Operating Instructions

Operating Instructions
Diesel engine
12 V 4000 C10, C10R, C11, C11R
12 V 4000 C20, C20R, C21, C21R
16 V 4000 C10, C11, C11R
16 V 4000 C20, C20R, C21, C21L
MS150049/02E
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Printed in Germany
© 2012 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.

Table of Contents
1 Safety 4.7 Plant cleaning 46
1.1 Important provisions for all MTU engines or
systems 5
1.2 Personnel and organizational requirements 6 5 Maintenance
1.3 Transport 7
5.1 Maintenance task reference table [QL1] 47
1.4 Crankshaft transport locking device 8
1.5 Crankshaft transport locking device – For
transport with flanged-on generator 11
1.6 Safety regulations for startup and operation 13 6 Troubleshooting
1.7 Safety regulations for maintenance and
repair work 14 6.1 Troubleshooting 49
1.8 Fire prevention and environmental 6.2 Fault messages from DDEC engine
protection, auxiliary materials, fluids and governor 52
lubricants 17
1.9 Standards for safety messages in the text 19
7 Task Description
7.1 Engine 72
2 General Information 7.1.1 Engine – Barring manually 72
7.1.2 Engine – Barring with starting system 73
2.1 Engine side and cylinder designations 20
2.2 Engine – Overview 21 7.2 Cylinder Liner 74
2.3 Sensors, actuators and injectors – 7.2.1 Cylinder liner – Endoscopic examination 74
Overview 23 7.2.2 Instructions and comments on endoscopic
and visual examination of cylinder liners 76
7.3 Crankcase Breather 78

3 Technical Data 7.3.1 Crankcase breather – Filter element
replacement 78
3.1 Engine data 12 V 4000 C10, C10R, C11, 7.3.2 Crankcase breather (open-circuit crankcase
C11R 26 ventilation) – Filter element cleaning 80
3.2 Engine data 16 V 4000 C10, C11, C11R 29
3.3 Engine data 12 V 4000 C20, C20R, C21, 7.4 Running Gear 81
7.4.1 Grounding device – Check carbon brush 81
C21R 32
7.4.2 Grounding device – Carbon brush
3.4 Engine data 16 V 4000 C20, C20R, C21,
replacement 83
C21L 35
3.5 Firing order 38 7.5 Valve Drive 84
3.6 Engine – Main dimensions 39 7.5.1 Valve gear – Lubrication 84
7.5.2 Valve clearance – Check and adjustment 85
7.5.3 Cylinder head cover – Removal and
installation 89
4 Operation
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7.6 Injection Pump / HP Pump 90

4.1 Putting the engine into operation after 7.6.1 HP pump – Relief bore check 90
extended out-of-service periods (>3
months) 40 7.7 Injection Valve / Injector 91
7.7.1 Injector – Replacement 91
4.2 Putting the engine into operation after
7.7.2 Injector – Removal and installation 92
scheduled out-of-service-period 41
4.3 Starting the engine in manual mode 42 7.8 Fuel System 97
4.4 Operational checks 43 7.8.1 Fuel system – Venting 97
4.5 Stopping the engine in manual mode 44
4.6 After stopping the engine 45 7.9 Fuel Filter 98
7.9.1 Fuel filter – Replacement 98
MS150049/02E 2012-11 | Table of Contents | 3

7.10 Charge-Air Cooling 99 7.18 Belt Drive 128
7.10.1 Charge-air cooler – Check water drain for 7.18.1 Drive belt – Condition check 128
coolant leakage and absence of restrictions 99
7.19 Battery-Charging Generator 129
7.11 Starting Equipment 100 7.19.1 Battery-charging generator – Condition check 129
7.11.1 Starter – Condition check 100 7.19.2 Battery-charging generator – Check 130
7.11.2 Cold start system with ether injection – Check 101 7.19.3 Battery-charging generator – Removal and
installation 131
7.12 Air Intake 102 7.19.4 Battery-charging generator – Drive belt and
7.12.1 Service indicator – Check 102 belt tensioner replacement 133
7.19.5 Battery-charging generator – Drive belt
7.13 Lube Oil System, Lube Oil Circuit 103 tension adjustment 135
7.13.1 Engine oil – Level check 103
7.13.2 Engine oil – Change 104 7.20 Fan Drive 136
7.13.3 Engine oil – Sample extraction and analysis 106 7.20.1 Fan drive – Adjust and check drive belt
tension 136
7.14 Oil Filtration / Cooling 107 7.20.2 Fan drive – Drive belt replacement 138
7.14.1 Engine oil filter – Replacement 107
7.14.2 Oil indicator filter – Check 108 7.21 Auxiliary PTO 139
7.14.3 Centrifugal oil filter – Cleaning and filter 7.21.1 Compressor – Check 139
sleeve replacement 110
7.22 Wiring (General) for Engine/Gearbox/Unit 140
7.15 Coolant Circuit, General, High- 7.22.1 Engine wiring – Check 140
Temperature Circuit 112
7.15.1 Engine coolant – Level check 112 7.23 Accessories for (Electronic) Engine
7.15.2 Engine coolant – Change 113 Governor / Control System 141
7.15.3 Engine coolant – Draining 114 7.23.1 DDEC and connectors – Cleaning 141
7.15.4 Engine coolant – Filling 115 7.23.2 DDEC – Checking plug-in connections 143
7.15.5 Engine coolant pump – Relief bore check 117
7.15.6 Coolant filter – Replacement 118
7.15.7 Engine coolant – Sample extraction and
analysis 119
8 Appendix A
7.16 Low-Temperature Circuit 120
7.16.1 Charge-air coolant – Level check 120 8.1 Abbreviations 144
7.16.2 Charge-air coolant – Change 121 8.2 MTU contact persons/service partners 147
7.16.3 Charge-air coolant – Drainage 122
7.16.4 Charge-air coolant – Filling 123
7.16.5 Charge-air coolant pump – Relief bore check 126
9 Appendix B
7.17 Engine Mounting / Support 127
7.17.1 Engine mounting – Check 127 9.1 Special Tools 148
9.2 Index 154
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4 | Table of Contents | MS150049/02E 2012-11

1 Safety
1.1 Important provisions for all MTU engines or systems
Nameplate
Engine identification is provided by the engine serial number on the nameplate.
The nameplate is located on the engine.
General information
This engine or plant may present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions
Correct use
The engine or plant is intended solely for use in accordance with contractual agreements and the pur‐
pose envisaged for it on delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ engine data)
• With fluids and lubricants approved by MTU in accordance with the (→ MTU Fluids and Lubricants
Specifications)
• With spare parts approved by MTU in accordance with the associated (→ Spare Parts Catalog)
• In the original as-delivered configuration or in a configuration approved by MTU in writing (engine and
engine control/parameters)
• In compliance with all safety instructions and in adherence to all warning notices in these Operating
Instructions
• In compliance with the maintenance and repair instructions contained in these Operating Instructions,
in particular with regard to the specified tightening torques
• Appointing only qualified personnel to carry out work related to initial startup, operation, maintenance
and repair
• Contracting only workshops authorized by MTU to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in engine/plant operation.MTU will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the engine or plant represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
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Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies.
MTU will accept no liability or warranty claims for any damage caused by the use of other spare parts.
MS150049/02E 2012-11 | Safety | 5

1.2 Personnel and organizational requirements
Organizational measures of the operator

This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair
and transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on
explaining safety-relevant instructions.
This is particularly important in the case of personnel who only occasionally perform work on or around
the engine or plant. This personnel must be instructed repeatedly.
For the identification and layout of the spare parts during maintenance or repair work, take photos or use
the spare parts catalog.
Personnel requirements
All work on the engine or plant shall be carried out by trained and qualified personnel only:
• Training at the MTU Training Center
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair
and transport.
Working clothes and protective equipment

Wear proper protective clothing for all work.
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6 | Safety | MS150049/02E 2012-11

1.3 Transport
Transport
Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.
Always use the lifting eyes on the engine when transporting an engine separately.
Only use transport and lifting devices approved by MTU.
The engine/genset must only be transported in installation position: maximum permissible diagonal pull
10°.
Remove any loose parts on the genset.
Raise the engine/genset slowly. The lifting ropes or chains must not make contact with the engine or its
components. Readjust lifting device as necessary.
Pay attention to the center of gravity of the engine/genset.
For special packaging with aluminium foil: Suspend the engine/genset by the lifting eyes on the bearing
pedestal or transport by means of handling equipment (forklift truck) capable of bearing the load.
Fit the crankshaft transportation lock on the engine and fit the engine mount locking devices prior to
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transport.
Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip‐
ping and tipping when driving up or down inclines and ramps.
Placement after transport

Place the engine/genset on a firm, flat surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis.
MS150049/02E 2012-11 | Safety | 7

1.4 Crankshaft transport locking device
Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 10-60Nm F30452769 1
Engine oil
Note: The transport locking device on both sides protects the crankshaft bearings from shocks and possible
vibration damage during engine transport.
For installation and removal of the transport locking device, follow the instructions
below:
1. The transport locking device on both sides must remain installed as long as possible during engine in‐
stallation in order to avoid damage.
2. Prior to every engine transport (without generator) , the transport locking device on both sides must be
installed according to the instructions.
3. If the engine is to be moved together with the generator, the transport locking device for the generator
must also be installed (→ Page 11).
4. Always use the screws supplied with or installed in the transport locking device to secure it on the en‐
gine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the generator
is already mounted on the engine, ensure that the transport locking device of the generator is also re‐
moved.
6. Attach this documentation to a highly visible area of the engine.
Removing the transport locking

device from driving end (KS),
version A
1. Remove parts (1) to (8) from engine.
Spacer sleeves (5), optional.
2. Store the removed parts of the transport
locking device carefully for possible reuse.
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8 | Safety | MS150049/02E 2012-11

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

Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 160Nm +16Nm
3. Screw nut (3) with washer (2) onto holder (4). Screw on carrier (1) with washer (7) and nut (8) and tight‐
en nut (8) to the specified tightening torque using the torque wrench.
Nut M24 Tightening torque (Engine oil) 100Nm +10Nm
4. Secure with nut (3).
5. Mark the engine as "Fitted with transport locking device".

device from driving end (KS),
version B
1. Release the locknuts (2) on both sides of
the flywheel housing, remove screw (3) and
take off holder (8).
2. Unscrew screws (5) and remove with wash‐
ers (4), cover plate (7) sign (6) and
plates (1).
3. Store the removed parts of the transport
locking device carefully for possible reuse
together with this documentation.
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MS150049/02E 2012-11 | Safety | 9

Installing the transport locking
device on driving end (KS), version
B
1. Secure plate (1) with screws (5) and washers (4) together with cover plate (7) at the bores on both sides
of the flywheel housing and tighten to the specified tightening torque.
2. Screw locknut (2) onto screws (3) up to the end of the thread.
3. Insert holder (8) through opening in plate (1) and secure with screw (3).
4. Tighten screws (3) alternately with torque wrench to the specified tightening torque.
5. Place locknuts (2) of screw (3) in position on both sides of plate (1) and lock.
6. Fit sign (6) to mark the engine as "Fitted with transport locking device".
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10 | Safety | MS150049/02E 2012-11

1.5 Crankshaft transport locking device – For transport with
flanged-on generator

Engine oil
Note: The transport locking device on the engine protects the crankshaft bearings from shocks and vibration
damage during genset transport.
The following must be taken into account when removing/installing the transport
locking device:
1. The transport locking device must remain installed as long as possible during genset installation in order
to avoid damage.
2. Prior to every genset transport, the transport locking device must be reinstalled on the engine and gener‐
ator according to the instructions.
3. Always use the screws supplied with or installed in the transport locking device to secure it on the en‐
gine.
4. Starting or barring the engine is allowed only with the transport locking device removed from engine and
generator.

device from driving end (KS)
1. Release nut (11) on both sides.
2. Remove screw (5), washer (4), holder (3)
and screw (6) from flywheel (2).
3. Remove screw (9), washer (8) and hold‐
er (7) from crankcase (12).
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4. Install the two screws with washers to secure the diaphragm coupling to the flywheel.
Screw Tightening torque (Engine oil) 250Nm +25Nm
Installing the transport locking device on driving end (KS)

1. Remove the transport locking device installed by MTU (→ Page 8).
2. Remove protective cover from flywheel housing (1).
MS150049/02E 2012-11 | Safety | 11

3. Install the holders (7) on both sides of the crankcase (12) with screw (9) and washer (8). Tighten
screw (9).
4. To allow the holders (3) to be secured on each side of the flywheel (2), the corresponding screws and
washers must be removed from the driving end.
5. Leave the unscrewed screws with washers on engine and screw back in when the transport locking de‐
vice has been removed.
6. Place screw (6) in the recess of holder (3) and insert through the opening at the flywheel housing (1).
Secure holder (3) with screw (5) and washer (4) to flywheel (2). Tighten screw (5).
7. Fit conical spring washer (10) on screw (6) and tighten nut (11).
Nut Tightening torque (Engine oil) 27Nm +3Nm
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12 | Safety | MS150049/02E 2012-11

1.6 Safety regulations for startup and operation
Safety requirements for initial operation

Before the engine or plant is put into operation for the first time, the engine or plant must be installed and
accepted in accordance with MTU specifications.
Before the engine or plant is put into operation for the first time, all official authorizations must be availa‐
ble and commissioning preconditions met.
When putting the engine / plant into operation, always ensure:
• that all maintenance and repair work has been completed;
• that all loose parts have been removed from rotating machine components;
• that no-one is present in the danger zone of rotating machine components.
Immediately after putting the engine or plant into operation, make sure that all control and display instru‐
ments as well as the monitoring, signaling and alarm systems work properly.
Safety regulations for equipment 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 re‐
gard to present operating status, violation of limit values and warning or alarm messages.
Engine malfunctions and engine emergency stop

The procedures for cases of emergency, in particular, engine emergency stop, must be practiced regu‐
larly.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency stop.
Engine operation
The following conditions must be fulfilled before starting the engine or plant:
• Wear ear protection.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.
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Observe the safety instructions for these devices.
MS150049/02E 2012-11 | Safety | 13

1.7 Safety regulations for maintenance and repair work
Safety regulations prior to maintenance and repair work

Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine or plant to cool down to less than 50°C before starting maintenance work (risk of explo‐
sion of oil vapors, fluids and lubricants, risk of burning).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use
suitable containers of adequate capacity to catch fluids and lubricants.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Never carry out maintenance and repair work with the engine running.
Carry out function checks on a running engine only if expressly permitted to do so.
Secure the engine or plant against accidental starting.
Disconnect the battery. Lock circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the engine or plant.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. 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 de‐
vice as an additional measure.
Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the engine or plant. Cover the screw or
plug with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and, if applicable, calibrated tools. Observe the specified tightening torques during as‐
sembly/disassembly.
Carry out work only on assemblies or plants which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐
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tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com‐
ponents are placed on stable surfaces.
Observe special cleanness when conducting maintenance and repair work on the engine or plant. After
completion of maintenance and repair work, make sure that no loose objects are in/on the assembly or
plant (e.g. cloths and cable ties)
14 | Safety | MS150049/02E 2012-11

Safety regulations after completion of maintenance and repair work
Before barring the engine, make sure that nobody is standing in the danger zone of the engine or plant.
Check that all guards have been reinstalled and that all tools and loose parts have been removed after
working on the engine or plant (in particular, the barring tool).
Welding work
Never carry out welding work on the assembly or plant, or attached units. Cover the engine or plant when
welding in its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the engine or plant while weld‐
ing is going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.
Do not use the engine or plant as ground terminal.
Do not route the welding lead over or near the wiring harnesses of the engine or plant. The welding cur‐
rent may otherwise induce an interference voltage in the wiring harnesses which could conceivably dam‐
age the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices 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.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool 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 on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
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Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work. In particular, check the
function of the engine emergency stop feature.
MS150049/02E 2012-11 | Safety | 15

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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16 | Safety | MS150049/02E 2012-11

1.8 Fire prevention and environmental protection, auxiliary
materials, fluids and lubricants
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires –
therefore always keep the engine or plant in a clean condition. Do not leave cloths soaked with fluids and
lubricants on the engine or plant. Do not store combustible materials near the engine or plant.
Do not weld pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to
the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their
use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal

Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐
lent components. Noncompliance with these guidelines will lead to forfeiture of the operating permit is‐
sued by the emission monitoring authorities. MTU does not accept any liability for violations of the emis‐
sion regulations. The Maintenance Schedules of MTU must be observed over the entire life cycle of the
engine or plant.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are
subjected to proper recycling procedures.
Auxiliary materials, fluids and lubricants

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using
them, make sure you have the latest version. The latest version is also available at: http://www.mtu-on‐
line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.
Auxiliary materials, fluids and lubricants might be hazardous goods or toxic substances.When using flu‐
ids, lubricants and other chemical substances, follow the safety instructions that apply to the product.
Take special care when using hot, chilled or caustic materials. When using flammable materials, avoid
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contact with ignition sources and do not smoke.
Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.
MS150049/02E 2012-11 | Safety | 17

Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Wear goggles when blowing off components or blowing away chips.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Pay special attention to the pressure level in the compressed air network or pressure vessel.
• Assemblies or plants to be connected must either be designed for this pressure, or, if the permitted
pressure for the connecting elements is lower than the pressure required, a pressure reducing valve
and safety valve (set to permitted pressure) must form an intermediate connection.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before the equipment or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Paints and lacquers

• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure 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
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids and alkaline solutions

• When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and
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protective clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately.
• Rinse injured parts of the body thoroughly with clean water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.
18 | Safety | MS150049/02E 2012-11

1.9 Standards for safety messages in the text
DANGER
In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
WARNING
In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
CAUTION
In the event of hazardous situations.
Consequences: Minor or moderate injuries
• Remedial action
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
Note: This manual contains highlighted safety messages in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety messages
1. Read and familiarize yourself with all safety message before starting up or repairing the product.
2. Pass on all safety messages to operating, maintenance, repair and transport personnel.
TIM-ID: 0000000881 - 020
MS150049/02E 2012-11 | Safety | 19

2 General Information
2.1 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
1 Left engine side 3 Right engine side

2 KGS = Free end 4 KS = Driving end TIM-ID: 0000002185 - 010
20 | General Information | MS150049/02E 2012-11

2.2 Engine – Overview
Figure applies to 16V4000 Cxy analogously
1 Oil cooler 8 Combustion-air inlet 15 Air conditioning com‐

2 Fan coupling 9 Charge-air cooler pressor drive
3 Crankcase breather 10 Charge-air line 16 HP pump
4 Control valve for fan 11 Starter 17 Engine mounting
coupling 12 Engine governor 18 Battery-charging gener‐
5 Centrifugal oil filter 13 Easy-change fuel filter ator
6 Exhaust outlet 14 Oil filter 19 Charge-air coolant
7 Turbocharger pump
20 Charge-air coolant ther‐
mostat
21 Engine coolant outlet
TIM-ID: 0000002071 - 003
MS150049/02E 2012-11 | General Information | 21

1 Charge-air line 8 Lifting eyes 15 Crankcase
2 Cylinder head / cylinder 9 Crankcase breather 16 Flywheel housing
head cover 10 Charge-air coolant inlet 17 Flywheel
3 Crankcase breather 11 Engine coolant pump 18 Charge-air line
4 Coolant circuit / vent 12 Inspection port cover 19 Charge-air cooler
connection 13 Oil filler neck
5 Oil cooler 14 Oil pan
6 Charge-air coolant out‐
let
7 Engine coolant inlet
Engine model designation

Key to the engine model designations 12/16V 4000 Cxy
12 / 16 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
C Application: Construction and Industrial, mobile
x Application segment: 1, 2
TIM-ID: 0000002071 - 003
y Configuration status: 0, 1

2.3 Sensors, actuators and injectors – Overview
1 Engine coolant temper‐ 3 Charge-air temperature

ature 4 Charge-air pressure
2 Crankshaft speed
The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and necessa‐
ry activities (→ Page 91).
TIM-ID: 0000008365 - 002

1 Camshaft speed 3 Fuel temperature 5 Charge-air coolant pres‐
2 Fuel pressure (LP) 4 Fuel high pressure sure
6 Engine coolant pressure
TIM-ID: 0000008365 - 002

1 Lube oil temperature 3 Crankcase pressure
2 Lube oil pressure 4 Charge-air coolant tem‐
perature
TIM-ID: 0000008365 - 002

3 Technical Data
3.1 Engine data 12 V 4000 C10, C10R, C11, C11R
Explanation
Abbr. Meaning
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power set‐
ting)
N Not yet defined value
- Not applicable
X Applicable
12 V 4000 C11: T1237K33 / 06N04M 1328

12 V 4000 C11R: T1237K33 / 06N04M 1329
REFERENCE CONDITIONS
Engine model 12V 12V 12V 12V
4000 4000 4000 4000
C10 C10R C11 C11R
Application group 5A, 5B 5A, 5B 5A, 5B 5A, 5B
Intake air temperature °C 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level m 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 12 12 12 12
Rated engine speed A rpm - - 1900 1900
Continuous power (without fan) (fuel A kW - - 1286 1193
stop power)
TIM-ID: 0000040201 - 001
GENERAL CONDITIONS (for maximum power)

Intake depression (new filter) A mbar 30 - 30 30
Intake depression, max. L mbar 50 - 50 50
Exhaust overpressure A mbar 37 - 37 37
Exhaust pressure, max. L mbar 50 - 50 50
26 | Technical Data | MS150049/02E 2012-11

MODEL RELATED DATA (basic design)
Cylinder arrangement: V angle Degrees 90 90 90 90
Bore mm 165 165 165 165
Stroke mm 190 190 190 190
Displacement of a cylinder Liters 4.1 4.1 4.1 4.1
Displacement, total Liters 48.80 48.80 48.80 48.80
Number of inlet valves per cylinder 2 2 2 2
Number of exhaust valves per cylinder 2 2 2 2
COMBUSTION AIR / EXHAUST GAS

Charge-air pressure before cylinder R bar 2.0 - 2.1 1.95
Exhaust gas temperature R °C 385 - 395 382
COOLANT SYSTEM (HT circuit)

Coolant temperature (at engine connec‐ A °C 90 - 95 95
tion: outlet to cooling equipment)
Coolant pump: inlet pressure, max. R °C 1.5 - 1.5 1.5
Thermostat: Starts to open R % 76 - 76 76
Thermostat: Fully open R bar 87 - 87 87
LUBE OIL SYSTEM

Lube oil operating pressure upstream of R bar 6.1 - 6.3 6.3
engine, from
FUEL SYSTEM
Fuel temperature before pump, max. L °C 60 - 60 60
CAPACITIES
Engine coolant capacity, engine side R Liters 127 - 127 127
(without cooling equipment)
TIM-ID: 0000040201 - 001
Charge-air coolant, engine side R Liters 33 - 33 33

Engine oil, max. R Liters 198 - 198 198
WEIGHTS / MAIN DIMENSIONS

Engine weight, dry (basic engine config‐ R kg 6044 6044 6044 6044
uration acc. to scope of delivery specifi‐
cation)
MS150049/02E 2012-11 | Technical Data | 27

NOISE
Unsilenced exhaust noise at 1m dis‐ R dB(A) 108 - 110 108
tance
TIM-ID: 0000040201 - 001

3.2 Engine data 16 V 4000 C10, C11, C11R
Explanation
Abbr. Meaning
A Design value
G Guaranteed value
R Guideline value
ting)
- Not applicable
X Applicable
16 V 4000 C11: T1637K33 / 06N04M 1477

16 V 4000 C11R: T1637K33 / 06N04M 1336
Engine model 16 V 16 V 16 V
4000 4000 4000
C10 C11 C11R
Application group 5A, 5B 5A, 5B 5A, 5B
Intake air temperature °C 25 25 25
Barometric pressure mbar 1000 1000 1000
Site altitude above sea level m 100 100 100
Number of cylinders 16 16 16
Rated engine speed A rpm - 1900 1800
Continuous power (without fan) (fuel stop A kW - 1715 1600
power)

TIM-ID: 0000040208 - 001
Intake depression (new filter) A mbar 30 30 30

Intake depression, max. L mbar 50 50 50
Exhaust overpressure A mbar 37 37 37
Exhaust pressure, max. L mbar 50 50 50

Cylinder arrangement: V angle Degrees 90 90 90
Bore mm 165 165 165
Stroke mm 190 190 190
Displacement of a cylinder Liters 4.1 4.1 4.1
Displacement, total Liters 65.0 65.0 65.0
Number of inlet valves per cylinder 2 2 2
Number of exhaust valves per cylinder 2 2 2

Charge-air pressure before cylinder R bar 2.0 2.1 1.95
Exhaust gas temperature R °C 375 377 376

Coolant temperature (at engine connection: A °C 95 95 95
outlet to cooling equipment)
Coolant pump: inlet pressure, max. R °C 1.5 1.5 1.5
Thermostat: Starts to open R % 76 76 76
Thermostat: Fully open R bar 87 87 87
LUBE OIL SYSTEM

Lube oil operating pressure upstream of en‐ R bar 6,1 6,1 6,0
gine, from
FUEL SYSTEM
Fuel temperature before pump, max. L °C 60 60 60
CAPACITIES
Engine coolant capacity, engine side (without R Liters 164 164 164
cooling equipment)
TIM-ID: 0000040208 - 001
Charge-air coolant, engine side R Liters 42 42 42

Engine oil, max. R Liters 230 230 230

Engine weight, dry (basic engine configura‐ R kg 7083 7083 7083
tion acc. to scope of delivery specification)

NOISE
Unsilenced exhaust noise at 1m distance R dB(A) 108 110 108
TIM-ID: 0000040208 - 001

3.3 Engine data 12 V 4000 C20, C20R, C21, C21R
Explanation
Abbr. Meaning
A Design value
G Guaranteed value
R Guideline value
ting)
- Not applicable
X Applicable
12 V 4000 C21: T1237K33 / 06N04M 1326

12 V 4000 C21R: T1237K33 / 06N04M 1327
Engine model 12V 12V 12V 12V
4000 4000 4000 4000
C20 C20R C21 C21R
Rated engine speed A rpm 1900 1900 1900 1900
Continuous power (without fan) (fuel A kW 1500 - 1510 1398
stop power)

TIM-ID: 0000040210 - 001


Bore mm 165 165 165 165
Stroke mm 190 190 190 190


LUBE OIL SYSTEM

engine, from
FUEL SYSTEM
CAPACITIES
TIM-ID: 0000040210 - 001


cation)

NOISE
tance
TIM-ID: 0000040210 - 001

3.4 Engine data 16 V 4000 C20, C20R, C21, C21L
Explanation
Abbr. Meaning
A Design value
G Guaranteed value
R Guideline value
ting)
- Not applicable
X Applicable
16 V 4000 C21: T1637K33 / 06N04M 1476

16 V 4000 C21L: T1637K33 / 06N04M 1475
Engine model 16 V 16 V 16 V 16 V
4000 4000 4000 4000
C20 C20R C21 C21L
Rated engine speed A rpm 1900 1900 1900 1900
Continuous power (without fan) (fuel A kW 2013 1864 1864 2013
stop power)

TIM-ID: 0000040213 - 001


Bore mm 165 165 165 165
Stroke mm 190 190 190 190


LUBE OIL SYSTEM

engine, from
FUEL SYSTEM
CAPACITIES
TIM-ID: 0000040213 - 001


cation)

NOISE
tance
TIM-ID: 0000040213 - 001

3.5 Firing order
Firing order
Number of cylin‐ Firing order
ders
8V A1-B4-A4-A2-B3-A3-B2-B1
12V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
TIM-ID: 0000002794 - 004

3.6 Engine – Main dimensions
Engine model Length (A) Width (B) Height (C)

12 V 4000 Cxy approx. 2540 mm approx. 1620 mm approx. 1990 mm
16 V 4000 Cxy approx. 3010 mm approx. 1620 mm approx. 1990 mm
TIM-ID: 0000002136 - 003

4 Operation
4.1 Putting the engine into operation after extended out-of-
service periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting the engine into operation after extended out-of-service-periods (>3 months)
Item Action
Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).
Valve gear Lubricate valve gear every ≥ 6 months (→ Page 84).
Lube oil system Check engine oil level (→ Page 103);
Bar engine with startingsystem (→ Page 73).
Fuel system Vent (→ Page 97).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 113).
Change charge-air coolant (→ Page 121).
Coolant circuit Check engine coolant level (→ Page 112);
Check charge-air coolant level (→ Page 120).
Coolant circuit Preheat coolant with preheating unit, if fitted.
DDEC Check plug-in connections (→ Page 143).
TIM-ID: 0000002201 - 004
40 | Operation | MS150049/02E 2012-11

4.2 Putting the engine into operation after scheduled out-of-
service-period
Preconditions
Startup
Item Action
Lube oil system Check engine oil level (→ Page 103).
Coolant circuit Check engine coolant level (→ Page 112);
Check charge-air coolant level (→ Page 120).
Coolant circuit Preheat coolant with coolant preheating unit (if applicable).
Engine control system Put into operation.
TIM-ID: 0000002683 - 005
MS150049/02E 2012-11 | Operation | 41

4.3 Starting the engine in manual mode
Preconditions
☑ Engine is not under load.
☑ External start interlock is not activated.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Action
Operating mode switch (if Switch to manual mode.
applicable)
Coolant preheating unit (if Switch ON.
applicable).
Starting the engine

Item Action
Switchgear cabinet, opera‐ 1. If no coolant preheater is fitted, make sure that the coolant tempera‐
tor station etc. (depending ture is > 40 °C.
on manufacturer). 2. Press start button.
• Automatic starting procedure is performed;
• Engine speed instrument indicates increasing speed;
• After the starting sequence is completed, engine is running at idle
speed.
TIM-ID: 0000002233 - 005
42 | Operation | MS150049/02E 2012-11

4.4 Operational checks
DANGER
• Take special care when working on a running engine.
WARNING
Operational checks
Item Action
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine operation Visually inspect engine and attached components for condition and leaks;
Check for abnormal running noise, exhaust discoloration and vibrations
(→ Page 49).
Battery-charging generator Check for dirt, clean as necessary (→ Page 130).
HP pump Check relief bore (→ Page 90).
HT coolant pump Check relief bore (→ Page 117).
LT coolant pump Check relief bore (→ Page 126).
TIM-ID: 0000002261 - 002
MS150049/02E 2012-11 | Operation | 43

4.5 Stopping the engine in manual mode
Preconditions
☑ Engine is not under load.
☑ Engine is running in manual mode.
CAUTION
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
• Before stopping the engine, operate it at idle speed until operating temperatures decrease and
stable values are indicated.
Preparation
Item Action
Engine Operate engine at idling speed for approx. 5 minutes.
Stopping the engine

Item Action
Switch cabinet, operator Press stop button.
station etc. (depending on
• Automatic stopping sequence is executed.
manufacturer)
TIM-ID: 0000002291 - 004
44 | Operation | MS150049/02E 2012-11

4.6 After stopping the engine
Preconditions
After stopping the engine

Item Action
Coolant circuit Drain coolant (→ Page 114)(→ Page 122) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive;
• the coolant is not maintained at a suitable temperature;
• antifreeze concentration is 50 % and outside temperature is below
-40°C.
Engine control system Switch off.
Air intake and exhaust sys‐ Out-of-service-period > 1 week:
tem
Seal engine's air and exhaust sides.
Out-of-service-period > 1 month:
Preserve engine (→ MTU Fluids and Lubricants Specifications
A001061/.. ).
TIM-ID: 0000002321 - 002
MS150049/02E 2012-11 | Operation | 45

4.7 Plant cleaning
Preconditions
☑ Operating voltage is not present.

Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
WARNING
Water jet.
Risk of injury and scalding!
• Do not direct water jet at persons.
• Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• Observe manufacturer's instructions.
NOTICE
Dry with compressed air.
• Never aim compressed air directly at electronic components.
Plant cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐
tection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.
3. During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must
be observed. The temperature of the cleaning medium must not exceed 80 °C.
TIM-ID: 0000010171 - 024
4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable fashion.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
Note: Never aim compressed air directly at electronic components.
e) Dry engine.
46 | Operation | MS150049/02E 2012-11

5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Option Maintenance tasks
W0500 Check engine oil level. (→ Page 103)
W0501 Visually inspect engine for leaks and general condition. (→ Page 43)
W0502 X Check intercooler drain(s). (→ Page 99)
W0503 Check signal ring position of service indicator on air filter. (→ Page 102)
W0504 Check relief bores of HP fuel pump. (→ Page 43)
W0505 Check relief bores of water pump(s). (→ Page 117)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 43)
and vibrations .
W0507 X Drain water and contaminants from fuel prefilter. -
W0508 X Check reading on differential pressure gage of fuel prefil‐ -
ter.
W0525 Check battery-charging generator for contamination, clean (→ Page 130)
as necessary.
W1001 Replace fuel filter or fuel filter element. (→ Page 98)
W1003 Check belt condition and tension, replace if necessary. (→ Page 128)
W1006 Replace fuel injectors. (→ Page 91)
W1009 X Check layer thickness of oil residue, clean and replace fil‐ (→ Page 110)
ter sleeve of centrifugal oil filter (if fitted) at every oil
change, at the latest.
W1011 Perform endoscopic examination of combustion chambers. (→ Page 74)
W1036 Replace coolant filter. (→ Page 118)
W1046 Crankcase breather: Replace filter or filter element. (→ Page 78)
W1047 X Check and clean oil indicator filter. (→ Page 108)
W1164 Replace filter element and sealing ring depending on de‐ -
gree of contamination, when the limit (years) is reached, at
the latest.
W1207 Check valve clearance, adjust if necessary. Attention!First (→ Page 85)
TIM-ID: 0000034281 - 002
adjustment after 1,000 operating hours!

W1463 Check general condition of engine mounting (visual inspec‐ (→ Page 127)
tion).
W1481 Replace supplementary fuel filter or filter element of sup‐ -
plementary fuel filter.
W1697 X Check carbon brushes at flywheel, replace if necessary. (→ Page 81)
MS150049/02E 2012-11 | Maintenance | 47

Task Option Maintenance tasks
W1698 X Replace carbon brushes at flywheel. (→ Page 83)
W1716 Cleaning battery-charging generator. (→ Page 131)
Table 1: Maintenance task reference table [QL1]
TIM-ID: 0000034281 - 002
48 | Maintenance | MS150049/02E 2012-11

6 Troubleshooting
6.1 Troubleshooting
Engine does not turn when starter is actuated

Component Cause Action
Battery Low or faulty Charge or replace (see manufacturer's
documentation).
Cable connections faulty Check if cable connections are proper‐
ly secured (see manufacturer's docu‐
mentation).
Starter Engine cabling or starter faulty Check if cable connections are proper‐
ly secured, contact Service.
Engine cabling Faulty Check (→ Page 140).
Engine/generator Assemblies or connectors possibly Perform visual inspection (see manu‐
control system loose facturer's documentation).
DDEC Plug-in connections possibly loose Check plug-in connections
(→ Page 143).
Engine Running gear blocked (engine cannot Contact Service.
be barred manually)
Engine turns but does not fire

Starter Poor rotation by starter: Battery low or Charge or replace battery (see manu‐
faulty facturer's documentation).
Fuel system Air in fuel system Vent fuel system (→ Page 97).
DDEC Faulty Contact Service.
Engine fires unevenly

Fuel injection equip‐ Injector faulty Replace (→ Page 91).
ment
TIM-ID: 0000002542 - 003
Engine does not reach rated speed

Fuel supply Fuel prefilter clogged Clean or replace filter element.
Easy-change fuel filter clogged Replace (→ Page 98).
Air supply Air filter clogged Check signal ring position of service in‐
dicator (→ Page 102).
MS150049/02E 2012-11 | Troubleshooting | 49

ment
Engine Overloaded Contact Service.
Engine speed not steady

ment
Speed sensor Faulty Contact Service.
Charge air temperature too high

Engine coolant Engine coolant treatment incorrect Check (MTU test kit).
Intercooler Contaminated Contact Service.
Engine room Air-intake temperature too high Check fans and intake/exhaust lines.
Charge-air pressure too low

Intercooler Contaminated Contact Service.
Exhaust turbocharger Faulty Contact Service.
Coolant leaks at intercooler

Intercooler Leaking, major coolant discharge Contact Service.
Black exhaust gas

ment
TIM-ID: 0000002542 - 003
Engine Overloaded Contact Service.
50 | Troubleshooting | MS150049/02E 2012-11

Blue exhaust gas
Engine oil Too much oil in engine Drain engine oil (→ Page 104).
Filter element in oil separator is clog‐ Replace (→ Page 78).
ged
Exhaust turbocharg‐ Faulty Contact Service.
er, cylinder head, pis‐
ton rings, cylinder lin‐
er
White exhaust gas

Engine Not at operating temperature Run engine to reach operating temper‐
ature.
Fuel system Water in fuel Drain fuel prefilter
Check fuel system.
Intercooler Leaking Contact Service.
TIM-ID: 0000002542 - 003

6.2 Fault messages from DDEC engine governor
The DDEC engine governor generates alarms which are indicated in different ways depending on the
equipment configuration:
• Two-digit flashing code
• Fault code and text on a display or PC screen
To facilitate troubleshooting without additional auxiliary equipment, the two-digit flash codes can be read
out from the DDEC by means of the vehicle-side alarm lamps CHECK ENGINE LIGHT (yellow) and
STOP ENGINE LIGHT (red).
Two switches (DIAGNOSTIC REQUEST) must be provided in the plant in this case. The first switch is
used for reading out the flash codes of the master DDEC unit, the second one to read out the receiver
DDEC unit. The flash-code signals from master and receiver are transmitted to the same alarm lamps.
Active codes: Inactive codes:
indicated by STOP ENGINE LIGHT (red) indicated by CHECK ENGINE LIGHT (yellow)
Activation of “FLASH-CODES”:
1. Set “IGNITION” switch to ON.C.
2. Actuate “DIAGNOSTIC REQUEST” switch of Master or Receiver.
3. Read-off codes.
4. Identify fault on the basis of the DDC fault code list.
Example:
Active code 23: Inactive code 34:
STOP ENGINE LIGHT lamp CHECK ENGINE LIGHT lamp
flashes: flashes:
Flashing phase 1 Flashing phase 2 Flashing phase 1 Flashing phase 2
ОО ООО ООО ОООО
2 x flash 3 x flash 3 x flash 4 x flash
There is a pause lasting 0.5 seconds between flashing phases 1 and 2. There is a pause of approx. 3
seconds on changing between active and inactive code.
Switch off the “DIAGNOSTIC REQUEST” and “IGNITION” switches to cancel “FLASH-CODE” indication.
The “IGNITION” switch may only be switched back on after a 30 sec. delay.
Precise fault diagnosis is, however, not possible using this method as any one flashing code may be
used to cover several different fault causes.
Detailed diagnosis is possible using the Diagnostic Data Reader (DDR) readout/programming unit.
The Diagnostic Data Reader (DDR) is used to:
• Read out DDEC electronics fault messages
• Change a limited scope of parameters
Active and inactive fault codes can be read out with the DDR via separate menus. Inactive fault codes
TIM-ID: 0000003162 - 002
stored in the governor can also be deleted.

Refer to the DDR device description for details of the range of features.
The DDR (part no. 5355383601/77) comprises:
• One Pro Link 9000 basic unit
• One cartridge to accommodate a PCMCIA plug-in circuit board (MPC cartridge)
• One PCMCIA plug-in circuit board
• One connecting cable
• An additional adapter cable is also required (part no. J 38500 60A)

Additional accessories:
• Printer (part no. J-38699) for direct connection to the DDR
• Spare paper (part no. J-38480-5) for the printer (5 rolls respectively)
The following information is available on reading out the fault codes with the DDR.
Example:
33 MID:128 Engine
TURBO BOOST SENSOR
INPUT VOLTAGE HIGH
▴ A1 PID: 102 FMI:3 ▾
Explanation:
• 33 → Flashing code
• MID: 128 →Information about the source of the fault message
• TURBO-BOOST-SENSOR-INPUT-VOLTAGE-HIGH → Fault text
• ▴ ▾ → more faults pending A= active, I= inactive
MID (Message Identification Character)
• Information about the source of the fault message:
MID 128 → Master
MID 175 → Receiver 1
MID 183 → Receiver 2
PID (Parameter Identification Character).
• Information to identify transmitted data: (e.g. engine speed, coolant temperature etc.)
PID 0-127 → 1 data byte
PID 128-191 → 2 data bytes
PID 192-253 → Variable
SID (Subsystem Identification Character)
• Information about the source of fault messages from subordinate systems which may be replaced as a
unit (e.g. injectors).
FMI (Failure Mode Identifier)
• Information about the type of fault which has occurred.
FMI 0 → Measured value above limit value (monitoring of TOO HIGH) example: Coolant temperature
FMI 1 → Measured value below limit value (monitoring of TOO LOW) example: Lube oil pressure
FMI 3 → Signal disrupted or signal above admissible measuring range (sensor failure)
FMI 4 → Signal short-circuited to (-) supply of sensor or signal below admissible measuring range
(sensor failure)
Flashi PID SID FMI Description Maintenance tasks
ng
code
11 187 4 Position sensor of variable Contact Service.
speed governor → voltage
too low.
11 187 7 Control system/ variable Contact Service.
TIM-ID: 0000003162 - 002
speed governor→ voltage

too high.
12 187 3 Position sensor of variable Contact Service.
speed governor → voltage
too high.

ng
code
13 111 4 Coolant level sensor, input 1. Check coolant condition
voltage too low. (→ Page 119).
2. Check coolant level, top up if
required (→ Page 112).
3. Check cabling.
4. Contact Service.
13 111 6 Sensor "Top up coolant", in‐ 1. Check coolant condition
put voltage too low. (→ Page 119).
3. Check cabling.
4. Contact Service.
14 52 3 Temperature sensor/inter‐ 1. Check cabling.
cooler, input voltage too
2. Contact Service.
high.
14 110 3 Coolant temperature sen‐ 1. Check cabling.
sor, input voltage too high.
2. Contact Service.
14 175 3 Oil temperature sensor, in‐ Contact Service.
put voltage too high.
15 52 4 Temperature sensor/inter‐ 1. Check cabling.
cooler, input voltage too
2. Contact Service.
low.
15 110 4 Coolant temperature sen‐ 1. Check cabling.
sor, input voltage too low.
2. Contact Service.
15 175 4 Oil temperature sensor, in‐ Contact Service.
put voltage too low.
16 111 3 Coolant level sensor, input 1. Check coolant condition
voltage too high. (→ Page 119).
3. Check cooler for dirt.
4. Check cabling.
5. Contact Service.
16 111 5 Sensor "Top up coolant", in‐ 1. Check cabling.
TIM-ID: 0000003162 - 002
2. Contact Service.
17 51 3 Throttle sensor, input volt‐ 1. Check cabling.
age too high.
2. Contact Service.
17 72 3 Blower bypass position, in‐ 1. Check cabling.
2. Contact Service.
17 354 3 Humidity sensor, electric 1. Check cabling.
circuit defective / high (ver‐
2. Contact Service.
sion 33.0 or later).

ng
code
age too low.
2. Contact Service.
18 72 4 Blower bypass position, in‐ 1. Check cabling.
2. Contact Service.
18 354 4 Humidity sensor, electric 1. Check cabling.
circuit defective / low (ver‐
2. Contact Service.
age too high.
2. Contact Service.
age too low.
2. Contact Service.
23 174 3 Fuel temperature sensor, 1. Check cabling.
input voltage too high.
2. Contact Service.
23 65 Oxygen concentration cir‐ 1. Check cabling.
cuit, input voltage too high.
2. Contact Service.
24 174 4 Fuel temperature sensor, 1. Check cabling.
2. Contact Service.
24 65 4 Oxygen concentration cir‐ 1. Check cabling.
cuit, input voltage too low.
2. Contact Service.
25 Reserved for “No Codes”. No troubleshooting.
26 25 11 Aux. shutdown 1 active. Contact Service.
26 61 11 Aux. shutdown 2 active. Contact Service.
27 105 3 Inlet elbow temperature 1. Check cabling.
sensor, input voltage too
2. Contact Service.
high.
27 171 3 Outside temperature sen‐ 1. Check cabling.
2. Contact Service.
27 172 3 Air temperature sensor, in‐ 1. Check cabling.
2. Contact Service.
28 105 4 Inlet elbow temperature 1. Check cabling.
2. Contact Service.
low.
28 171 4 Outside temperature sen‐ 1. Check cabling.
TIM-ID: 0000003162 - 002

2. Contact Service.
28 172 4 Air temperature sensor, in‐ 1. Check cabling.
2. Contact Service.
29 351 4 Circuit exhaust turbocharg‐ 1. Check cabling.
er inlet temperature defec‐
2. Contact Service.
tive / low (version 33.0 or
later).

ng
code
29 404 4 Temperature sensor/ ex‐ 1. Check cabling.
haust turbocharger outlet,
2. Contact Service.
input voltage too low (ver‐
31 51 3 Auxiliary output 3, open cir‐ Contact Service.
cuit (side "high") S3.
31 51 4 Auxiliary output 3, ground Contact Service.
short circuit (side "high")
S3.
31 51 7 Auxiliary output 3, fault in Contact Service.
mechanical system S3.
cuit (side "high") S3.
31 52 4 Auxiliary output 4, ground Contact Service.
short circuit (side "high")
T3.
31 52 7 Auxiliary output 4, fault in Contact Service.
mechanical system T3.
32 238 3 SEL, short circuit on battery 1. Check cabling.
circuit (plus).
2. Contact Service.
32 238 4 SEL, open circuit . 1. Check cabling.
2. Contact Service.
32 239 3 CEL, short circuit on battery 1. Check cabling.
circuit (plus).
2. Contact Service.
32 239 4 CEL, open circuit . 1. Check cabling.
2. Contact Service.
33 102 3 Charge pressure sensor, in‐ 1. Check cabling.
2. Contact Service.
34 102 4 Charge pressure sensor, in‐ 1. Check cabling.
2. Contact Service.
35 19 3 Oil pressure sensor upper 1. Check cabling.
level, input voltage too high.
2. Contact Service.
35 100 3 Oil pressure sensor, input 1. Check cabling.
voltage too low.
2. Contact Service.
TIM-ID: 0000003162 - 002
36 19 4 Oil pressure sensor upper 1. Check cabling.

2. Contact Service.
36 100 4 Oil pressure sensor, input 1. Check cabling.
voltage too low.
2. Contact Service.
37 18 3 Fuel pressure sensor upper 1. Check cabling.
2. Contact Service.
37 94 3 Fuel pressure sensor, input 1. Check cabling.
voltage too high.
2. Contact Service.

ng
code
37 95 3 Fuel differential pressure 1. Check cabling.
2. Contact Service.
high.
38 18 4 Fuel pressure sensor upper 1. Check cabling.
level, input voltage too low.
2. Contact Service.
38 94 4 Fuel pressure sensor, input 1. Check cabling.
voltage too low.
2. Contact Service.
38 95 4 Fuel differential pressure 1. Check cabling.
2. Contact Service.
low.
39 146 2 EGR system leaking, Contact Service.
charge-air pressure (ver‐
39 146 12 EGR system leaking, ex‐ Contact Service.
haust brake operation (ver‐
39 146 7 EGR valve does not re‐ Contact Service.
spond (version 33.0 or lat‐
er).
39 147 2 VNT nozzles do not re‐ Contact Service.
spond, charge-air pressure
(version 33.0 or later).
39 147 11 VNT nozzles at maximum, Contact Service.
exhaust brake operation
39 147 12 VNT nozzles do not re‐ Contact Service.
spond, brake pressure (ver‐
39 147 14 Exhaust gas recirculation Contact Service.
flow too low, VNT nozzles
do not respond, charge-air
pressure (version 33.0 or
later).
39 147 7 VNT vanes do not respond, Contact Service.
EGR (version 33.0 or later).
39 152 7 No signal from EGR valve 1. Check contamination indica‐
(version 29.0 or later). tor signal ring position
(→ Page 102).
TIM-ID: 0000003162 - 002
2. Contact Service.
39 153 7 VNT vanes do not respond, 1. Check contamination indica‐
(version 29.0 or later). tor signal ring position
(→ Page 102).
2. Contact Service.
41 21 0 Too many SRS (TRS miss‐ Contact Service.
ing).
42 21 1 Too few SRS (SRS miss‐ Contact Service.
ing).

ng
code
43 111 1 Coolant level too low. 1. Check coolant level, top up if
2. Contact Service.
44 52 0 Intercooler coolant temper‐ 1. Check coolant condition
ature too high. (→ Page 119).
3. Check intercooler for contam‐
ination.
4. Contact Service.
44 105 0 Inlet elbow temperature too 1. Check contamination indica‐
high. tor signal ring position
(→ Page 102).
2. Contact Service.
44 110 0 Coolant temperature too 1. Check coolant condition
high. (→ Page 119).
4. Contact Service.
44 172 0 Air inlet temperature too 1. Check contamination indica‐
high. tor signal ring position
(→ Page 102).
2. Contact Service.
44 175 0 Oil temperature too high. 1. Check engine oil level
(→ Page 103).
2. Contact Service.
105 14 Inlet elbow temperature: 1. Check contamination indica‐
power reduction. tor signal ring position
(→ Page 102).
2. Contact Service.
110 14 Coolant temperature: power 1. Check coolant condition
reduction. (→ Page 119).
TIM-ID: 0000003162 - 002

4. Contact Service.
45 19 1 High range: Oil pressure 1. Check engine oil level
too low. (→ Page 103).
2. Contact Service.
45 100 1 Oil pressure too low. 1. Check engine oil level
(→ Page 103).
2. Contact Service.

ng
code
46 168 1 ECM battery voltage too Contact Service.
low.
46 214 1 Real-time clock auxiliary Contact Service.
battery, voltage too low
46 232 1 Sensor supply voltage too Contact Service.
low.
47 18 0 High range: Fuel pressure Contact Service.
too high.
47 94 0 Fuel pressure too high. Contact Service.
47 102 0 Charge pressure too high. Contact Service.
47 106 0 Air inlet pressure too high. Contact Service.
47 164 0 Injection control pressure Contact Service.
too high.
48 18 1 High range: Fuel pressure 1. Check fuel prefilter.
too low.
2. Check fuel filter (→ Page 98).
3. Fill tank as necessary.
4. Contact Service.
48 94 1 Fuel pressure too low. 1. Check fuel prefilter.
2. Check fuel filter (→ Page 98).
3. Fill tank as necessary.
4. Contact Service.
48 106 1 Air inlet pressure too low. Contact Service.
too low.
48 351 1 Exhaust turbocharger inlet Contact Service.
temperature below range
48 404 1 Exhaust turbocharger outlet Contact Service.
temperature too low (ver‐
48 411 1 EGR OPD low (version 33.0 Contact Service.
or later).
48 412 1 EGR temperature too low Contact Service.
TIM-ID: 0000003162 - 002
48 154 1 EGR temperature too low. Contact Service.

48 155 1 EGR differential pressure Contact Service.
too low.
49 351 0 Temperature at exhaust tur‐ 1. Check contamination indica‐
bocharger inlet above range tor signal ring position
(version 33.0 or later). (→ Page 102).
2. Check exhaust system.
3. Contact Service.

ng
code
49 404 0 Temperature at exhaust tur‐ 1. Check contamination indica‐
bocharger outlet too high tor signal ring position
(version 32.0 or later). (→ Page 102).
2. Check exhaust system.
3. Contact Service.
404 14 TCO temperature- power Contact Service.
reduction.
51 351 3 Temperature sensor on ex‐ 1. Check cabling.
haust turbocharger inlet, cir‐
2. Contact Service.
cuit defective / high.
51 404 3 Temperature sensor on ex‐ 1. Check cabling.
haust turbocharger outlet,
2. Contact Service.
input voltage too high (ver‐
52 254 12 A/D conversion, fault. Contact Service.
53 253 2 Nonvolatile check sum er‐ Contact Service.
ror.
53 253 12 EEPROM write error. Contact Service.
53 253 13 Out of calibrated range. Contact Service.
54 84 12 Vehicle's speed sensor de‐ 1. Check cabling.
fect.
2. Contact Service.
55 216 14 Fault in another control unit Contact Service.
(version 27.0 or later). This
fault is stored in conjunction
with another fault in order to
indicate missing information
from another control unit .
55 231 12 Data link J1939, fault. Contact Service.
55 248 8 System-related data link, Contact Service.
fault (Master).
55 248 9 System-related data link Contact Service.
(Receiver).
58 92 0 Torque too high. Contact Service.
61 xxx 0 Reaction time injection noz‐ Contact Service.
TIM-ID: 0000003162 - 002
zle xxx too long.

62 26 3 Auxiliary output 1, short cir‐ Contact Service.
cuit on battery circuit (plus)
F3.
cuit F3.
62 26 7 Auxiliary output 1, mechani‐ Contact Service.
cal system does not re‐
spond correctly F3.

ng
code
A2.
cuit A2.
spond correctly A2.
W3.
cuit W3.
spond correctly W3.
X3.
cuit X3.
spond correctly X3.
Y3.
cuit Y3.
spond correctly Y3.
A1.
cuit A1.
TIM-ID: 0000003162 - 002
spond correctly A1.

63 57 0 PWM 1 above normal Contact Service.
range.
63 57 1 PWM 1 below normal Contact Service.
range.
63 57 3 PWM 1 short circuit on bat‐ Contact Service.
tery circuit (plus).
63 57 4 PWM 1 open circuit. Contact Service.

ng
code
range.
range.
range.
range.
range.
range.
64 103 0 Turbocharger speed too Contact Service.
high.
64 103 8 Exhaust turbocharger Contact Service.
speed sensor, input signal
faulty (irregular period).
65 51 0 Throttle position above nor‐ Contact Service.
mal range.
65 51 1 Throttle position below nor‐ Contact Service.
mal range.
65 51 2 Throttle position not regular. Contact Service.
65 51 7 Throttle does not respond. Contact Service.
65 107 3 Air filter differential pressure 1. Check cabling.
sensor, voltage too high.
2. Contact Service.
65 107 4 Air filter differential pressure 1. Check cabling.
sensor, voltage too low.
TIM-ID: 0000003162 - 002
2. Contact Service.
66 99 3 Oil filter differential pressure 1. Check cabling.
sensor, voltage too high.
2. Contact Service.
66 99 4 Oil filter differential pressure 1. Check cabling.
sensor, voltage too low.
2. Contact Service.
66 76 0 Engine knock level above Contact Service.
normal range.

ng
code
66 76 3 Knock sensor, input voltage Contact Service.
too high.
66 76 4 Knock sensor, input voltage Contact Service.
too low.
66 76 7 Knock sensor does not re‐ Contact Service.
spond.
67 20 3 Coolant pressure sensor, Contact Service.
high range (input voltage
too high).
high range (input voltage
too low).
67 106 3 Air inlet pressure sensor, in‐ Contact Service.
67 106 4 Air inlet pressure sensor, in‐ Contact Service.
input voltage too low.
68 230 5 Idle detection pedal travel Contact Service.
sensor (TPS), fault in circuit
(circuit disrupted).
68 230 6 Idle detection pedal travel Contact Service.
sensor (TPS), fault in circuit
(short-circuit to ground).
71 xxx 1 Reaction time injection noz‐ Contact Service.
zle xxx too short.
72 84 0 Vehicle's speed too high. Contact Service.
72 84 11 Vehicle's speed too high Contact Service.
(absolute).
72 65 0 Oxygen concentration too Contact Service.
high.
72 65 1 Oxygen concentration too Contact Service.
low.
73 107 0 Air filter differential pressure 1. Check contamination indica‐
too high. tor signal ring position
(→ Page 102).
TIM-ID: 0000003162 - 002
2. Contact Service.
73 77 0 Gas valve position above Contact Service.
normal range.
73 77 1 Gas valve position below Contact Service.
normal range.
73 77 3 Gas valve position input Contact Service.
voltage too high.

ng
code
73 77 4 Gas valve position input Contact Service.
voltage too low.
73 77 7 Gas dosing valve does not Contact Service.
respond.
73 151 14 ESS transmission, engaged Contact Service.
gear step jamming.
73 226 11 Transmission idling switch Contact Service.
defective, (ESS transmis‐
sion).
73 227 2 Analog auxiliary input: data Contact Service.
failing irregularly or defec‐
tive (ESS transmission).
73 227 3 Analog auxiliary input 1, Contact Service.
voltage too high (ESS
transmission).
73 227 4 Analog auxiliary input 1, Contact Service.
voltage too low (ESS trans‐
mission).
74 70 4 Optimized idle security Contact Service.
loop) ground short circuit.
74 99 0 Oil filter badly clogged. 1. Replace oil filter
(→ Page 107)
2. Contact Service.
75 168 0 ECM battery voltage too Contact Service.
high.
75 214 0 Real-time clock backup, Contact Service.
battery voltage too high
75 232 0 Sensor supply voltage too Contact Service.
high.
76 121 0 Engine overspeed with ex‐ Contact Service.
haust brake.
77 3 0 Cylinder head temperature Contact Service.
too high.
77 19 0 High range: oil pressure too Contact Service.
high.
77 20 0 High range: coolant pres‐ Contact Service.
sure too high.
TIM-ID: 0000003162 - 002
77 72 0 Blower bypass position too Contact Service.

high.
77 72 1 Blower bypass position too Contact Service.
low.
77 73 1 Fire pump pressure too low. Contact Service.
77 81 0 Exhaust back pressure too Contact Service.
high.

ng
code
77 81 1 Exhaust back pressure too Contact Service.
low.
77 81 3 Exhaust back pressure sen‐ Contact Service.
sor voltage too high.
77 81 4 Exhaust back pressure sen‐ Contact Service.
sor voltage too low.
77 81 12 Exhaust back pressure near Contact Service.
limit for power reduction.
77 95 1 Fuel filter differential pres‐ Contact Service.
sure too low.
77 99 1 Oil filter differential pressure Contact Service.
too low.
77 100 0 Engine oil pressure too Contact Service.
high.
77 102 1 Charge-air pressure too Contact Service.
low.
77 105 1 Inlet elbow temperature too Contact Service.
low.
77 107 1 Air filter differential pressure Contact Service.
too low.
77 108 0 Atmospheric pressure too Contact Service.
high.
77 108 1 Atmospheric pressure too Contact Service.
low.
77 109 0 Coolant pressure too high. Contact Service.
77 110 1 Coolant temperature too Contact Service.
low.
77 111 0 Coolant level too high. 1. Check engine coolant level
(→ Page 112).
2. Contact Service.
77 171 0 Outside temperature too Contact Service.
high.
77 171 1 Outside temperature too Contact Service.
low.
77 172 1 Intake air temperature too Contact Service.
low.
TIM-ID: 0000003162 - 002
77 174 0 Fuel temperature too high. Contact Service.

77 174 1 Fuel temperature too low. Contact Service.
77 175 1 Engine oil temperature too Contact Service.
low.
77 222 14 Theft protection faulty. Contact Service.
77 251 10 Clock module with irregular Contact Service.
alteration speed.
77 251 13 Clock module faulty. Contact Service.

ng
code
77 252 10 Clock module with irregular Contact Service.
alteration speed.
77 252 13 Clock module faulty. Contact Service.
77 354 0 Relative air humidity above Contact Service.
range (version 33.0 or lat‐
er).
77 354 1 Relative air humidity under Contact Service.
range (version 33.0 or lat‐
er).
77 446 0 Cylinder head temperature Contact Service.
above range (version 33.0
or later).
77 151 11 Maintenance display lamp, Contact Service.
faulty / service interval ex‐
ceeded (version 32.0 or lat‐
er).
78 86 14 Self-adaptive speed control Contact Service.
faulty (version 27.0 or later).
81 98 3 Oil level sensor, input volt‐ Contact Service.
age too high.
81 101 3 Crankcase pressure sen‐ Contact Service.
81 153 3 Crankcase pressure, input Contact Service.
voltage too high (version
27.0 or later).
high.
81 173 3 Exhaust temperature sen‐ Contact Service.
81 411 3 EGR OPD, circuit defec‐ Contact Service.
tive / high (version 33.0 or
later).
81 412 3 EGR temperature too high Contact Service.
81 129 3 Exhaust duct temperature Contact Service.
1, sensor voltage too high
TIM-ID: 0000003162 - 002


ng
code
81 154 3 EGR temperature, input Contact Service.
voltage too high.
81 155 3 EGR differential pressure, Contact Service.
TIM-ID: 0000003162 - 002

81 277 9 EGR mass flow, intelligent Contact Service.
sensor does not respond
81 277 12 EGR mass flow, intelligent Contact Service.
sensor failure (version 33.0
or later).
82 98 4 Oil level sensor, input volt‐ Contact Service.
age too low.

ng
code
sor, input voltage (version
27.0 or later).
low.
82 173 4 Exhaust temperature sen‐ Contact Service.
82 411 4 EGR OPD, sensor circuit Contact Service.
defective / low (version 33.0
or later).
82 412 4 EGR temperature too low Contact Service.
1, sensor voltage too low
TIM-ID: 0000003162 - 002


ng
code
82 154 4 EGR- temperature, input Contact Service.
voltage too high.
82 155 4 EGR differential pressure Contact Service.
input voltage too low.
82 412 9 EGR temperature, intelli‐ Contact Service.
gent sensor does not re‐
spond (version 33.0 or lat‐
er).
82 412 12 EGR temperature, intelli‐ Contact Service.
gent sensor failure (version
33.0 or later).
83 73 0 Pump pressure too high. Contact Service.
83 98 0 Oil level is too high. 1. Check engine oil level
(→ Page 103).
2. Contact Service.
83 101 0 Crankcase pressure too Contact Service.
high.
high (version 27.0 or later).
83 173 0 Exhaust temperature too Contact Service.
high.
83 411 0 EGR OPD, high (version Contact Service.
33.0 or later).
TIM-ID: 0000003162 - 002
83 412 0 EGR temperature too high Contact Service.


ng
code
TIM-ID: 0000003162 - 002

84 98 1 Oil level low. 1. Check engine oil level
(→ Page 103).
2. Contact Service.
low.

ng
code
84 153 1 Crankcase pressure too low Contact Service.
85 190 0 Engine speed too high. Contact Service.
85 190 14 Engine overspeed signal Contact Service.
86 73 3 Pump pressure sensor, in‐ Contact Service.
86 108 3 Atmospheric pressure sen‐ Contact Service.
87 73 4 Pump pressure sensor, in‐ Contact Service.
87 108 4 Atmospheric pressure sen‐ Contact Service.
88 20 1 High range: coolant pres‐ Contact Service.
sure too low.
88 109 1 Coolant pressure too low. Contact Service.
89 95 0 Fuel differential pressure Contact Service.
too high.
89 111 12 Coolant level, maintenance 1. Check engine coolant level
indication, fault. (→ Page 112).
2. Contact Service.
TIM-ID: 0000003162 - 002

7 Task Description
7.1 Engine
7.1.1 Engine – Barring manually
Preconditions
☑ Engine shut down and starting disabled.

Barring device F6555766 1
Adapter F6558528 1
Ratchet with extension F30006212 1
DANGER
Risk of serious injury – Danger to life!
• Before barring the engine, ensure that nobody is in the danger zone.
Barring the engine manually

1. Remove guard plate.
2. Install barring device (2) with adapter on the
flywheel housing in the 6 o'clock position.
3. Set ratchet (1) onto barring device (2).
4. Rotate crankshaft in engine direction of ro‐
tation. Apart from the normal compression
resistance, there should be no resistance.
5. Remove barring tool in reverse order.
TIM-ID: 0000002522 - 002
72 | Task Description | MS150049/02E 2012-11

7.1.2 Engine – Barring with starting system
DANGER
Risk of serious injury – Danger to life!
• Before barring the engine, ensure that nobody is in the danger zone.
Barring engine with starting system

1. Remove screws (1, 3) and take off perforat‐
ed plate (2).
2. Withdraw plug (5) from crankshaft angle

sensor for injection timing of any cylinder
(→ Page 23). For this purpose, unlock
latch (4).
3. Bar engine in unloaded condition: Press
START button.
Note: Interrupt engine start after maximum ten
seconds for thirty seconds to prevent starter
from overheating.
4. Let the crankshaft rotate until oil pressure is
indicated.
Note: If no oil pressure is indicated after three
start cycles, contact Service.
5. Slide connector (5) until lock (4) latches into
position.
6. Fit perforated plate (2) and secure with two
screws (1, 3).
TIM-ID: 0000002786 - 002
MS150049/02E 2012-11 | Task Description | 73

7.2 Cylinder Liner
7.2.1 Cylinder liner – Endoscopic examination
Preconditions
☑ Engine is stopped and starting disabled

Barring device F6555766 1
Ratchet with extension F30006212 1
Endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 89).
2. Remove injector (→ Page 92).
Positioning crankshaft at BDC

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

Findings Measure
• Thin carbon coating on carbon scraper ring No action required.
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits on entire circumference between top piston ring
and bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark on entire circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Dark areas with even or varying degrees of discoloration Further endoscopic examina‐
• Beginning and end of the discoloration are not sharply defined and tion required as part of main‐
do not cover the entire stroke area tenance work.
• Dark areas in the upper section of the cooling bore, remaining cir‐
cumference cannot be faulted
• Piston rings cannot be faulted
TIM-ID: 0000003304 - 004
• On the entire circumference, apart from light areas of discoloration Cylinder liner must be re‐
(do not impair operation) clearly darker stripes that start at the top placed; Service must be con‐
piston ring tacted.
• Heat discoloration in the direction of stroke and honing pattern dam‐
age
• Heat discoloration of piston rings

1. Compile endoscopy report using the table.
2. Use technical terms for description of the liner surface (→ Page 76).
3. Depending on findings:
• Do not take any action or
• carry out a further endoscopic examination as part of maintenance work or
• contact Service; cylinder liner must be replaced.
Final steps
1. Install injector (→ Page 92).
2. Install cylinder head cover (→ Page 89).
TIM-ID: 0000003304 - 004

7.2.2 Instructions and comments on endoscopic and visual examination of cylinder
liners
Terms used for endoscopic examination

Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐
nation report.
Findings Measure
Light scoring Minor dirt scores can occur during the assembly of a new engine (honing prod‐
ucts, particles, broken-off burrs). Removed cylinders clearly exhibit such scor‐
ing 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 lengths and depths next to one an‐
other. In most cases, they are found at the 6-o'clock and 12-o'clock positions
(inlet/exhaust) along the transverse engine axis.
Smoothened area Smoothened areas are changes to the running surface but almost the whole
honing pattern is still visible. Smoothened areas appear brighter and more bril‐
liant than the surrounding running surface.
Polished area Polished areas are on the running surface and show local removal of the hon‐
ing pattern. Grooves from the honing process are not visible any more.
New cylinder liners must be fitted in the following cases
Polished area:
covers more than 20% of the entire piston running surface,
covers more than 30° of the circumference and extends over more than 50%
of piston stroke,
is wider than 15 mm over the entire piston stroke.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐
perature differences around the liner. It appears rather darker within the honed
structure in contrast to the bright metallic running surface. The honing pattern
is undisturbed. Discolorations extend in stroke direction and may be interrupt‐
ed.
TIM-ID: 0000003285 - 003
Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves in
the overlap (open) position. They are clearly visible due to the dark color of the
honing groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear
discoloration from TDC to BDC in the running surface and the start of localized
damage to the honing pattern.
Cylinders with a number of black lines around the running surface have limited
service life and should be replaced.

Findings Measure
Discolorations (Heat) These are caused by a disturbance in the liner / ring tribosystem. Usually they
run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring
and becoming more visible from the second TDC-ring onwards and less pro‐
nounced from TDC-ring 1. The honing pattern is usually no longer visible and
displays a clearly defined (straight) edge to the undisturbed surface. The dam‐
aged surface is usually discolored. The circumferential length varies.
Liners with heat discoloration starting in the TDC-ring 1 have to be replaced.
Seizures, Seizure Seizure marks are of irregular circumferential length and depth. Can be
marks caused by either the piston skirt or the piston crown. Material deposits on the
liner (smears) show heavy discoloration and scoring.
Replace liner.
Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough in‐
vestigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid un‐
necessary disassembly work, it is recommended that another inspection be carried out after further oper‐
ation of the engine.
TIM-ID: 0000003285 - 003

7.3 Crankcase Breather
7.3.1 Crankcase breather – Filter element replacement
Preconditions

Engine oil
Filter insert (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Avoid contact with skin.
• Do not inhale oil vapor.
Crankcase breather (closed-circuit

crankcase ventilation) – Filter
element replacement
1. Loosen clamps (1), push rubber sleeves (2)
over pipe (3).
2. Release band clamp (4) with lever (6).
3. Remove cover (7).
4. Replace filter element (5).
5. Fit cover (7).
6. Operate lever (6) to tension clamping
band (4).
7. Push back rubber sleeve (2) and tighten
clamp (1).
8. Replace further filter elements in the same
way.
TIM-ID: 0000003532 - 003

Crankcase breather (open-circuit
crankcase ventilation) – Filter
element cleaning or replacement
1. Clean filter externally.
2. Release vent hose on oil separator cov‐
er (1) and remove.
3. Remove oil separator cover (1).
4. Loosen clamp (5).
5. Clean or replace filter element (2)
(→ Page 80).
6. Insert new sealing ring (3).
7. Install cleaned or new filter element (2) with
filter holder (5).
8. Mount oil separator cover (1).
9. Tighten nut of clamp (4) with torque wrench to specified tightening torque.
Nut Tightening torque (Engine oil) 9Nm +1Nm
10. Push vent hose onto oil separator cover (3) and bolt on.
11. Replace further filter elements (2) in the same way.
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7.3.2 Crankcase breather (open-circuit crankcase ventilation) – Filter element
cleaning
Preconditions
WARNING
Compressed air
Risk of injury!
CAUTION
Excessive reaction time of cleaning agents on components.
Clean filter element

1. Remove filter element (→ Page 78).
2. Clean filter element with cleaning agent.
3. Remove cleaner.
4. Blow out filter element thoroughly with compressed air.
5. Install filter element (→ Page 78).
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7.4 Running Gear
7.4.1 Grounding device – Check carbon brush
Preconditions

Cold cleaner (Hakutex 60) 50602
Carbon brush (→ Spare Parts Catalog)
WARNING
Compressed air
Risk of injury!
CAUTION
Unsuitable cleaning tool.
• Use appropriate cleaning tool.
Remove grounding assembly

1. Remove screws (1) with washers.
2. Remove grounding device (2) from flywheel
housing (3).
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Checking grounding device
Item Findings Measure
Carbon brush Damaged Fit new part (→ Page 83)
Wear limit 45 mm (new condition Fit new part (→ Page 83)
60mm)
Press carbon brush against
spring pressure
Spring broken, damaged Fit new part (→ Page 83)
Running surface on adapter contaminated, corroded Clean
Cleaning running surface on adapter

1. Clean running surface of carbon brushes on adapter with cold cleaner.
2. Remove stubborn deposits with soft brush.
3. Blow out adapter with compressed air.
Installing grounding device

1. Check mounting surface on flywheel housing for cleanness.
2. Install grounding device on flywheel housing and secure with screws.
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7.4.2 Grounding device – Carbon brush replacement
Preconditions

Loctite 270 40083
Carbon brush (→ Spare Parts Catalog) 2
Replace carbon brush

1. Loosen screw (5).
2. Disconnect cable (6) from screw (5).
3. Loosen screws (3).
4. Remove screws (2).
5. Remove carbon brush (1) from grounding
device (4).
6. Fit new carbon brush (1) in grounding de‐
vice (4).
7. Tighten screws (2) by hand.
8. Insert screws (3) as far as the stop and
tighten screws lightly.
9. Tighten screws (2).
Note: Apply Loctite 270 only to threads.
10. Secure cable (6) with screw (5).
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7.5 Valve Drive
7.5.1 Valve gear – Lubrication
Preconditions

Engine oil
Valve gear – Lubrication

1. Remove cylinder head covers (→ Page 89).
2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjust‐
ing screws with oil.
4. Install cylinder head covers (→ Page 89).
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7.5.2 Valve clearance – Check and adjustment
Preconditions
☑ Engine coolant temperature is max. 40°C.
☑ Valves are closed.

Feeler gauge Y20098771 1
Socket box wrench F30039526 1
Engine oil
Preparatory steps
2. Install barring device (→ Page 72).
3. Rotate crankshaft with barring device in en‐
gine direction of rotation until "TDC-A1"
mark and pointer are aligned.
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Diagram for 8V engines (two
crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve

I Inlet valve
X Exhaust valve

I Inlet valve
X Exhaust valve
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I Inlet valve
X Exhaust valve
Checking valve clearance at two crankshaft positions

1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet valves (long rocker arm) = 0.2 mm
• Exhaust valves (short rocker arm) = 0.5 mm
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as
per diagram.
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the set value exceeds 0.1mm, adjust valve clearance.
Adjusting valve clearance

1. Release locknut (1).
2. Insert feeler gauge (3) between valve
bridge and rocker arm.
3. Using Allen key, set adjusting screw (2) so
that the specified valve clearance is
reached.
4. Feeler gauge (3) must just pass through the
gap.
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5. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2)
to prevent it from turning.
Nut M16 x 1.5 Tightening torque (Engine oil) 90Nm +9Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.

Final steps
1. Remove barring device (→ Page 72).
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7.5.3 Cylinder head cover – Removal and installation
Preconditions

Gasket (→ Spare Parts Catalog)
Removing cylinder head cover

1. Clean very dirty cylinder head covers prior
to removal.
2. Remove screws.
3. Remove cylinder head cover with gasket
from cylinder head.
Installing cylinder head cover

1. Clean mating face.
2. Check condition of gasket, replace if necessary.
3. Place gasket and cylinder head cover on cylinder head.
4. Install cylinder head cover.
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7.6 Injection Pump / HP Pump
7.6.1 HP pump – Relief bore check
DANGER
WARNING
HP pump – Relief bore check

1. Check relief bore for oil and fuel discharge
by visual inspection.
2. If relief bore is contaminated, stop the en‐
gine, disable engine start, and clean relief
bore.
3. Note the following in case of fluid dis‐
charge:
• Heavy discharge means continuous dis‐
charge of fluids (leakage). Contact Serv‐
ice.
• Minor discharge of fluids up to 10 drops
per day is normal (moistening) and not
considered a leakage.
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7.7 Injection Valve / Injector
7.7.1 Injector – Replacement

Injector (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new injector (→ Page 92).
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7.7.2 Injector – Removal and installation
Preconditions

Installation and removal tool for injector F6790161 1
Milling cutter F30452739 1
Slotted screwdriver F30452578 1
Torque wrench, 1-20Nm F30044239
Assembly paste (Optimoly Paste White T) 40477 1
Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1
Engine oil
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
CAUTION
Removal of all injectors.
• Ensure that the high-pressure fuel accumulator is secured on the engine through two HP lines.
CAUTION
Cable damage during operation.
Fire hazard!
• Twist cables when installing.
• Ensure that cables do not touch components.
Preparatory steps
1. Close off fuel supply to engine.
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Removing injector
Note: Always replace the first and last injectors of
one engine side first. Replace the inner in‐
jectors only after the installation of the outer
injectors on this engine side is completed.
1. Release the cable terminal threaded con‐
nection (arrows) on the injector and remove
cable terminals.
2. Remove screw (2) and take off hold-down

clamp (1).
3. Remove high-pressure fuel line (5).
4. Install installation/removal device on the

cylinder head.
5. Remove injector with installation/removal
device.
6. Remove the installation/removal device.
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7. Remove sealing ring (1) from injector or use
a self-made hook to take it out of the cylin‐
der head.
8. Remove O-rings (2) from injector.
9. Cover all connections and installation
bores, or seal with suitable plugs.
Installing injector
1. Prior to installation, remove all blanking
plugs.
2. Coat injector with assembly paste in the
area of the nozzle retaining nut.
3. Fit new O-rings on injector and coat with
grease.
4. Fit new sealing ring with grease on injector,
observe installation position of sealing ring.
5. Clean sealing face on cylinder head and

protective sleeve with milling cutter.
6. Insert injector into cylinder head, making
sure that the HP line connections are
aligned correctly.
7. Push in the injector using the installation/re‐
moval device.
8. Remove the installation/removal device.
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9. Use slotted screwdriver to check thrust ring
at both line ends for secure seating.
10. Tighten loose thrust ring to the specified tightening torque.

Thrust ring Tightening torque 5Nm to 10Nm
11. Coat screw head mating face (2) and
thread with engine oil.
12. Fit hold-down clamp (1) in correct position by hand. Tighten screw (2) with torque wrench to the specified
initial tightening torque.
Screw M12 Preload torque (Engine oil) 5Nm to 10Nm
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13. Fit O-rings (4) and (6) on high-pressure fuel line (5) and coat with grease.
14. Tighten high-pressure fuel line (5) to the specified initial tightening torque.
HP line Preload torque (Engine oil) 5Nm to 10Nm
15. Tighten screw (2) to specified torque using a torque wrench.
Screw M12 Tightening torque 100Nm + 10Nm

16. Tighten union nut of adapter (limiting valve) with torque wrench to the specified tightening torque.
Union nut Tightening torque 140Nm + 10Nm
17. Tighten union nut of adapter (injector) with torque wrench to the specified tightening torque.
Union nut Tightening torque 120Nm +10Nm
18. Twist cable several times.
19. Insert cable lugs (arrows) underneath the screws on the injector and tighten screws with torque wrench
to the specified tightening torque.
Screw Tightening torque 1.5Nm
Final steps
2. Open up fuel supply to engine.
TIM-ID: 0000000952 - 009

7.8 Fuel System
7.8.1 Fuel system – Venting
Preconditions

Filling device B80144852 1
Diesel fuel
WARNING
• Do not smoke.
Venting LP fuel system

1. Connect filling device to connection (4).
2. Disconnect return line at connection (1).
3. Use hand pump to fill fuel system, providing
pressure of min. 0.5 bar / max. 2.0 bar, until
fuel emerges without bubbles at connec‐
tion (1).
4. Connect return line to connection (1).
5. Open vent plug (2) on filter housing (3).
6. Use hand pump to fill fuel system, providing
pressure of min. 0.5 bar / max. 2.0 bar, until
fuel emerges without bubbles at connec‐
tion (2).
7. Close threaded vent plug (2).
8. Remove filling device and seal connec‐
tion (4).
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7.9 Fuel Filter
7.9.1 Fuel filter – Replacement
Preconditions

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

1. Remove easy-change filter using the filter
wrench.
2. Clean sealing surface on filter head.
3. Slightly lubricate seal on the easy-change
filter (arrow).
4. Screw on the easy-change filter by hand
until the seal makes contact and tighten fin‐
ger-tight.
5. Replace further easy-change filters in the
same way.
6. Vent fuel system (→ Page 97).
TIM-ID: 0000004909 - 007

7.10 Charge-Air Cooling
7.10.1 Charge-air cooler – Check water drain for coolant leakage and absence of
restrictions
DANGER
WARNING
WARNING
Compressed air
Risk of injury!
Checking charge-air cooler water

drain for coolant leakage and
absence of restrictions
1. With the engine running check the drain
bore(s) on the right and left of the engine
for emerging air (at driving end). If no air
escapes:
• Clean condensate drain bore(s)
• Blow out with compressed air
2. If a large amount of coolant is continuously
discharged, the charge-air cooler is leaking.
Contact Service.
Emergency measures prior to engine start with a leaking charge-air cooler

1. Remove injectors (→ Page 92).
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2. Bar engine manually (→ Page 72).

3. Bar engine with starting system to blow out combustion chambers (→ Page 73).
4. Install injectors (→ Page 92).

7.11 Starting Equipment
7.11.1 Starter – Condition check
Preconditions
Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 140).
TIM-ID: 0000000905 - 017

7.11.2 Cold start system with ether injection – Check
Preconditions

Ether cartridge (→ Spare Parts Catalog)
DANGER
Cleaner is an explosive and poisonous substance.
Danger to life, major material damage!
• Wear goggles/facial protection.
• Only work in a well-ventilated room.
• Do not smoke.
Checking filling level and condition

of system
Note: After two successive starting trials with cold
start system, make next starting trial after
10 minutes only. If the next two staring trials
fail, contact Service.
1. If the indicator lamp on the relay module (5)
lights up, fit a new ether cartridge (1).
2. Check the condition of lines (2) and con‐
nections. If damage is found, contact Serv‐
ice.
3. Check the condition of electric lines (4) and
connections. If damage is found, contact
Service.
4. In case of system failure, check the fuses in
the fuse holder (3). If fuses are broken, con‐
tact Service.
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7.12 Air Intake
7.12.1 Service indicator – Check
See manufacturer's documentation.
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7.13 Lube Oil System, Lube Oil Circuit
7.13.1 Engine oil – Level check
Preconditions
Checking oil level prior to engine

start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to stop,
withdraw after approx. 10 seconds and
check oil level.
Note: After extended standstill, the oil level may
exceed the mark (1) by up to 2 cm. This
can be caused by oil flowing from e.g. oil fil‐
ter or heat exchanger back to the oil pan.
3. The oil level must reach mark (1) or exceed
mark (1) by up to 2 cm.
4. Top up with oil to mark (1) as necessary
(→ Page 104).
5. Insert oil dipstick into guide tube up to the
stop.
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 oil dipstick into guide tube up to stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between marks (1) and (2).
4. Top up with oil to mark (1) as necessary (→ Page 104).
5. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000000931 - 010

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

Ratchet adapter F30027341 1
Engine oil
Sealing ring (→ Spare Parts Catalog)
WARNING
Hot oil.
Procedure without pump: Draining oil at drain plug(s) on oil pan

1. Provide a suitable container in which to collect the engine oil.
2. Remove drain plug(s) and drain engine oil.
3. Install drain plug(s) with new sealing ring.
Procedure with pump: Extracting engine oil

1. Provide a suitable container in which to collect the engine oil.
2. Extract all oil from oil pan using the pump.
Draining residual oil from

equipment carrier (only with
unscheduled engine oil change)
1. Provide a suitable container in which to col‐
lect the engine oil.
2. Remove drain plug (1) and drain oil (ap‐
prox. 7 liters) from oil heat exchanger and
oil filter.
TIM-ID: 0000006152 - 008
3. Remove drain screws (2) and (3) and drain

engine oil:
• (2) approx. 12 liters
• (3) approx. 5 liters
4. Install drain screws(s) with new sealing
ring.

5. Tighten drain screws (2) and (3) with torque wrench to the specified torque.
Screw M26 x 1.5 Tightening torque (Engine oil) 100Nm +10Nm
Filling with new engine oil

1. Open cover on filler neck.
2. Pour oil in at filler neck up to "max." mark at
oil dipstick.
3. Close cap on filler neck.
4. Check engine oil level (→ Page 103).
TIM-ID: 0000006152 - 008

7.13.3 Engine oil – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
Hot oil.
WARNING
Engine oil – Sample extraction and

analysis
1. With the engine running at operating tem‐
perature, open screw (1) on flange of centri‐
fugal 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 oil for:
• Dispersing capacity (spot test);
• Water content;
TIM-ID: 0000000956 - 004
• Fuel dilution.

7.14 Oil Filtration / Cooling
7.14.1 Engine oil filter – Replacement
Preconditions

Engine oil
Engine oil filter (→ Spare Parts Catalog)
WARNING
Hot oil.
Replacing engine oil filter

1. Remove engine oil filter using the filter
wrench.
2. Clean the sealing surface on the connecting
piece.
Note: Use only oil filters with integrated safety
valve.
3. Check condition of the new oil filter sealing
ring and coat it with engine oil.
4. Screw on and tighten new engine oil filter
by hand.
5. Replace other engine oil filters in the same
way.
6. Check engine oil level (→ Page 103).
7. After oil change and oil filter replacement,
bar engine with starting system
(→ Page 73).
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7.14.2 Oil indicator filter – Check
Preconditions

Cleaner (Snow-White 11-0) 40460 1
Cleaner (Hakupur 312) 30390 1
Engine oil
Strainer (→ Spare Parts Catalog)
Square-section ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
Compressed air
Risk of injury!
CAUTION
Unsuitable cleaning tool.
• Use appropriate cleaning tool.
Removing strainer
1. Clean oil indicator filter before disassem‐
bling it.
2. Remove screws (1).
3. Take off cover (2) with O-ring (3).
4. Remove strainer (5) from housing and allow
oil to drip into container.
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Cleaning strainer
1. Shake coarse contamination out of strainer (5).
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
3. Use a soft brush to remove stubborn deposits from strainer if required. Ensure that the mesh is not dam‐
aged.
4. Blow out strainer (5) with compressed air from inside.
Checking strainer
Item Findings Action
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Contact Service.
Strainer Damaged Fit new part
Square-section ring Damaged Fit new part
O-ring Damaged Fit new part
Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Insert strainer into housing.
3. Fill housing with new engine oil.
4. Coat O-ring (3) with engine oil and fit in filter housing.
5. Fit cover (2) and secure with screws (1) and washers.
TIM-ID: 0000036227 - 002

7.14.3 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions

Torque wrench, 6-50 Nm F30027336 1
Cold cleaner (Hakutex 60) 50602 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
Compressed air
Risk of injury!
TIM-ID: 0000000958 - 005

Centrifugal oil filter – Cleaning and
filter sleeve replacement
1. Undo screw (1) and remove.
2. Remove clamp (3) and take off hood (2).
3. Carefully remove rotor (5) from housing.
4. Hold rotor assembly (5) firmly in position
with filter wrench and undo knurled nut (7).
5. Take off rotor cap (8).
6. Remove filter sleeve (9), stiffener plate (10)
and sealing ring (11).
7. Measure thickness of oil residues on filter
sleeve.
8. If maximum layer thickness of oil residue
exceeds 30 mm, shorten maintenance in‐
terval.
9. Remove standpipe (12) from lower rotor
section (13).
10. Wash hood (2), rotor cap (8), stiffener
plate, (10) standpipe (12), rotor lower sec‐
tion (13) and nozzles (14) with cold cleaner
and blow out with compressed 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 ro‐
tor cap (8).
14. Check sealing ring (11), replace if necessa‐
ry. Coat sealing ring with grease and insert
in groove of rotor cap (8).
15. Place rotor cap (8) onto standpipe (12).
16. Hold rotor assembly (5) firmly in position
with filter wrench and tighten knurled
nut (7).
17. Lubricate bearings of rotor (5) with oil, 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: 0000000958 - 005
Clamp Tightening torque 6 Nm + 1 Nm

Screw Tightening torque 6 Nm + 1 Nm

7.15 Coolant Circuit, General, High-Temperature Circuit
7.15.1 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
• Let the engine cool down.
Checking engine coolant level at filler neck:

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

remote cooler:
1. Check engine coolant level (coolant must
be visible at marker plate).
2. Top up engine coolant if necessary
(→ Page 115).
3. Check and clean breather valve.
4. Place breather valve on filler neck and
close.
Checking engine coolant level via level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up engine coolant if necessary (→ Page 115).
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7.15.2 Engine coolant – Change

Coolant
Engine coolant – Change

1. Drain engine coolant (→ Page 114).
2. Fill with engine coolant (→ Page 115).
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7.15.3 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide a suitable receptacle to catch the coolant.
2. Switch off preheating unit.
Draining engine coolant

1. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pres‐
sure to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off separated corrosion inhibitor oil in expansion tank through the filler neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• HT coolant pump elbow;
• At crankcase, A and B sides
• At the preheating unit
5. Close all open drain points.
6. Position breather valve on filler neck and
close.
Final steps
u Switch on preheater.
TIM-ID: 0000000936 - 004

7.15.4 Engine coolant – Filling
Preconditions

Engine coolant
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first
stop and allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
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Filling with coolant using a pump
1. Connect appropriate pump with hose to
drain valve.
2. Open drain valve and pump coolant into en‐
gine at 0.5 bar minimum.
3. Fill expansion tank until overflow edge is
reached.
4. Close drain valve.
5. Check proper condition of breather valve
and clean sealing faces if required.
close.
7. Start engine (→ Page 42).
8. After 10 seconds of running the engine
without load, shut down the engine
(→ Page 44).
9. Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first
stop and allow pressure to escape.
11. Check coolant level (→ Page 112) and top
up engine coolant as required:
a) Fill in coolant in expansion tank until the
coolant level at top edge of filler neck
remains constant.
b) Place breather valve on filler neck and
close.
c) Repeat the steps from "Start engine"
(→ Step 7) until coolant is no longer
needed to be topped up.
d) Disconnect pump and hose.
Filling with coolant through filler neck

1. Alternatively: Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck
remains constant.
2. Check proper condition of breather valve and clean sealing faces if required.
3. Set breather valve onto filler neck and turn until the first stop.
5. After 10 seconds of running the engine without load, shut down the engine (→ Page 44).
6. Turn breather valve counterclockwise and remove.
7. Check coolant level (→ Page 112) and top up engine coolant as required:
a) Repeat the steps from "Start engine" (→ Step 4) until coolant is no longer needed to be topped up.
b) Check proper condition of breather valve and clean sealing faces if required.
c) Place breather valve on filler neck and close.
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Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 112) and top up engine coolant as required.

7.15.5 Engine coolant pump – Relief bore check
DANGER
WARNING
Check relief bore of engine coolant

pump
1. Check relief bore for oil and coolant dis‐
charge.
2. Stop engine (→ Page 44) and disable en‐
gine start, observe general safety instruc‐
tions for maintenance and repair.
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.
4. If discharge exceeds the specified limits:
Contact Service.
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7.15.6 Coolant filter – Replacement
Preconditions

Engine oil
Coolant filter (→ Spare Parts Catalog)
WARNING
Replacing coolant filter

1. Close shutoff cocks (1).
2. Remove coolant filter (2) with filter wrench.
3. Clean the sealing surface on the connecting
piece.
4. Coat seal on new coolant filter with engine
oil.
5. Screw on coolant filter and tighten hand-
tight.
6. Open shutoff cocks (1).
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7.15.7 Engine coolant – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
WARNING
Engine coolant – Sample extraction

and analysis
1. With the engine running, open drain
valve (1).
2. Flush sample-extraction point by draining
approx. 1 liter coolant.
3. Drain approx. 1 liter coolant into a clean
container.
4. Close drain valve (1).
5. Using the equipment and chemicals of the
MTU test kit, check the coolant for:
• Antifreeze concentration
• Corrosion inhibitor concentration
• pH value.
6. For engine coolant change intervals,
(→ MTU Fluids and Lubricants Specifica‐
TIM-ID: 0000000938 - 007
tions (A001061/..)).

7.16 Low-Temperature Circuit
7.16.1 Charge-air coolant – Level check
Preconditions
WARNING
Checking charge-air coolant level

at filler neck:
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
3. Check coolant level (coolant must be visible
at marking plate).
4. Top up coolant if necessary (→ Page 123).
5. Check proper condition of breather valve,
clean sealing faces if required.
6. Fit breather valve and close it.
Checking charge-air coolant level by means of level sensor:

1. Switch on engine control system and check display (coolant level is automatically monitored by engine
control system).
2. Top up coolant if necessary (→ Page 123). TIM-ID: 0000000042 - 007

7.16.2 Charge-air coolant – Change

Coolant
Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 122).
2. Fill with charge-air coolant (→ Page 123).
TIM-ID: 0000000041 - 011

7.16.3 Charge-air coolant – Drainage
Preconditions

WARNING
Draining charge-air coolant

1. Provide a suitable receptacle to catch the
coolant.
2. Turn breather valve of coolant expansion
tank counterclockwise until the first stop
and allow pressure to escape.
4. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
5. Open drain valves and/or drain plugs and
drain coolant at the following points:
• at the LT coolant pump
• at the coolant lines to and from the
charge-air cooler
6. Draining of residual coolant:

• at charge-air cooler
7. Close all drain valves and screw in drain
screws with new sealing rings.
close.
TIM-ID: 0000007023 - 004

7.16.4 Charge-air coolant – Filling
Preconditions

Coolant
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
2. Turn breather valve counterclockwise and
remove.
TIM-ID: 0000007013 - 003

Filling with coolant using a pump
1. Connect a suitable pump with a hose to the
drain valve (arrowed).
2. Open vent on intercooler (arrow).

3. Open drain valve and pump coolant into en‐
gine at 0.5 bar minimum.
4. Close venting point when coolant emerges.
5. Fill expansion tank up to overflow.
6. Close drain valve.
close.
(→ Page 44).
remove.
up coolant as required:
a) Top up with coolant via expansion tank
until the coolant level is constant at the
overflow.
close.
14. Repeat the steps from "Start engine"
(→ Step 9) until coolant is no longer needed
to be topped up.
TIM-ID: 0000007013 - 003
15. Disconnect pump and hose.

Alternatively: Filling coolant
through filler neck
1. Remove plug screws from filling points (ar‐
rows) on coolant lines from and to the inter‐
cooler.
2. Open air bleed on the intercooler (arrow).

3. Fill coolant via the filling points on the cool‐
ant lines to and from the intercooler and via
the expansion tank up to the overflow.
4. Close venting point when coolant emerges.
5. Install plug screws of filling points with new
sealing rings.
7. Set breather valve onto filler neck and turn
to the first stop.
(→ Page 44).
remove.
up coolant as required:
a) Top up with coolant via expansion tank
until the coolant level is constant at the
overflow.
close.
12. Repeat the steps from "Start engine"
(→ Step 8) until coolant is no longer needed
to be topped up.
Final steps
TIM-ID: 0000007013 - 003
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 120) and top up coolant as required.

7.16.5 Charge-air coolant pump – Relief bore check
DANGER
WARNING
Checking relief bore on charge-air

coolant pump
1. Check relief bore for oil and coolant dis‐
charge.
2. Stop engine (→ Page 44) and disable en‐
gine start, observe general safety instruc‐
tions for maintenance and repair.
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.
4. If discharge exceeds the specified limits:
Contact Service.
TIM-ID: 0000000964 - 004

7.17 Engine Mounting / Support
7.17.1 Engine mounting – Check
Engine mounting – Check

Visually inspect mounts. • Damage Replace (contact Service).
• Brittleness
• Deformation
• Crack formation
• Swelling
visible
TIM-ID: 0000015370 - 004

7.18 Belt Drive
7.18.1 Drive belt – Condition check
Preconditions
☑ Guard is removed.
Drive belt – Condition check

Drive belt A Singular cracks None
Drive belt Belt is oily, shows signs of over‐ Replace (→ Page 133)
heating
Drive belt B Cracks on entire circumference
Drive belt C Chunking
TIM-ID: 0000000920 - 010

7.19 Battery-Charging Generator
7.19.1 Battery-charging generator – Condition check
Preconditions
Battery-charging generator – Condition check

1. Check if securing screws of battery-charging generator fit firmly.
2. Tighten any loose threaded connections.
3. Check wiring (→ Page 140).
TIM-ID: 0000007427 - 001

7.19.2 Battery-charging generator – Check
Preconditions
WARNING
Compressed air
Risk of injury!
Checking battery-charging generator

Item Findings Measure
Ventilation area (arrow) Clean None
Ventilation area (arrow) Contaminated Clean
Cleaning battery-charging generator

Note: Dry-clean battery-charging generator only.
1. Remove coarse dirt from battery-charging generator.
2. Blow out ventilation area (arrow) with compressed air until all dust is cleared.
TIM-ID: 0000007378 - 004

7.19.3 Battery-charging generator – Removal and installation
Preconditions

WARNING
Heavy object.
Risk of crushing!
• Use appropriate lifting devices and appliances.
Removing battery-charging generator

1. Remove protective cover.
2. Mark electric cables on battery-charging generator and remove.
3. Protect all cables from damage.
4. Slacken screws (2) and (3) by half a turn.
5. Mount socket or box wrench on screw (4)
and press belt tensioner in direction of ar‐
row as far as the stop.
6. Tighten screw (2).
7. Remove drive belt (1).
TIM-ID: 0000007425 - 005

8. Release screws (arrow).
9. Remove battery-charging generator (1).
10. Clean battery-charging generator (1) thor‐
oughly (→ Page 130).
11. Install battery-charging generator (1) follow‐
ing reverse sequence of working steps.
Tensioning drive belt

1. Fit drive belt.
2. Slacken screw (2) by half a turn.
Result: Belt tensioner moves against the drive belt
and tensions it.

Screw M10x1.5 Tightening torque 60Nm +5Nm
4. Tighten screw (1) with torque wrench to the specified tightening torque.
Screw M10x1.5 Tightening torque 42Nm
TIM-ID: 0000007425 - 005
5. Install protective cover.

6. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 135).

7.19.4 Battery-charging generator – Drive belt and belt tensioner replacement
Preconditions

Drive belt (→ Spare Parts Catalog)
Belt tensioner (→ Spare Parts Catalog) 1
WARNING
Heavy object.
Risk of crushing!
• Use appropriate lifting devices and appliances.
Replacing drive belt and belt tensioner

3. Mount socket or box wrench on screw (1)
and press belt tensioner in direction of ar‐
row as far as the stop.
4. Tighten screw (3).
5. Remove drive belt.
6. Screw on screw (2) and replace belt ten‐
sioner.
7. Fit new drive belt.
Tensioning drive belt

TIM-ID: 0000007421 - 007
1. Slacken screw (3) by half a turn.

Result: Belt tensioner moves against the drive belt and tensions it.

5. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 135).
TIM-ID: 0000007421 - 007

7.19.5 Battery-charging generator – Drive belt tension adjustment
Preconditions

WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
Adjusting belt tension

Result: Belt tensioner moves against the drive belt
and tensions it.

TIM-ID: 0000007386 - 004


7.20 Fan Drive
7.20.1 Fan drive – Adjust and check drive belt tension
Preconditions

Optibell 2 belt tension tester Y4345711 1
Preparatory steps
2. Check belt condition visually (→ Page 128).
Result: Measure for drive replacement (→ Page 138).
Check V-belt tension – fan coupling

Rockford S270
1. Switch on belt tension tester.
2. Hold measuring tip of belt tension tester
over belt drive. Tap drive belt (arrow) with a
suitable tool.
3. Hold belt tension tester over belt drive until
the measured value is indicated.
Initial assembly at MTU Initial operation with fan Belt tension adjustment
- 60Hz ± 1Hz 52Hz ± 1Hz
TIM-ID: 0000040791 - 002

Adjusting drive belt tension
1. Release screws (2) until fan coupling can
be moved.
2. Tighten stud (1) until the required frequency
is achieved.
3. Tighten screws (2) to specified tightening torque.

Screw M12x60 Tightening torque 100Nm +10Nm
TIM-ID: 0000040791 - 002

7.20.2 Fan drive – Drive belt replacement
Preconditions

Drive belt (→ Spare Parts Catalog)
Preparatory steps
2. Remove fan.
Replacing drive belt

1. Release screws (2).
2. Slacken off stud (1) until drive belt can be
removed.
3. Clean belt pulleys.
4. Fit new drive belt on belt pulleys, ensuring
that it is not under tension.
5. Adjust belt tension (→ Page 136).
TIM-ID: 0000007457 - 004

7.21 Auxiliary PTO
7.21.1 Compressor – Check
Preconditions
WARNING
Compressed-air pipes may still be under pressure, although the shut-off valve is closed.
Risk of injury!
• Before starting work, release pressure from pipework.
Checking compressor
1. Check oil supply line (3) and connections
for condition and leaks.
2. Check coolant lines (1) and connections for
condition and leaks.
3. Check air intake line (2) and connections
for condition and leaks.
4. Check compressor (4) for leaks.
5. If damage or leaks are found, contact Serv‐
ice.
TIM-ID: 0000007722 - 002

7.22 Wiring (General) for Engine/Gearbox/Unit
7.22.1 Engine wiring – Check
Preconditions

Isopropyl alcohol X00058037 1
Engine wiring – Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check that cable ties are firm, tighten loose cable ties.
4. Replace faulty cable ties.
5. Visually inspect the following electrical line components for damage:
• connector housings;
• contacts;
• sockets;
• cables and terminals;
• plug-in contacts.
6. (→ Contact Service) if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
8. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 018

7.23 Accessories for (Electronic) Engine Governor / Control
System
7.23.1 DDEC and connectors – Cleaning
Preconditions

Isopropyl alcohol
DANGER
Cleaner is an explosive and poisonous substance.
Danger to life, major material damage!
• Wear goggles/facial protection.
• Only work in a well-ventilated room.
• Do not smoke.
DDEC and connectors – Cleaning

1. Remove coarse dirt from housing surface
using a cloth moistened with isopropyl alco‐
hol.
2. Remove dirt from surface of connectors (1),
connector sockets and shrink sleeves (2)
using a cloth moistened with isopropyl alco‐
hol.
3. Check legibility of cable labels.
• Clean or replace illegible labels.
TIM-ID: 0000008476 - 001

Cleaning severely contaminated
connectors on DDEC
1. Disconnect connectors on both sides of
DDEC. For this purpose, withdraw connec‐
tors (1).
2. Unscrew connectors (3).
3. Remove covers (2).
4. Clean connector housings, connector sock‐
et housings and all contacts with isopropyl
alcohol.
5. When connectors, sockets and all contacts
are dry: Install connectors and check plug-
in connection on DDEC (→ Page 143).
TIM-ID: 0000008476 - 001

7.23.2 DDEC – Checking plug-in connections
Preconditions
Checking plug-in connections on

DDEC
1. Check all plug-in connections on both sides
of DDEC for secure seating.
2. Slide connectors (1) on until they latch into
position.
3. Screw in connectors (3) securely.
4. Seal non-assigned connector bases with
covering caps (2).
5. If plug-in connection is defective, contact
Service.
TIM-ID: 0000008478 - 001

8 Appendix A
8.1 Abbreviations
Abbre‐ Meaning Explanation

viation
A/D Analog/Digital Transformer: transforms sensor voltages into nu‐
meric values
ADEC Advanced Diesel Engine Controller Engine management system
AFRS Air Filter Restriction Sensor
ANSI American National Standards Institute Association of American standardization organiza‐
tions
ATL Abgasturbolader Exhust turbocharger (ETC)
ATS Air Temperature Sensor
BR Baureihe Series
BV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, publica‐
tion No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Setting of drift compensation in engine governor
with DiaSys
CEL Stop engine light 1st function: Warning lamp (rectify fault as soon as
possible)
2nd function: Read out fault codes
CKT Circuit
CLS Coolant level sensor
CPS Coolant pressure sensor
CTS Coolant temperature sensor
DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel
DDL Diagnostic Data Link
DDR Diagnostic Data Reader
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards
(DIN = “Deutsche Industrie-Norm”)
DL Default Lost Alarm: Default CAN bus failure
DOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel particu‐
late filter
DPF Diesel particulate filter
TIM-ID: 0000000858 - 010
DT Diagnostic Tool
ECM Electronic Control Module Electronic control unit of the DDEC system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EE‐ Electrically Erasable Programmable Read
PROM Only Memory
EFPA Electronic Foot Pedal Assembly
EGR Exhaust Gas Recirculation
144 | Appendix A | MS150049/02E 2012-11

viation
EMU Engine Monitoring Unit
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
EUI Electronic Unit Injector
FPS Fuel Pressure Sensor
FRS Fuel Differential Pressure Sensor
FTS Fuel Temperature Sensor
FWCP Fire Water Control Panel
GND Ground
HP High pressure
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum
limit value
HT High Temperature
IDM Interface Data Module Memory module for interface data
INJ Injector
ISO International Organization for Standardi‐ International umbrella organization for all national
zation standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO
1204
LED Light Emitting Diode
LO Low Alarm: Measured value lower than 1st minimum
limit value
LOLO Low Low Alarm: Measured value lower than 2nd minimum
limit value
LSG Limiting Speed Governor
N/A Not Applicable
LP Low pressure
OEM Original Equipment Manufacturer
OI Optimized Idle
OLS Oil Level Sensor
OPS Oil pressure sensor
OTS Oil Temperature Sensor
OT Oberer Totpunkt Top dead center (TDC)
PAN Panel Control panel
TIM-ID: 0000000858 - 010
PIM Peripheral Interface Module

PWM Modulated signal
P-xyz Pressure-xyz Pressure measuring point, xyz specifies the meas‐
uring point designation
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
MS150049/02E 2012-11 | Appendix A | 145

viation
SEL Stop engine light 1st function: Warning lamp (stop engine and rectify
fault)
2nd function: Read out fault codes
SID System Identifier
SRS Synchronous Reference Sensor TDC cylinder 1
SS Safety System Safety system alarm
TBS Turbocharger Boost Sensor Monitors charge-air pressure
TCI Turbo Compressor Inlet
TCO Turbo Compressor Outlet
TD Transmitter Deviation Alarm: Deviation in transmitter values
TPS Throttle Position Sensor
TRS Timing Reference Sensor
T-xyz Temperature-xyz Temperature measuring point, xyz specifies the
measuring point designation
UT Unterer Totpunkt Bottom dead center (BDC)
VNT Variable nozzle turbine
VSG Variable-speed governor
VSS Vehicle Speed Sensor
WZK Werkzeugkatalog Tool Catalog
TIM-ID: 0000000858 - 010
146 | Appendix A | MS150049/02E 2012-11

8.2 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you
– either during operation, for preventive maintenance, corrective work in case of malfunction or changed
operating conditions, or for spare parts supply.
Your contact at Headquarters: Service-support@mtu-online.com
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
Phone: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 014
MS150049/02E 2012-11 | Appendix A | 147

9 Appendix B
9.1 Special Tools
Adapter
Part No.: F6558528
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 72)
Barring device
Part No.: F6555766
Qty.: 1
Qty.: 1
Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page
74)
Cold cleaner (Hakutex 60)

Part No.: 50602
Qty.:
Used in: 7.4.1 Grounding device – Check carbon brush (→ Page
81)
Endoscope
Part No.: Y20097353
Qty.: 1
74)
DCL-ID: 0000017488 - 004
148 | Appendix B | MS150049/02E 2012-11

Feeler gauge
Part No.: Y20098771
Qty.: 1
Used in: 7.5.2 Valve clearance – Check and adjustment (→ Page
85)
Filling device
Part No.: B80144852
Qty.: 1
Used in: 7.8.1 Fuel system – Venting (→ Page 97)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.9.1 Fuel filter – Replacement (→ Page 98)
Qty.: 1
Used in: 7.14.1 Engine oil filter – Replacement (→ Page 107)
Qty.: 1
Used in: 7.14.3 Centrifugal oil filter – Cleaning and filter sleeve
replacement (→ Page 110)
Qty.: 1
Used in: 7.15.6 Coolant filter – Replacement (→ Page 118)
Installation and removal tool for injector

Part No.: F6790161
Qty.: 1
Used in: 7.7.2 Injector – Removal and installation (→ Page 92)
DCL-ID: 0000017488 - 004
MS150049/02E 2012-11 | Appendix B | 149

Milling cutter
Part No.: F30452739
Qty.: 1
MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 7.13.3 Engine oil – Sample extraction and analysis (→
Page 106)
Qty.: 1
Used in: 7.15.7 Engine coolant – Sample extraction and analysis
(→ Page 119)
Optibell 2 belt tension tester

Part No.: Y4345711
Qty.: 1
Used in: 7.20.1 Fan drive – Adjust and check drive belt tension
(→ Page 136)
Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 7.13.2 Engine oil – Change (→ Page 104)
DCL-ID: 0000017488 - 004
150 | Appendix B | MS150049/02E 2012-11

Ratchet adapter
Part No.: F30027339
Qty.: 1
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 7.19.3 Battery-charging generator – Removal and in‐
stallation (→ Page 131)
Qty.: 1
Used in: 7.19.4 Battery-charging generator – Drive belt and belt
tensioner replacement (→ Page 133)
Qty.: 1
Used in: 7.19.5 Battery-charging generator – Drive belt tension
adjustment (→ Page 135)
Ratchet with extension

Part No.: F30006212
Qty.: 1
Qty.: 1
74)
Slotted screwdriver
Part No.: F30452578
Qty.: 1
DCL-ID: 0000017488 - 004
MS150049/02E 2012-11 | Appendix B | 151

Socket box wrench
Part No.: F30039526
Qty.: 1
85)
Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 4.7 Plant cleaning (→ Page 46)
Torque wrench, 1-20Nm

Part No.: F30044239
Qty.:

Part No.: F30452769
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)
Qty.: 1
Used in: 1.5 Crankshaft transport locking device – For transport
with flanged-on generator (→ Page 11)
Qty.: 1
Used in: 7.3.1 Crankcase breather – Filter element replacement
(→ Page 78)
Qty.: 1
DCL-ID: 0000017488 - 004
Qty.: 1
152 | Appendix B | MS150049/02E 2012-11

Part No.: F30026582
Qty.: 1
Used in: 7.19.4 Battery-charging generator – Drive belt and belt
tensioner replacement (→ Page 133)
Qty.: 1
Used in: 7.19.5 Battery-charging generator – Drive belt tension
adjustment (→ Page 135)

Part No.: F30027337
Qty.: 1
Used in: 7.13.2 Engine oil – Change (→ Page 104)
Torque wrench, 6-50 Nm

Part No.: F30027336
Qty.: 1

Part No.: F30452768
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)
Qty.: 1
Used in: 1.5 Crankshaft transport locking device – For transport
DCL-ID: 0000017488 - 004
with flanged-on generator (→ Page 11)

Qty.: 1
85)
Qty.: 1
Qty.: 1
MS150049/02E 2012-11 | Appendix B | 153

9.2 Index
A D
Abbreviations 144 DDEC and connectors – Cleaning 141
After stopping the engine 45 DDEC – Checking plug-in connections 143
Auxiliary materials 17 Drive belt
– Condition check 128
B
Battery-charging generator E
– Check 130 Engine
– Drive belt tension adjustment 135 – Barring with starting system 73
Battery-charging generator – Barring manually 72
– Drive belt and belt tensioner replacement 133 – Main dimensions 39
Battery-charging generator – Condition check 129 – Start in manual mode 42
Battery-charging machine – Stopping in manual mode 44
– Removal and installation 131 – Wiring check 140
Engine coolant
C – Change 113
Centrifugal oil filter – Draining 114
– Cleaning 110 – Filling 115
– Filter sleeve replacement 110 – Level check 112
Charge-air coolant – Sample extraction and analysis 119
– Change 121 Engine coolant pump
– Drainage 122 – Relief bore check 117
– Filling 123 Engine data 12 V 4000 C10, C10R, C11, C11R 26
– Level check 120 Engine data 12 V 4000 C20, C20R, C21, C21R 32
Charge-air coolant level Engine data 16 V 4000 C10, C11, C11R 29
– Check 120 Engine data 16 V 4000 C20, C20R, C21, C21L 35
Charge-air coolant pump Engine mounting
– Relief bore check 126 – Check 127
Charge-air cooler Engine oil
– Check water drain for coolant leakage and absence of – Analysis 106
restrictions 99 – Sample extraction 106
Cold start system with ether injection Engine oil
– Check 101 – Change 104
Compressor Engine oil filter
– Check 139 – Replacement 107
Contact persons 147 Engine oil level
Coolant – Check 103
– Change 121 Engine side
Coolant - charge air – Designation 20
– Level check 120 Engine wiring
Coolant filter – Check 140
– Replacement 118 Engine – Overview 21
Crankcase breather Environmental protection 17
– Filter element replacement 78
Crankcase breather (open-circuit crankcase ventilation F
DCL-ID: 0000017488 - 004
– Filter element cleaning 80 Fan drive

Crankshaft transport locking device – Adjust and check drive belt tension 136
– Removal/installation 8 – Drive belt replacement 138
– With flanged-on generator Fault messages from DDEC engine governor 52
– Removal/assembly 11 Fire prevention 17
Cylinder Firing order 38
– Designation 20 Fluids and lubricants 17
Cylinder head cover Fuel filter
– Removal and installation 89 – Replacement 98
Cylinder liner Fuel system
– Endoscopic examination 74 – Venting 97
154 | Appendix B | MS150049/02E 2012-11

G Starter
Grounding device – Condition check 100
– Check carbon brush 81 Startup
Grounding device – Safety regulations 13
– Carbon brush replacement 83
T
H Technical data (engine data) 26, 29, 32, 35
Hotline 147 Transport 7
HP pump Troubleshooting 49
– Relief bore check 90
V
I Valve clearance
Important provisions 5 – Adjustment 85
Injector – Check 85
– Installation 92 Valve gear
– Removal 92 – Lubrication 84
– Replacement 91
W
Instructions and comments on endoscopic and visual ex‐
amination of cylinder liners 76 Wiring - engine
– Check 140
M
Main dimensions
– Engine 39
Maintenance work
– Safety regulations 14
MTU contact persons 147
O
Oil indicator filter
– Check 108
Operation
Operational checks 43
Organizational requirements 6
P
Personnel requirements 6
Plant
– Cleaning 46
Provisions 5
Putting the engine into operation
– Preparation after scheduled out-of-service-period
41
Putting the engine into operation after extended out-of-
service periods (>3 months) 40
R
Repair work
DCL-ID: 0000017488 - 004
S
Safety messages
– Standards 19
Safety regulations 13, 14
Sensors, actuators and injectors – Overview 23
Service indicator
– Check 102
Service partners 147
Spare parts service 147
MS150049/02E 2012-11 | Appendix B | 155


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7.3 Crankcase Breather 78

7.6 Injection Pump / HP Pump 90

MS150049/02E 2012-11 | Table of Contents | 3

4 | Table of Contents | MS150049/02E 2012-11

MS150049/02E 2012-11 | Safety | 5

Organizational measures of the operator

Working clothes and protective equipment

TIM-ID: 0000000874 - 020

6 | Safety | MS150049/02E 2012-11

Placement after transport

MS150049/02E 2012-11 | Safety | 7

Special tools, Material, Spare parts

Removing the transport locking

TIM-ID: 0000040575 - 001

8 | Safety | MS150049/02E 2012-11

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

Removing the transport locking

MS150049/02E 2012-11 | Safety | 9

TIM-ID: 0000040575 - 001

10 | Safety | MS150049/02E 2012-11

Special tools, Material, Spare parts

Removing the transport locking

Installing the transport locking device on driving end (KS)

MS150049/02E 2012-11 | Safety | 11

TIM-ID: 0000040576 - 001

12 | Safety | MS150049/02E 2012-11

Safety requirements for initial operation

Safety regulations for equipment operation

Engine malfunctions and engine emergency stop

Operation of electrical equipment

Observe the safety instructions for these devices.

MS150049/02E 2012-11 | Safety | 13

Safety regulations prior to maintenance and repair work

Safety regulations during maintenance and repair work

14 | Safety | MS150049/02E 2012-11

Hydraulic installation and removal

Working on electrical and electronic assemblies

MS150049/02E 2012-11 | Safety | 15

Working with laser equipment

TIM-ID: 0000000879 - 024

16 | Safety | MS150049/02E 2012-11

Environmental protection and disposal

Auxiliary materials, fluids and lubricants

contact with ignition sources and do not smoke.

MS150049/02E 2012-11 | Safety | 17

Paints and lacquers

Acids and alkaline solutions

18 | Safety | MS150049/02E 2012-11

MS150049/02E 2012-11 | Safety | 19

1 Left engine side 3 Right engine side

20 | General Information | MS150049/02E 2012-11

Figure applies to 16V4000 Cxy analogously

1 Oil cooler 8 Combustion-air inlet 15 Air conditioning com‐

MS150049/02E 2012-11 | General Information | 21

Engine model designation

22 | General Information | MS150049/02E 2012-11

1 Engine coolant temper‐ 3 Charge-air temperature

MS150049/02E 2012-11 | General Information | 23

TIM-ID: 0000008365 - 002

24 | General Information | MS150049/02E 2012-11