/02E 2017-08 | Appendix A | 241

10 Appendix B
10.1 Special Tools
Allen key
Part No.: F30002815
Qty.: 1
Used in: 8.4.3 Valve clearance – Check and adjustment
(→ Page 140)
Barring gear
Part No.: F6792918
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 125)
Barring gear
Part No.: F6555766
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 125) DCL-ID: 0000033031 - 006
242 | Appendix B | MS150120/02E 2017-08

Barring tool
Part No.: F6555766
Qty.: 1
Used in: 8.2.1 Cylinder liner – Endoscopic examination
(→ Page 129)
Crossbeam
Part No.: T80092360
Qty.: 1
Used in: 2.1 Transportation (→ Page 17)
Depth gauge, 200 mm

Part No.: Y20000918
Qty.: 1
Used in: 8.4.2 Valve protrusion – Measurement (→ Page 136)
Endoscope
Part No.: Y20097353
Qty.: 1
(→ Page 129)
Qty.: 1
DCL-ID: 0000033031 - 006
Used in: 8.9.2 Exhaust turbocharger (HP) – Turbine housing check

(→ Page 162)
Qty.: 1
Used in: 8.9.3 Exhaust turbocharger (LP) – Turbine housing check
(→ Page 168)
MS150120/02E 2017-08 | Special Tools | 243

Feeler gage
Part No.: Y20098771
Qty.: 1
(→ Page 140)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 8.8.1 Fuel filter – Replacement (→ Page 156)
Qty.: 1
Used in: 8.8.2 Additional fuel filter – Replacement (→ Page 157)
Qty.:
Used in: 8.16.1 Engine oil filter – Replacement (→ Page 195)
Fuel suction device

Part No.: F30378207
Qty.: 1
Used in: 8.5.1 HP fuel pump – Filling with engine oil (→ Page 145)
High-pressure cleaner
Part No.:
Qty.: 1
Used in: 5.10 Plant – Cleaning (→ Page 52)
DCL-ID: 0000033031 - 006
244 | Special Tools | MS150120/02E 2017-08

Installation/removal jig
Part No.: F6796646
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 148)
Measuring jig 1
Part No.: Y4350009
Qty.: 1
Measuring jig 2, optional

Part No.: Y4350010
Qty.: 1
Milling cutter
Part No.: F30452739
Qty.: 1
DCL-ID: 0000033031 - 006

Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 8.13.3 Exhaust flaps – Coupling rod replacement
(→ Page 185)
Qty.: 1
Used in: 8.20.2 Battery-charging generator – Drive belt tension ad-
justment (→ Page 222)
Qty.: 1
Used in: 8.23.4 NOx sensor – Replacement (→ Page 230)
Qty.: 1
Used in: 8.23.5 Lambda sensor – Replacement (→ Page 232)
Ratchet adapter
Part No.: F30027341
Qty.: 1
Ratchet bit
Part No.: F30027341
Qty.: 1
Used in: 8.15.3 Engine oil – Change (→ Page 191)
Qty.: 1
Used in: 8.20.3 Battery-charging generator drive – Drive belt re-
placement (→ Page 223)
Ratchet bit
Part No.: F30450902
Qty.: 1
DCL-ID: 0000033031 - 006

Ratchet bit
Part No.: F30027340
Qty.: 1
Ratchet with extension

Part No.: F30006212
Qty.: 1
Used in: 8.1.1 Engine – Barring manually (→ Page 125)
Qty.: 1
(→ Page 129)
Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
(→ Page 140)
Test kit
Part No.: F6798833
Qty.: 1
Used in: 8.15.4 Engine oil – Sample extraction and analysis
(→ Page 193)
DCL-ID: 0000033031 - 006

Test kit
Part No.: F6798833
Qty.: 1
Used in: 8.17.6 Engine coolant – Sample extraction and analysis
(→ Page 209)
Torque wrench 10-60 Nm

Part No.: F30452769
Qty.: 1
Used in: 8.17.4 Engine coolant – Filling (→ Page 205)
Qty.: 1
Used in: 8.18.4 Charge-air coolant – Filling (→ Page 216)
DCL-ID: 0000033031 - 006

Torque wrench, 10–60 Nm
Part No.: F30452769
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 19)
Qty.: 1
Used in: 8.3.1 Oil mist fine separator – Replacement (→ Page 133)
Qty.: 1
Used in: 8.5.1 HP fuel pump – Filling with engine oil (→ Page 145)
Qty.: 1
Qty.: 1
(→ Page 162)
Qty.: 1
Used in: 8.9.3 Exhaust turbocharger (LP) – Turbine housing check
(→ Page 168)
Qty.: 1
Qty.: 1
Used in: 8.16.2 Centrifugal oil filter – Cleaning and filter-sleeve re-
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1
Used in: 8.23.5 Lambda sensor – Replacement (→ Page 232)
Qty.: 1
Used in: 8.24.3 Back Pack – Checking securing screws for firm
seating (→ Page 236)

Part No.: F30047798
Qty.: 1
DCL-ID: 0000033031 - 006

Part No.: F30044239
Qty.: 1
Used in: 8.4.4 Cylinder head cover – Removal and installation
(→ Page 143)
Qty.: 1
Qty.: 1
Qty.: 1

Part No.: F30452768
Qty.: 1
Used in: 2.3 Crankshaft transport locking device (→ Page 19)
Qty.: 1
(→ Page 140)
Qty.: 1
Qty.: 1
(→ Page 162)
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1
Used in: 8.21.1 Engine mounting – Check (→ Page 224)
Qty.: 1
Used in: 8.24.3 Back Pack – Checking securing screws for firm
seating (→ Page 236)
DCL-ID: 0000033031 - 006

Part No.: F30027336
Qty.: 1
Used in: 8.13.3 Exhaust flaps – Coupling rod replacement
(→ Page 185)
Torque wrench 10–60 Nm

Part No.: F30452769
Qty.: 1
Used in: 8.17.3 Engine coolant – Draining (→ Page 203)
Qty.: 1
Used in: 8.17.6 Engine coolant – Sample extraction and analysis
(→ Page 209)
Qty.: 1
Used in: 8.18.3 Charge-air coolant – Draining (→ Page 213)
DCL-ID: 0000033031 - 006

10.2 Index
A Crankshaft
Actuators – Transport locking device
– Function test 226 – Installation 19
– Overview 29 – Removal 19
– Visual inspection 226 Cylinder
Additional fuel filter – Designation 23
– Replacement 157 Cylinder head cover
After stopping the engine – Removal and installation 143
– Putting the engine out of operation 51 Cylinder liner
Air filter – Endoscopic examination 129
– Replacement 174 – Instructions and comments on endoscopic and visual
examination 131
B
D
Back Pack
– Overview 28 Drive belt
– Securing screws – Condition check 220
– Check for firm seating 236
E
– Visual inspection 235
Battery-charging generator ECU9
– Check 221 – Fault messages 58
– Drive belt replacement 223 Emergency stop
– Drive belt tension adjustment 222 – Engine 50
Emergency-air shutoff flaps
C – Functional check 176
Cabling – Opening 179
– Check Emission label
– On engine 225 – Check 47
Centrifugal oil filter Engine
– Cleaning 197 – Barring
Charge-air coolant – Manually 125
– Change 212 – With starting system 127
– Check – Emergency stop 50
– Level at filler neck 211 – Main dimensions 39
– Level via level sensor 211 – Mounting check 224
– Draining 213 – Overview 24
– Filling 216 – Starting in manual mode 48
Charge-air coolant pump – Stopping in manual mode 49
– Relief bore check 219 – Test run 128
Charge-air cooler Engine cabling
– Leak check 173 – Check 225
Condensate drain Engine coolant
– Check – Change 202
– Exhaust silencer 234 – Check
– Level at external cooler 200
DCL-ID: 0000033031 - 006
Connector
– Cleaning 228 – Level at filler neck 200
Contact persons 241 – Level via level sensor 200
Coolant – Draining 203
– Change 202, 212 – Filling 205
Coupling rods – Sample extraction and analysis 209
– Check Engine coolant pump
– Exhaust flaps 183 – Relief bore check 208
– Replacement Engine driving end
– Exhaust flaps 185 – Definition 23
Engine free end
– Definition 23
252 | Index | MS150120/02E 2017-08

Engine governor HP pump
– Cleaning 228 – Filling
– Plug connections – With engine oil 145
– Check 229
Engine mounting I
– Check 224 Injector
Engine oil – Replacement 147
– Analysis 193 Injectors
– Change 191 – Installation 148
– Level check with oil dipstick 190 – Removal 148
– Sample extraction 193
Engine oil filter L
– Replacement 195 Lambda sensor
Engine oil level – Replacement 232
– Check at sight glass 189 Lifting requirements 18
– Check with oil dipstick 190 List of abbreviations 238
Engine sides
M
– Designation 23
Engine – Overview 24 Maintenance schedule
Exhaust flaps – Maintenance task reference table [QL1] 53
– Check MTU contact persons 241
– Coupling rods 183
N
– Overview 180
– Replacement NOx sensor
– Coupling rods 185 – Replacement 230
Exhaust silencer
O
– Condensate drain
– Check 234 Oil mist fine separator
Exhaust turbocharger – Replacement 133
– Check Operational monitoring 42, 43
– Turbine housing (high pressure) 162 Overview
– Turbine housing (low-pressure) 168 – Back Pack 28
– Turbine housing check 161 – Engine 24
F P
Fault messages Plant

– ECU9 58 – Cleaning 52
Filter Pump
– Replacement – Charge-air coolant
– Additional fuel 157 – Relief bore check 219
– Fuel 156 – Engine coolant
Filter sleeve – Relief bore check 208
– Replacement 197 – Fuel high pressure
Firing order 38 – Filling 145
Flaps Putting into operation
– Overview 180 – Preparation after scheduled out-of-service period 41
Fuel filter
R
DCL-ID: 0000033031 - 006
– Replacement 156
Fuel prefilter Recommissioning
– Draining 158 – Preparations after long out-of-service periods (>3
– Easy-change fuel filter months) 40
– Replacement 159
– Filter element
– Replacement 159
Fuel system
– Venting 155
H
Hotline 241
MS150120/02E 2017-08 | Index | 253

S W
Safety regulations Warning notices, standards 16
– Assembly work 10
– Environmental protection 14
– Fire prevention 14
– Fluids and lubricants 14
– Important provisions 5, 6
– Indirect materials 14
– Initial start-up 8
– Maintenance work 10
– Operation 8
– Organizational requirements 7
– Personnel requirements 7
– Repair work 10
Safety requirements
– Warning notices, standards 16
Securing screws
– Check for firm seating
– Back Pack 236
– Visual inspection
– Back Pack 235
Sensors
– Overview 29
– Replacement
– Lambda 232
– NOx 230
Service indicator
– Signal ring position check 175
Service partners 241
Spare parts service 241
Starter
– Condition check 188
T
Transport locking device
– Installation
– Crankshaft 19
– Removal
– Crankshaft 19
Transportation
– Description 17
– Lifting requirements 18
Troubleshooting 55
Turbine housing
– Check 161
V
DCL-ID: 0000033031 - 006
Valve clearance
– Adjustment 140
– Check 140
Valve cover
– Replacement 210
Valve gear
– Lubrication 135
Valve protrusion
– Measurement 136
254 | Index | MS150120/02E 2017-08

Operating Instruction - Motores Diesel

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Operating Instructions

© 2017 Copyright MTU Friedrichshafen GmbH

8.2 Cylinder Liner 129

8.5 Injection Pump / HP Pump 145

MS150120/02E 2017-08 | Table of Contents | 3

8.12 Air Intake 175 8.19 Belt Drive 220

4 | Table of Contents | MS150120/02E 2017-08

Emission regulations and emission labels

Replacing components with emission labels

MS150120/02E 2017-08 | Safety | 5

6 | Safety | MS150120/02E 2017-08

Clothing and personal protective equipment

MS150120/02E 2017-08 | Safety | 7

Safety regulations during operation

Malfunctions and emergency stop

8 | Safety | MS150120/02E 2017-08

Operation of electrical equipment

MS150120/02E 2017-08 | Safety | 9

Safety regulations when performing assembly, maintenance, and repair work

Setting down, lifting and climbing

10 | Safety | MS150120/02E 2017-08

Removing, installing and cleanliness

Safety regulations after performing assembly, maintenance, and repair work

MS150120/02E 2017-08 | Safety | 11

Hydraulic installation and removal

Working with batteries

Working on electrical and electronic assemblies

De-energize the appropriate areas prior to working on assemblies.

12 | Safety | MS150120/02E 2017-08

Working with laser equipment

Measuring component dimensions

MS150120/02E 2017-08 | Safety | 13

Environmental protection and disposal

Indirect materials, fluids and lubricants

contaminate sensors and other components leading to malfunction.

REACH regulation (Registration, Evaluation, Authorisation and restriction of

14 | Safety | MS150120/02E 2017-08

Paints and lacquers

Acids/alkaline solutions/urea (e.g. AdBlue®, DEF)

MS150120/02E 2017-08 | Safety | 15

16 | Safety | MS150120/02E 2017-08

Setting down after transport

MS150120/02E 2017-08 | Transport | 17

This overview applies analogously to 12V and 16V engines.

1 Max. admissible diagonal 2 Center of gravity

Note engine center of gravity

18 | Transport | MS150120/02E 2017-08

Transport locking device

MS150120/02E 2017-08 | Transport | 19

2. Tighten screws (6) with torque wrench to specified tightening torque.

3. Screw nut (3) with washer (2) onto holder (4).

5. Lock with nut (3).

Removing the transport locking

20 | Transport | MS150120/02E 2017-08

Fitting the transport locking de-

MS150120/02E 2017-08 | Transport | 21

TIM-ID: 0000027593 - 005

22 | Transport | MS150120/02E 2017-08

1 Left engine side (A-side) 3 Right engine side (B-side)