Operating Instructions: Diesel Engine 12V 4000 C64 Application Group 5B

Operating Instructions
Diesel engine
12V 4000 C64
Application group 5B
MS150112/01E
Downloaded from www.Manualslib.com manuals search engine

Engine model kW/cyl. Application group
12V4000C64 155 kW/cyl. 5B; Continuous operation, variable
Table 1: Applicability
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Table of Contents
1 Safety 7 Task Description
1.1 Important requirements for all products 5 7.1 Engine 99
1.2 Personnel and organizational requirements 6 7.1.1 Engine – Barring manually 99
1.3 Safety requirements for startup and 7.1.2 Barring engine with starting system 100
operation 7 7.1.3 Engine – Test run 101
1.4 Safety requirements for maintenance and 7.2 Auxiliary PTO 102
repair work 8 7.2.1 Auxiliary PTO – Replacement 102
1.5 Fire prevention and environmental
7.3 Cylinder Liner 103
protection, fluids and lubricants, auxiliary 7.3.1 Cylinder liner – Endoscopic examination 103
materials 11 7.3.2 Instructions and comments on endoscopic and
1.6 Standards for safety notices in the text 13 visual examination of cylinder liners 105
1.7 Transport 14
7.4 Crankcase Breather 107
7.4.1 Crankcase breather – Oil mist fine separator
2 General Information replacement 107
2.1 Engine side and cylinder designations 15 7.5 Valve Drive 108
2.2 Engine – Overview 16 7.5.1 Valve gear – Lubrication 108
2.3 Sensors, actuators and injectors – Overview 17 7.5.2 Valve projection – Measurement 109
7.5.3 Valve clearance – Check and adjustment 112
3 Technical Data 7.5.4 Cylinder head cover ‒ Removal and
installation 115
3.1 12V 4000 C64 engine data 20
7.6 Injection Pump / HP Pump 116
3.2 Firing order 24 7.6.1 HP pump – Relief bore check 116
3.3 Engine – Main dimensions 25
7.7 Injection Valve / Injector 117
7.7.1 Injector – Replacement 117
4 Operation
7.7.2 Injector – Removal and installation 118
4.1 Putting the engine into operation after 7.8 Fuel System 122
extended out-of-service periods (>3 months) 26 7.8.1 Fuel system – Venting 122
4.2 Putting the engine into operation after
scheduled out-of-service-period 27 7.9 Fuel Filter 123
7.9.1 Fuel filter – Replacement 123
4.3 Operational checks 28
7.9.2 Additional fuel filter – Replacement 124
4.4 Engine – Starting in manual mode 29
4.5 Engine – Stopping in manual mode 30 7.10 Exhaust Turbocharger 125
4.6 After stopping the engine 31 7.10.1 Exhaust turbocharger – Turbine housing
4.7 Plant – Cleaning 32 check 125
7.10.2 Exhaust turbocharger (LP) – Turbine housing
check 126
5 Maintenance 7.10.3 Exhaust turbocharger (HP) – Turbine housing
check 134
5.1 Maintenance task reference table [QL1] 33
7.11 Charge-Air Cooling 140
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6 Troubleshooting 7.11.1 Intercooler – Leak check 140
6.1 Troubleshooting 35 7.12 Exhaust Gas Recirculation 141

7.12.1 EGR cooler – Overview 141
6.2 Fault messages on the SAM display
7.12.2 EGR cooler – Cleaning 142
(optional) 37 7.12.3 EGR cooler ‒ Check 143
6.3 Fault messages of Engine Control Unit ECU 7.12.4 Exhaust flaps – Overview 144
9 for Series 4000 38 7.12.5 Exhaust flaps – Actuator function check 145
7.12.6 Exhaust flaps – Overview 146
MS150112/01E 2014-10 | Table of Contents | 3

7.12.7 Exhaust flaps – Checking coupling rods 7.18.1 Drive belt – Condition check 181
operability and play 147
7.12.8 Exhaust flaps – Coupling rod replacement 149
7.19 Battery-Charging Generator 182
7.19.1 Checking battery-charging generator 182
7.13 Starting Equipment 152 7.19.2 Battery-charging generator drive – Drive belt
7.13.1 Starter – Condition check 152 tension adjustment 183
7.19.3 Battery-charging generator drive – Drive belt
7.14 Lube Oil System, Lube Oil Circuit 153 replacement 184
7.14.1 Engine oil level – Check at sight glass 153
7.14.2 Engine oil – Level check with oil dipstick 154 7.20 Fan Drive 185
7.14.3 Engine oil – Change 155 7.20.1 Fan drive – Drive belt check / adjustment 185
7.14.4 Engine oil – Sample extraction and analysis 157 7.20.2 Fan drive – Drive belt replacement 187
7.15 Oil Filtration / Cooling 158 7.21 Engine Mounting / Support 188
7.15.1 Engine oil filter – Replacement 158 7.21.1 Engine mounting – Check 188
7.15.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 160
7.22 Wiring (General) for Engine/Gearbox/Unit 189
7.22.1 Еngine cabling ‒ Check 189
7.16 Coolant Circuit, General, High-Temperature
7.23 Accessories for (Electronic) Engine
Circuit 162
7.16.1 Engine coolant – Level check 162
Governor / Control System 190
7.23.1 Resetting CDC parameter and entering IIG
7.16.2 Engine coolant – Change 163
with DiaSys® 190
7.16.3 Engine coolant – Draining 164
7.23.2 Actuators – Visual inspection and test 191
7.16.4 Exhaust flaps – Draining coolant from
7.23.3 Engine governor and connectors – Cleaning 193
servomotors 166
7.23.4 Engine governor plug connections – Check 194
7.16.5 Engine coolant – Filling 167
7.23.5 NOx sensor – Replacement 195
7.16.6 Engine coolant pump – Relief bore check 170
7.23.6 Lambda sensor – Replacement 197
7.16.7 Engine coolant – Sample extraction and
analysis 171
7.17 Low-Temperature Circuit 172 8 Appendix A

7.17.1 Charge-air coolant – Level check 172
7.17.2 Charge-air coolant – Change 173
8.1 Abbreviations 199
7.17.3 Charge-air coolant – Draining 174 8.2 MTU contact persons/service partners 202
7.17.4 Charge-air coolant – Filling 177
7.17.5 Checking charge-air coolant pump pressure 9 Appendix B
relief port 180
9.1 Special Tools 203
7.18 Belt Drive 181 9.2 Index 212
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4 | Table of Contents | MS150112/01E 2014-10

1 Safety
1.1 Important requirements for all products
Nameplate
The product is identified by a nameplate, model designation or serial number which must match the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices
Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine management/parameters)
• In compliance with all safety regulations and in accordance with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re-
sulting from improper, non-intended use.
Changes or modifications
Unauthorized changes to the product represent a contravention of its intended use and compromise
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safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
MS150112/01E 2014-10 | Safety | 5

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

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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6 | Safety | MS150112/01E 2014-10

1.3 Safety requirements for startup and operation
Safety requirements for startup
The product must be installed and accepted in accordance with manufacturers' specifications prior to
initial startup.
All the requisite regulatory approvals must have been granted and all startup requirements fulfilled prior
to initial startup.
Whenever the product is started, always ensure that:
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• Wearers of cardiac pacemakers or other active medical implants are well clear.
• The operating room is adequately ventilated.
• Exhaust pipework is leak-tight and routed to atmosphere.
• Battery terminals, generator terminals and cables are guarded to preclude accidental contact.
• All personnel is clear of the danger zone represented by moving parts.
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.
Safety requirements for operation

The operator must be familiar with the controls and displays.
The operator must be aware of the consequences of any operations he/she performs.
During operation, the display instruments and monitoring units must be constantly observed in regard
of present operating status, limit value violation and warning or alarm messages.
Malfunctions and emergency stop

Emergency procedures, in particular emergency stop, must be practiced on a regular basis.
Take the following steps if a system malfunction is detected or signaled by the system:
• Inform the duty supervisor(s).
• Evaluate the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.
Operation
Do not stay in the operating room when the product is running unless absolutely necessary and then as
briefly as possible.
Keep a safe distance away from the product whenever possible. Do not touch the product unless ex-
pressly instructed to do so.
Do not inhale exhaust gases emitted by the product.
Ensure that the following requirements have been fulfilled before starting the product:
• Ear protectors are worn.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
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agent.
Operation of electrical equipment

Some components are live (high voltage) when electrical equipment is in operation.
Observe the safety instructions for these appliances.
MS150112/01E 2014-10 | Safety | 7

1.4 Safety requirements for maintenance and repair work
Safety requirements before commencing maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collection vessels with a sufficient filling volume.
Ensure that the operating room is adequately ventilated when changing the oil or working on the fuel
system.
Do not perform maintenance or repair work when the product is running unless:
• expressly instructed to do so.
• the product is running in the low load range and only for as long as necessary to complete the task.
Lock-out the product to preclude undesired starting, e.g. start interlock.
Tag-out the product with a “Do Not Start” sign in the operation room or on the control facility.
Disconnect the battery. Lock the contactor.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control facility from the product.
For starters with pinions made of copper-beryllium alloy:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the
starter with compressed air. Clean the interior of the flywheel housing with a class H dust extractor.
• Observe the safety data sheet.
Safety requirements during maintenance and repair work

Take special care when removing vent plugs or plug screws from the product. Hold a cloth over the
screw or plug to prevent discharge of highly pressurized liquids.
Take care when draining hot fluids and lubricants (risk of burning).
Use suitable and calibrated tools only. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assembles and/or installations which are properly secured.
Never climb up on the lines.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Avoid damaging lines, particularly the fuel lines.
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Ensure that all retainers and dampers are installed correctly.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Never route fuel or oil lines in the vicinity of hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).
Always use suitable ladders and work platforms when working above head-height. Ensure that compo-
nents or assemblies are placed on stable surfaces.
8 | Safety | MS150112/01E 2014-10

Pay particular attention to cleanliness at all times.
Safety requirements after completing maintenance and repair work

Ensure that all personnel is clear of danger zones before cranking.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been re-
moved (especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Welding work
Do not perform welding on the product or its attachments. Cover the product when performing welding
work in the vicinity.
Before commencing welding work:
• Switch off the master power supply switch.
• Disconnect the battery.
• Disconnect electronic and genset grounds.
Do not perform maintenance or repair work on the product when welding is in progress in its vicinity.
Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use the product as a grounding terminal.
Do not route the welding cable over or near the wiring harnesses of the product. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .
Hydraulic installation and removal

Check function and satisfactory condition of the jigs and fixtures to be used. Use only the specified jigs
and fixtures for hydraulic removal/installation.
Observe the max. permissible force-on pressure specified for the installation/removal jig.
Do not attempt to bend or exert force on HP lines.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For hydraulic installation/removal jigs with central expansion pressure supply, screw the spindle into
the shaft end until correct sealing has been established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries

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Observe the safety requirements of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte (battery acid) to come into contact with skin or clothing.
Wear goggles and protective gloves.
Do not place tools on the battery.
Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.
MS150112/01E 2014-10 | Safety | 9

Working on electrical/electronic assemblies
Always obtain the permission of the duty supervisor before commencing maintenance or 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.
Avoid damaging cabling during removal. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cabling to lines bearing fluids.
Do not use cable ties to secure cabling.
Always use connector pliers to tighten union nuts on connectors.
Subject the device and also the product to appropriate function testing whenever repair work has been
completed. In particular, check the function of the emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack-
age faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.
Working with laser equipment

Always wear special laser-protection goggles when working with laser equipment (danger due to in-
tensely focused radiation).
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 nm to
700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to pre-
vent any risk to the eyes.
Measuring component deviations

Workpieces, components and measuring instruments are within specified tolerances at a reference
temperature of 20°C. TIM-ID: 0000040535 - 006
10 | Safety | MS150112/01E 2014-10

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

Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer. Noncompliance with these guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.
Fluids and lubricants and auxiliary materials

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum-
ables and other chemical substances, follow the safety regulations that apply to the product. Take spe-
cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
TIM-ID: 0000040536 - 006
coming into contact with ignition sources and do not smoke.
Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.
MS150112/01E 2014-10 | Safety | 11

Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale
lead vapors.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products to be connected must either be designed for that pressure, or, if the permis-
sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Paints and varnishes

• Observe the relevant safety data sheet for all materials.
• When painting in areas other than spray booths equipped with extractors, ensure good ventilation.
Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (AdBlue®, DEF)

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• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• If spilled onto clothing, remove the affected clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi-
ble.
12 | Safety | MS150112/01E 2014-10

1.6 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Safety notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.
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MS150112/01E 2014-10 | Safety | 13

1.7 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
transport.
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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.
14 | Safety | MS150112/01E 2014-10

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

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on
the left-hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The
cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
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MS150112/01E 2014-10 | General Information | 15

2.2 Engine – Overview
1 Oil heat exchanger 11 Engine mounting 21 Fuel priming pump

2 Crankcase breather 12 Cylinder head 22 Engine mounting
3 Cable harness holder 13 EGR line 23 Lube oil filter
4 Exhaust outlet 14 Flywheel 24 Vibration damper
5 Exhaust turbocharger (LP) 15 Charge-air line 25 Fan drive
6 Exhaust turbocharger (HP) 16 Starter 26 Auxiliary PTO
7 Charge-air cooler (low 17 Oil pan 27 Battery-charging generator
pressure) 18 Fuel filter head 28 Centrifugal oil filter
8 EGR cooler 19 Supplementary fuel filter
9 Engine coolant line 20 Fuel filter
10 Air intake
Engine model designation

Explanation of engine model designation 12 V 4000 C64
12 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
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C Application: Construction and Industrial, mobile

6 Application segment: 6
4 Design index
16 | General Information | MS150112/01E 2014-10

2.3 Sensors, actuators and injectors – Overview
1 B13 - Crankshaft speed 3 F57 - Charge-air coolant

2 F70 - Water level in fuel level
prefilter (external) 4 F33 - Engine coolant level
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1 M52 - Bypass flap 5 B91.3 - Exhaust pressure 9 B13 - Crankshaft speed
2 B44.2 - Turbocharger B 6 B88 - NOx 10 B10.11 - Charge-air pres-
speed 7 B16 - Engine coolant pressure, B-side
3 B90 - Humidity (pressure, sure
temperature) of intake air 8 Y39.B1-B6 - Injectors B1-
4 B89 - Lambda B6
The injectors (8) are underneath the cylinder head covers of the cylinders. Injector replacement and
associated activities (→ Page 117).
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18 | General Information | MS150112/01E 2014-10

1 M55 - Donor cylinder flap 6 B9 - Charge-air tempera- 11 F46 - Leak-off fuel level
2 B44.3 - Turbocharger C ture 12 B5.3 - Lube-oil pressure
speed 7 Y39.A1-A6 - Injectors A1- before filter
3 B10.1 - Charge-air pres- A6 13 B7 - Lube oil temperature
sure, A-side 8 B34.3 - Fuel pressure be- 14 B44.1 - Turbocharger A
4 M53 - EGR shutoff flap fore supplementary filter speed
5 A19 - EIL connection 9 B34.2 - Fuel pressure be- 15 B4 - Exhaust temperature
fore filter
10 B34.1 - Fuel pressure after
filter
The injectors (6) are underneath the cylinder head covers of the cylinders. Injector replacement and
associated activities (→ Page 117).
TIM-ID: 0000045455 - 001

3 Technical Data
3.1 12V 4000 C64 engine data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 12V
Application group 5B
Intake air temperature °C 25
Charge-air coolant temperature °C 45
Barometric pressure mbar 1000
Site altitude above sea level m 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders 12V
Rated engine speed A rpm 1900
Net brake power (w/o fan) (fuel stop power ISO 3046) A kW 1865
GENERAL CONDITIONS (for maximum power)

Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 50
Exhaust overpressure A mbar 30
Exhaust overpressure, max. L mbar 85
Fuel temperature at engine inlet connection R °C 25
Fuel temperature at engine inlet connection, max (w/o power L °C 65
TIM-ID: 0000045457 - 001
reduction)
CONSUMPTION
Lube oil consumption after 100 h runtime (B = hourly fuel con- R % of B 0.2
sumption)
20 | Technical Data | MS150112/01E 2014-10

MODEL-RELATED DATA (basic design)
Number of cylinders 12
Cylinder arrangement: V angle degrees 90
Bore mm 170
Stroke mm 210
Cylinder displacement Liters 4.77
Total displacement Liters 57.2
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2
COMBUSTION AIR / EXHAUST GAS

Charge-air pressure before cylinder R bar abs 4.9
Exhaust temperature after turbocharger R °C 370
COOLANT SYSTEM (HT circuit)

Coolant temperature (at engine connection: outlet to cooling A °C 100
equipment)
Coolant temperature after engine, warning R °C 107
Coolant temperature after engine, shutdown L °C 109
Coolant antifreeze content, max. L % 50
Coolant pump: inlet pressure, max. L bar 2.5
Thermostat: Starts to open R °C 79
Thermostat: Fully open R °C 92
COOLANT SYSTEM (LT circuit)

Coolant temperature difference after/before charge-air cooler, L °C 8
min.
Coolant temperature difference after/before charge-air cooler, L °C 16
max.
Coolant antifreeze content, max. L % 50
Thermostat: Starts to open R °C 38
TIM-ID: 0000045457 - 001
Thermostat: Fully open R °C 51
LUBE OIL SYSTEM

Lube oil operating temperature before engine, from R °C 60
Lube oil operating temperature before engine, to R °C 95
Lube oil temperature before engine, alarm R °C 97
Lube oil temperature before engine, shutdown L °C 99
MS150112/01E 2014-10 | Technical Data | 21

Lube oil operating pressure upstream of engine, from R bar 6.0
Lube-oil operating pressure before engine, to R bar 7.0
FUEL SYSTEM
Fuel pressure at engine inlet connection, min. (when engine is L bar -0.3
starting)
Fuel pressure at return connection on engine, max. L bar 0.5
Fuel pressure at engine inlet connection, max. (when engine is L bar 1.5
starting)
GENERAL OPERATING DATA

Coolant preheating: preheating temperature (min.) R °C 40
INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Longitudinal inclination, continuous max. driving end down (op- L Degrees 15
tion: max. operating inclinations)
Longitudinal inclination, temporary max. driving end down (op- L Degrees 15
tion: max. operating inclinations)
Longitudinal inclination, continuous max. driving end up (option: L Degrees 15
max. operating inclinations)
Transverse inclination, continuous max. (option: max. operating L Degrees 15
inclinations)
CAPACITIES
Engine coolant, engine side (without cooling equipment) R Liters 220
Charge-air coolant, engine side R Liters 69
Engine oil on initial filling (standard oil system) (option: max. op- R Liters 245
erating inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) L Liters 150
(option: max. operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) L Liters 190
(option: max. operating inclinations)
TIM-ID: 0000045457 - 001
WEIGHTS (basic design, dry engine)

Engine dry weight (with attached standard accessories, without R kg 8200
coupling)

ACOUSTICS
Exhaust noise, unsilenced - BL (free-field sound-pressure level R dB(A) 112
Lp, 1m distance, ISO 6798)
Exhaust noise, unsilenced - BL (sound power level LW, ISO R dB(A) 124
6798)
Engine surface noise with attenuated intake noise (filter) - BL R dB(A) 109
(free-field sound-pressure level Lp, 1m distance, ISO 6798)
Engine surface noise with attenuated intake noise (filter) - BL R dB(A) 128
(sound power level LW, ISO 6798)
TIM-ID: 0000045457 - 001

3.2 Firing order
Firing order
Number of cylinders Firing order
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
TIM-ID: 0000026627 - 002

3.3 Engine – Main dimensions
Engine – Main dimensions
Item Dimensions
Length (A) approx. 2878 mm
Width (B) approx. 1631 mm
Height (C) approx. 2393 mm
TIM-ID: 0000045458 - 001

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 Preservation and Represervation Specifications (A001070/..) are available.
Putting the engine into operation after extended out-of-service periods

(>3 months)
Item Action
Engine Depreserve (→ Preservation and Represervation Specifications A001070/..).
Cylinder liner Perform endoscopic examination of cylinder liner (→ Page 103).
Valve drive Lubricate valve gear every ≥ 6 months (→ Page 108).
Lube oil system Check engine oil level (→ Page 154).
Bar engine using starting system (→ Page 100).
Fuel prefilter Fill with fuel (if fitted).
Coolant circuit If engine has been out of service for more than 1 year, change engine cool-
ant (→ Page 163).
Change charge-air coolant (→ Page 173).
Coolant circuit Check engine coolant level (→ Page 162);
Check charge-air coolant level (→ Page 172).
Coolant circuit Preheat coolant with coolant preheating unit (if available).
Engine governor Check electrical connections (→ Page 194).
Engine management Read out fault memory using DiaSys, see (→ manufacturer's documentation).
Check all active fault messages, eliminate faults as necessary (→ Page 38).
TIM-ID: 0000045459 - 002
26 | Operation | MS150112/01E 2014-10

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 154).
Coolant circuit Check engine coolant level (→ Page 162);
Check charge-air coolant level (→ Page 172).
Coolant circuit Heat coolant with coolant preheater (if available; see manufacturer's docu-
mentation).
Engine control system Put into operation (see manufacturer's documentation).
TIM-ID: 0000002683 - 006
MS150112/01E 2014-10 | Operation | 27

4.3 Operational checks
DANGER
Rotating, moving engine parts.
Risk of crushing! Risk of body parts being caught or drawn in!
• Take special care when the engine is running.
• Stay well clear of danger zones at the engine.
WARNING
Loud engine noises with the engine running:
Risk of hearing damage!
• Wear ear protection.
Operational checks
Item Action
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine oil Check engine oil level (→ Page 154).
Engine operation Visually inspect engine for leaks and general condition.
Check engine for abnormal running noises, exhaust color and vibrations.
Air filter Check signal ring position of service indicator on air filter (if fitted).
Battery-charging generator Check battery-charging generator for contamination, clean as necessary
(→ Page 182).
Exhaust system Check exhaust color (→ Page 35).
Fuel prefilter Drain water and contaminants via drain cock on fuel prefilter (if fitted, see
manufacturer's documentation).
Check service indicator at fuel prefilter (if fitted, see manufacturer's docu-
mentation).
Engine coolant pump Check relief bore (→ Page 170).
Charge-air coolant pump Check relief bore (→ Page 180).
TIM-ID: 0000030232 - 003
28 | Operation | MS150112/01E 2014-10

4.4 Engine – Starting in manual mode
Preconditions
☑Engine is not under load.
☑External start interlock is not activated.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the en-
gine's danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Measure
Operating mode switch (if Switch to manual mode.
applicable).
Coolant preheating unit (if Switch ON
applicable).
Start engine
Item Measure
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 - 006
MS150112/01E 2014-10 | Operation | 29

4.5 Engine – Stopping in manual mode
Preconditions
☑Engine is not under load.
☑Engine is running in manual mode.
NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical
stresses.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and
constant levels are indicated.
Preparation
Item Measure
Engine Operate engine at idling speed for approx. 5 minutes.
Stop engine
Item Measure
Switch cabinet, operator Press stop button.
station etc. (depending on • Automatic stopping sequence is executed.
manufacturer)
TIM-ID: 0000002291 - 005
30 | Operation | MS150112/01E 2014-10

4.6 After stopping the engine
Preconditions
☑MTU Preservation and Represervation Specifications (A001070/..) are available.
NOTICE
Coolant sensors may freeze if there is a risk of frost.
Risk of sensor damage!
• Protect sensors from frost.
After stopping the engine

Item Action
Coolant circuit Drain engine coolant (→ Page 164) and
Drain charge-air coolant (→ Page 174) if
• freezing temperatures are expected, the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive.
• the engine room is not heated.
• the coolant is not kept at a suitable temperature.
• the antifreeze concentration is insufficient for the engine-room tem-
perature.
• the antifreeze concentration is 50 % and the engine-room temperature
is below -40°C.
Engine control system Switch off (see manufacturer's documentation).
Air intake and exhaust sys- If the engine is to remain out of service for more than one week, seal the en-
tem gine's air and exhaust sides. Otherwise, the components that carry air or ex-
haust gas are at risk of corrosion.
If the engine is to remain out of service for more than one month, carry out
preservation (→ MTU Preservation and Represervation Specifications
(A001070/..) ).
TIM-ID: 0000002709 - 007
MS150112/01E 2014-10 | Operation | 31

4.7 Plant – Cleaning
Preconditions
☑Operating voltage is not applied.
Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
• Never direct water jet at people.
• Wear protective clothing, protective gloves and safety goggles/face mask.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors
or ECUs.
Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).
2. Prior to putting the cleaning unit into operation, read the operating instructions of the water/steam jet
unit carefully and observe the safety precautions.
3. For external cleaning of the plant with water or steam-jet cleaners:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 029
• The temperature of the cleaning medium must not exceed 80°C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Note: Never aim compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.
32 | Operation | MS150112/01E 2014-10

5 Maintenance
5.1 Maintenance task reference table [QL1]
The required 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 154)
W0501 Visually inspect engine for leaks and general condition.
W0502 X Check charge-air cooler drain. (→ Page 140)
W0505 Check relief bores of coolant pump(s). (→ Page 170)
(→ Page 180)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 28)
and vibrations.
W0507 X Drain water and contaminants from fuel prefilter.
W0508 X Check reading on differential pressure gauge of fuel prefil-
ter.
W1001 Replace fuel filter or fuel filter element. (→ Page 123)
W1006 Replace fuel injectors. (→ Page 117)
W1008 X Replace engine oil filter when changing engine oil, or (→ Page 158)
when the interval (years) is reached, at the latest.
W1009 Check layer thickness of the oil residue, clean out and re- (→ Page 160)
place filter sleeve after every oil change at the latest.
W1011 Perform endoscopic examination of cylinder chambers. (→ Page 103)
W1207 Check valve clearance and adjust if necessary. IMPOR- (→ Page 112)
TANT! First adjustment after 1,000 operating hours.
W1241 Check condition of belt drive and replace if necessary; ad- (→ Page 181)
just belt tension.
W1481 Replace fuel intermediate filter or filter element. (→ Page 124)
W1525 Replace sensor. (→ Page 195)
W1526 Replace sensor. (→ Page 197)
W1581 Replace impactors. (→ Page 107)
W1610 Check securing screws of trunnion bearings for secure (→ Page 188)
seating.
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W1636 Enter parameters for drift correction (CDC) and coding for (→ Page 190)
the injectors (IIG).
W1735 Replace auxiliary PTO. (→ Page 102)
W1817 Check clearance of coupling rod of EGR flaps and replace (→ Page 147)
if necessary. (→ Page 149)
MS150112/01E 2014-10 | Maintenance | 33

Task Option Maintenance tasks
W1906 In case of valve clearance deviations, check valve depth. (→ Page 109)
W1907 Check and clean EGR cooler. (→ Page 142)
(→ Page 143)
Table 2: Maintenance task reference table [QL1]
TIM-ID: 0000045502 - 003
34 | Maintenance | MS150112/01E 2014-10

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

Component Cause Action
Battery/UltraCaps Low or faulty. Charge or replace (see manufacturer's
documentation).
Cable connections defective. Check if cable connections are properly
secured (see manufacturer's documen-
tation).
Starter Engine wiring, POM or starter defective. Check if cable connections are properly
secured, contact Service.
Engine wiring Faulty Check (→ Page 189).
Engine/generator Secure seating of assemblies or connec- Perform visual inspection (see manufac-
control system tors not provided. turer's documentation).
Engine governor Plug-in connections are loose. Check plug connections(→ Page 194).
Engine Running gear blocked (engine cannot be Contact Service.
barred manually).
Engine turns but does not fire

Component Cause Action
Engine Too cold. Preheat (25 °C)
Starter Poor rotation by starter: Battery/Ultra- Charge or replace battery/UltraCaps
Caps low or defective. (see manufacturer's documentation).
Fuel system Air in fuel system. Vent fuel system (→ Page 122).
Engine governor Faulty Contact Service.
Engine fires unevenly

Component Cause Measure
Fuel injection equip- Injector defective. Replace (→ Page 117).
ment
TIM-ID: 0000018860 - 005
Engine does not reach rated speed

Fuel supply Fuel prefilter clogged. Replace
Easy-change fuel filter clogged. Replace (→ Page 123).
Air supply Air filter clogged. Clean.
Fuel injection equip- Injector faulty. Replace (→ Page 117).
ment
MS150112/01E 2014-10 | Troubleshooting | 35

Engine Overloaded Contact Service.
Engine speed not steady

Fuel injection equip- Injector faulty. Replace (→ Page 117).
ment
Speed sensor Faulty Contact Service.
Charge-air temperature too high

Coolant Coolant treatment incorrect. Check (MTU test kit).
Intercooler Contaminated Contact Service.
Engine room Inlet air temperature too high. Check fans and air supply / ventilation
ducts.
Charge-air pressure too low

Air supply Air filter clogged. Check
Intercooler Contaminated Contact Service.
Exhaust turbocharger Faulty Contact Service.
Coolant discharge at intercooler

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

Engine oil Too much oil in engine. Drain engine oil (→ Page 155).
Oil separator of crankcase breather con- Replace filter.
taminated.
Exhaust turbocharger, Faulty Contact Service.
cylinder head, piston
TIM-ID: 0000018860 - 005
rings, cylinder liner
White exhaust gas

Engine Not at operating temperature. Run up to operating temperature.
Fuel system Water in fuel. Check fuel system on fuel prefilter.
Drain fuel prefilter.
Intercooler Leaking Contact Service.
36 | Troubleshooting | MS150112/01E 2014-10

6.2 Fault messages on the SAM display (optional)
The fault code numbers are generated by the engine governor and transmitted to the following display:
The fault code (1) comprises three digits.

Fault messages can also be caused by faulty sensors/actuators. If the fault cannot be corrected with
the troubleshooting information provided in the following table, contact Service. Our Service will check
sensors/actuators and replace them if necessary.
The following fault codes may appear on the display: (→ Page 38).
TIM-ID: 0000029308 - 003

6.3 Fault messages of Engine Control Unit ECU 9 for Series 4000
3 – HI T-Fuel
ZKP-Number: 2.0122.931
Fuel temperature too high (limit value 1)
Yellow alarm – warning
Cause Corrective action
Fuel tank may be exposed to 1. Reduce power.
heat. 2. Contact Service.
4 – SS T-Fuel
Fuel temperature too high (limit value 2)
Red alarm – engine shutdown
Fuel tank may be exposed to u Contact Service.
heat.
5 – HI T-Charge Air
Charge-air temperature too high (limit value 1)
Intercooler not operating 1. Reduce power.
correctly. 2. Check intercooler.
3. Contact Service.
6 – SS T-Charge Air
Charge-air temperature too high (limit value 2)
Intercooler not operating 1. Check intercooler.
TIM-ID: 0000029153 - 005
correctly. 2. Contact Service.

9 – HI T-Coolant Intercooler
Coolant pressure in intercooler too high (limit value 1)
Coolant circuit for charge air 1. Reduce power.
faulty. 2. Check intercooler and coolant cooler.
3. Contact Service.
10 – SS T-Coolant Intercooler
Coolant pressure in intercooler too high (limit value 2).
Coolant circuit for charge air 1. Check intercooler and coolant cooler.
faulty. 2. Contact Service.
15 – LO P-Lube Oil
Lube oil pressure too low (limit value 1)
Insufficient oil. 1. Check oil level, top up as necessary (→ Page 154).
2. Contact Service.
16 – SS P-Lube Oil
Lube oil pressure too low (limit value 2)
Insufficient oil. 1. Check oil level, top up as necessary (→ Page 154).
2. Acknowledge alarm.
3. Restart engine (→ Page 29).
4. Contact Service.
TIM-ID: 0000029153 - 005

19 – HI T-Exhaust A
Exhaust temperature (A-side) too high (limit value 1)
Cable damage. 1. Check air filter and wiring (→ Page 189).
2. Contact Service.
20 – SS T-Exhaust A
Exhaust temperature (A-side) too high (limit value 2)
2. Contact Service.
21 – HI T-Exhaust B
Exhaust temperature (B-side) too high (limit value 1)
2. Contact Service.
22 – SS T-Exhaust B
Exhaust temperature (B-side) too high (limit value 2)
2. Contact Service.
23 – LO Coolant Level
TIM-ID: 0000029153 - 005
Coolant level too low (limit value 1)
Leak in coolant circuit. u Check coolant level in expansion tank (→ Page 162).

25 – HI P-Diff. Lube Oil
Differential oil pressure at oil filter too high (limit value 1)
Oil filter not operating correctly. u Replace oil filter (→ Page 158).
26 – SS P-Diff. Lube Oil

Differential oil pressure at oil filter too high (limit value 2)
Oil filter not operating correctly. 1. Replace oil filter (→ Page 158).
2. Contact Service.
27 – HI Leak Fuel Level

Leak-off fuel level too high (limit value 1)
Leak in fuel lines. 1. Check fuel system.
2. Contact Service.
30 – SS Engine Overspeed
Engine overspeed (limit value 2)
No fuel injection. 1. Restart engine. Fault can possibly be eliminated through restart
(→ Page 29).
2. Contact Service.
31 – HI ETC1 Overspeed
TIM-ID: 0000029153 - 005
Speed of primary turbocharger too high (limit value 1)
Obstructed charge-air circuit or 1. Reduce power.
fault in turbocharger. 2. Check air filter.
3. Contact Service.

32 – SS ETC1 Overspeed
Speed of primary turbocharger too high (limit value 2)
Obstructed charge-air circuit or 1. Check air filter.
fault in turbocharger. 2. Contact Service.
33 – HI P-Diff. Fuel
Fuel filter differential pressure too high (limit value 1)
Fuel filter not operating 1. Replace fuel filter (→ Page 123).
34 – SS P-Diff. Fuel
Fuel filter differential pressure too high (limit value 2)
Fuel filter not operating 1. Replace fuel filter (→ Page 123).
Speed of 1st secondary turbocharger too high (limit value 1)
fault in turbocharger. 2. Contact Service.
TIM-ID: 0000029153 - 005
Speed of 1st secondary turbocharger too high (limit value 2)
Obstructed charge-air circuit or u Contact Service.
fault in turbocharger.

44 – LO Coolant Level Intercooler
Coolant level of intercooler too low (limit value 1)
Insufficient charge-air coolant, 1. Check coolant level (→ Page 172).
e.g. due to leaks in charge-air 2. Contact Service.
coolant circuit.
51 – HI T-Lube Oil
Lube oil temperature too high (limit value 1)
Insufficient oil. 1. Reduce power.
2. Check engine oil level (→ Page 154).
3. Contact Service.
52 – SS T-Lube Oil
Lube oil temperature too high (limit value 2)
Insufficient oil. 1. Check engine oil level (→ Page 154).
2. Contact Service.
57 – LO P-Coolant
Coolant pressure too low (limit value 1)
Leak in coolant circuit. u Check coolant level (→ Page 162).
58 – SS P-Coolant
TIM-ID: 0000029153 - 005
Coolant pressure too low (limit value 2)
Red alarm – engine shutdown or reduced injection quantity
Leak in coolant circuit. u Check coolant level (→ Page 162).

59 – SS T-Coolant L3
Coolant temperature too high / low (limit value 3)
Red alarm – forced idle
Coolant circuit not operating 1. Activate fan emergency operating mode if required.
correctly (e.g. damage, leaks, 2. Allow engine to cool down.
low coolant level). 3. Check engine coolant cooler, clean if dirty.
6. Contact Service.
60 – SS T-Coolant L4
Coolant temperature too high / low (limit value 4)
Coolant circuit not operating 1. Activate fan emergency operating mode if required.
correctly (e.g. damage, leaks, 2. Allow engine to cool down.
low coolant level). 3. Check engine coolant cooler, clean if dirty.
6. Contact Service.
63 – HI P-Crankcase
Crankcase pressure too high (limit value 1)
Crankcase extraction system 1. Reduce power.
obstructed or leaking. 2. Replace oil mist fine separator insert .
3. Contact Service.
64 – SS P-Crankcase
Crankcase pressure too high (limit value 2)
TIM-ID: 0000029153 - 005

Crankcase extraction system 1. Reduce power.
obstructed or leaking. 2. Replace oil mist fine separator insert .
3. Contact Service.

65 – LO P-Fuel
Fuel supply pressure too low (limit value 1)
Leaky or obstructed fuel lines or 1. Check fuel lines for leakage.
fuel filter. 2. Check fuel filter, low-pressure side.
3. Replace fuel filter (→ Page 123).
66 – SS P-Fuel
Fuel supply pressure too low (limit value 2)
Leaky or obstructed fuel lines or 1. Check fuel lines for leakage.
fuel filter. 2. Check fuel filter, low-pressure side.
3. Replace fuel filter (→ Page 123).
4. Contact Service.
67 – HI T-Coolant
Coolant temperature too high (limit value 1)
Coolant circuit not operating 1. Reduce power.
correctly (e.g. damage, leaks, 2. Check coolant circuit.
low coolant level).
68 – SS T-Coolant
Coolant temperature too high (limit value 2)
Coolant circuit not operating u Check coolant circuit.
TIM-ID: 0000029153 - 005
correctly (e.g. damage, leaks,

low coolant level).

81 – AL Rail Leakage
Leakage
During start: Pressure gradient 1. Check engine for leaks.
in rail too low (HP system 2. Contact Service.
leaking, air in system).
During stop: Pressure gradient 1. Seal engine system.
in rail too high. 2. Contact Service.
82 – HI P-Fuel (Common Rail)

Rail pressure > set value
Red alarm – DBR fuel limitation, start of injection readjusted towards late
HP fuel block jamming or HP 1. Check wiring (→ Page 189).
fuel control block wiring faulty. 2. Contact Service.
83 – LO P-Fuel (Common Rail)

Rail pressure < set value
Red alarm – DBR limitation
HP fuel control block faulty or u Contact Service.
leakage in HP fuel system.
89 – SS Engine Speed too Low

Engine speed too low
Various causes possible. 1. Acknowledge alarm.
2. Observe additional messages.
TIM-ID: 0000029153 - 005
3. Contact Service.

90 – SS Idle Speed Not Reached
Idling speed not attained
Red alarm – warning
Various causes possible. 1. Observe additional messages.
2. Contact Service.
91 – SS Release Speed Not Reached

Runup speed was not attained
Various causes possible. 1. Observe additional messages.
2. Contact Service.
92 – SS Starter Speed Not Reached

Starter speed not reached
Starter rotates too slowly or 1. Observe additional messages.
does not rotate at all. 2. Contact Service.
93 – SS T-Preheat
Preheating temperature too low (limit value 2)
Red alarm – engine start interlock
Coolant temperature for engine 1. Check preheating unit.
start too low because preheater 2. Contact Service.
is not working.
94 – LO T-Preheat
TIM-ID: 0000029153 - 005
Preheating temperature too low (limit value 1)
Coolant temperature for engine 1. Check preheating unit.
start too low because preheater 2. Contact Service.
is not working.

95 – AL Priming Fault
Oil priming fault.
Priming oil pressure not 1. Check priming system.
reached. 2. Contact Service.
102 – AL Fuel Cons. Counter Defect

Fault in fuel checksum
Consumption meter faulty. u Contact Service.
104 – AL Eng Hours Counter Defect

Fault in operating hours monitoring system
Hour meter faulty. u Contact Service.
118 – LO ECU Supply Voltage

Supply voltage too low (limit value 1)
Supply voltage at engine 1. Check engine governor supply voltage.
governor too low. 2. Contact Service.
119 – LOLO ECU Supply Voltage

TIM-ID: 0000029153 - 005
Supply voltage too low (limit value 2)

Red alarm – start terminated
governor too low. 2. Contact Service.

120 – HI ECU Supply Voltage
Supply voltage too high (limit value 1)
governor too high. 2. Contact Service.
121 – HIHI ECU Supply Voltage

Supply voltage too high (limit value 2)
Red alarm – start terminated or engine shutdown
governor too high. 2. Contact Service.
122 – HI T-ECU
Electronics temperature too high (limit value 1)
Electronics overheated. 1. Reduce power.
2. Improve engine room ventilation.
180 – AL CAN1 Node Lost

Connection to a node on CAN bus 1 failed
Connection to or communication 1. Check devices connected to CAN.
with a node at CAN bus 1 has 2. Check wiring (→ Page 189).
failed. 3. Contact Service.
181 – AL CAN2 Node Lost

TIM-ID: 0000029153 - 005
Connection to a node on CAN bus 2 failed
Connection to or communication 1. Check devices connected to CAN.
with a node at CAN bus 2 has 2. Check wiring (→ Page 189).
failed. 3. Contact Service.

182 – AL CAN Wrong Parameters
Incorrect parameters at CAN
Incorrect parameter values u Contact Service.
entered in data record.
183 – AL CAN No PU Data

CAN PU data not present or available
The selected CAN mode 1. Check devices connected to CAN.
initializes communication by 2. Contact Service.
means of the PU data module. A
fault occurred during an attempt
to copy a received data module
to the engine governor.
184 – AL CAN PU Data Flash Error

CAN PU data flash fault
A programming error occurred u Contact electronic Service.
when attempting to copy a
received PU data module into
the flash module.
186 – AL CAN1 Bus Off

CAN controller 1 is in "Bus-Off" status
Yellow alarm – automatic changeover to CAN 2
TIM-ID: 0000029153 - 005
Short circuit, massive 1. Check CAN bus for short circuit, rectify short circuit as
interference or Baud rate required.
incompatibility. 2. Check shielding, improve shielding if necessary.
3. Contact Service.

187 – AL CAN1 Error Passive
CAN 1 error
Missing associated nodes, minor 1. Check CAN bus for short circuit, rectify short circuit as
disruptions or temporary bus required.
overload. 2. Check shielding, improve shielding if necessary.
3. Contact Service.
188 – AL CAN2 Bus Off

CAN controller 2 is in "Bus-Off" status
Yellow alarm – automatic changeover to CAN 1
Short circuit, massive 1. Check CAN bus for short circuit, rectify short circuit as
interference or Baud rate required.
incompatibility. 2. Check shielding, improve shielding if necessary.
3. Contact Service.
189 – AL CAN2 Error Passive

CAN controller 2 error
Missing associated nodes, minor 1. Check CAN bus for short circuit, rectify short circuit as
disruptions or temporary bus required.
overload. 2. Check shielding, improve shielding if necessary.
3. Contact Service.
201 – SD T-Coolant
Coolant temperature sensor signal error
TIM-ID: 0000029153 - 005

Coolant temperature sensor 1. Check sensor and wiring (B6), replace as necessary
faulty. (→ Page 189).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 29).
3. Contact Service.

202 – SD T-Fuel
Fuel temperature sensor signal error
Fuel temperature sensor faulty. 1. Check sensor and wiring (B33), replace as necessary
Short circuit or wire break. (→ Page 189).
2. Fault is rectified when engine is restarted (→ Page 29).
3. Contact Service.
203 – SD T-Charge Air

Charge-air temperature sensor signal error
Charge air temperature sensor 1. Check sensor and wiring (B9), replace as necessary
Short circuit or wire break. 2. Fault is rectified when engine is restarted. (→ Page 29)
3. Contact Service.
204 – SD Level Lube Oil

Lube oil level sensor signal error
Lube oil level sensor faulty. 1. Check sensor and wiring, replace as necessary (→ Page 189).
3. Contact Service.
205 – SD T-Coolant Intercooler

Coolant temperature sensor signal error
TIM-ID: 0000029153 - 005
Coolant pressure sensor of 1. Check sensor and wiring (B26), replace as necessary
intercooler faulty. (→ Page 189).
3. Contact Service.

206 – SD T-Exhaust A
Signal error, exhaust temperature sensor on A-side
Exhaust temperature sensor on 1. Check sensor and cabling (B4.21), replace as necessary
A-side faulty. (→ Page 189).
3. Contact Service.
207 – SD T-Exhaust B
Signal error, exhaust temperature sensor on B-side
Exhaust temperature sensor on 1. Check sensor and cabling (B4.22), replace as necessary
B-side faulty. (→ Page 189).
3. Contact Service.
208 – SD P-Charge Air

Charge-air pressure sensor signal error
Charge-air pressure sensor 1. Check sensor and wiring (B10), replace as necessary
3. Contact Service.
211 – SD P-Lube Oil

Lube oil pressure sensor signal error
TIM-ID: 0000029153 - 005

Lube oil pressure sensor faulty. 1. Check sensor and wiring (B5), replace as necessary
3. Contact Service.

212 – SD P-Coolant
Coolant pressure sensor signal error
Coolant pressure sensor faulty. 1. Check sensor and wiring (B16), replace as necessary
3. Contact Service.
213 – SD P-Coolant Intercooler

Intercooler coolant pressure sensor signal error
Intercooler coolant pressure 1. Check sensor and wiring (B43), replace as necessary
sensor faulty. (→ Page 189).
3. Contact Service.
214 – SD P-Crankcase
Crankcase pressure sensor signal error
Crankcase pressure sensor 1. Check sensor and wiring (B50), replace as necessary
3. Contact Service.
215 – SD P-HD
Rail pressure sensor signal error
TIM-ID: 0000029153 - 005

Rail pressure sensor faulty. ==> 1. Check sensor and wiring (B48), replace as necessary
High pressure regulator (→ Page 189).
emergency operation mode. 2. Fault is rectified when engine is restarted (→ Page 29).
Short circuit or wire break. 3. Contact Service.

216 – SD T-Lube Oil
Lube oil temperature sensor signal error
Lube oil temperature sensor 1. Check sensor and wiring (B7), replace as necessary
3. Contact Service.
219 – SD T-Intake Air

Intake air temperature sensor signal error
Intake air temperature sensor 1. Check sensor and wiring (B3), replace as necessary
3. Contact Service.
220 – SD Level Coolant Water

Coolant level sensor signal error
Coolant level sensor faulty. 1. Check sensor and wiring (F33), replace as necessary
3. Contact Service.
221 – SD P-Diff Lube Oil

Lube oil pressure differential sensor signal error
TIM-ID: 0000029153 - 005

Lube oil differential pressure 1. Check sensor and wiring (F25), replace as necessary
sensor faulty. (→ Page 189).
3. Contact Service.

222 – SD Level Leakage Fuel
Leak-off fuel level sensor signal error
Leak-off fuel level sensor faulty. 1. Check sensor and wiring (F46), replace as necessary
3. Contact Service.
223 – SD Level Coolant Intercooler

Intercooler coolant level sensor signal error
Intercooler coolant level sensor 1. Check sensor and wiring (F57), replace as necessary
3. Contact Service.
227 – SD Oil Pressure before Filter

Lube oil pressure sensor before filter, signal error
Lube oil pressure sensor before 1. Check sensor and wiring (B5.3), replace as necessary
filter faulty. (→ Page 189).
3. Contact Service.
228 – SD P-Fuel before Filter

Fuel pressure sensor signal error
TIM-ID: 0000029153 - 005

Fuel pressure sensor faulty. 1. Check sensor and wiring (B5.3), replace as necessary
3. Contact Service.

229 – AL Stop Camshaft Sensor Defect
Stop camshaft sensor signal error
Camshaft sensor faulty (and a 1. Check sensor and wiring to connector B1, replace as necessary
prior camshaft sensor fault in (→ Page 189).
the same operating cycle). 2. Fault is rectified when engine is restarted (→ Page 29).
3. Contact Service.
230 – SD Crankshaft Speed

Crankshaft sensor signal error
Crankshaft sensor faulty. 1. Check sensor and wiring (B13), replace as necessary
3. Contact Service.
231 – SD Camshaft Speed

Camshaft sensor signal error
Camshaft sensor faulty. 1. Check sensor and wiring (B1), replace as necessary
3. Contact Service.
232 – SD Charger 1 Speed

Primary turbocharger speed sensor signal error
TIM-ID: 0000029153 - 005

Speed sensor of primary 1. Check sensor and wiring (B44.1), replace as necessary
turbocharger faulty. (→ Page 189).
3. Contact Service.

233 – SD Charger 2 Speed
Secondary turbocharger speed sensor signal error
Speed sensor of secondary 1. Check sensor and wiring (B44.2), replace as necessary
turbocharger faulty. (→ Page 189).
3. Contact Service.
239 – SD P-Diff Fuel

Differential pressure sensor for fuel signal error (only occurs with SD alarm "fuel before filter" or "fuel
after filter")
Fuel differential pressure sensor u Observe additional messages.
faulty.
240 – SD P-Fuel
Fuel sensor signal error
Fuel pressure sensor faulty. 1. Check sensor and wiring (B34), replace as necessary
3. Contact Service.
245 – SD ECU Supply Voltage

Engine governor supply voltage signal error
TIM-ID: 0000029153 - 005
Internal ECU fault. Electronics 1. Replace engine governor.


266 – SD Speed Setting
Speed setting signal error
Analog speed setpoint incorrect 1. Check speed setting transmitter and wiring, replace as
Short circuit or wire break. necessary (→ Page 189).
3. Contact Service.
268 – SD Skid Analog Value

Skid signal error
Analog skid signal faulty. 1. Check sensor and wiring, replace as necessary (→ Page 189).
3. Contact Service.
269 – SD Loadp. Analog Filt.

Load pulse analog signal faulty
The filtered analog signal from 1. Check wiring, replace as necessary (→ Page 189).
the load pulse is not present. 2. Fault is rectified when engine is restarted (→ Page 29).
270 – SD Frequency Input

Frequency input signal error
Frequency input faulty. 1. Check wiring (→ Page 189).
TIM-ID: 0000029153 - 005
Short circuit or wire break. 2. Check setpoint speed transmitter.

3. Contact Service.

321 – AL Wiring Cylinder A1
Wiring faulty, cylinder A1
Yellow alarm – misfiring
Short circuit fault in injector 1. Check solenoid valve.
wiring, cylinder A1. 2. Contact Service.




TIM-ID: 0000029153 - 005





TIM-ID: 0000029153 - 005

331 – AL Wiring Cylinder B1
Wiring faulty, cylinder B1
wiring, cylinder B1. 2. Contact Service.




TIM-ID: 0000029153 - 005





TIM-ID: 0000029153 - 005

341 – AL Open Load Cylinder A1
Injector wiring fault, cylinder A1
Disruption fault in injector 1. Check injector wiring and solenoid valve.




TIM-ID: 0000029153 - 005





TIM-ID: 0000029153 - 005

351 – AL Open Load Cylinder B1
Injector wiring fault, cylinder B1




TIM-ID: 0000029153 - 005





TIM-ID: 0000029153 - 005

361 – AL Injector Power Stage Low
Internal electronic fault
Red alarm – engine shutdown possible
Electronics possibly faulty. 1. Start ITS.
2. Replace engine governor if required.
3. Check additional messages if ITS indicates diagnosis
"Electronics OK" (e.g. wiring faulty).
4. Check solenoid valve wiring.
5. Contact Service.
362 – AL Injector Power Stage High

Internal electronic fault.
Red alarm – engine shutdown possible
2. Replace engine governor if required.
5. Contact Service.
363 – AL Stop Injector Power Stage

Internal electronic fault.
2. Replace engine governor.
5. Contact Service.
TIM-ID: 0000029153 - 005

365 – AL Stop SV Wiring Ground
Injector wiring faulty
Red alarm – engine shutdown via protection module possible
Short circuit of injector positive 1. Check wiring (→ Page 189).
connection to ground of one or 2. Restart engine (→ Page 29).
more injectors.
Short circuit of the negative
injector connection or of one or
more injectors to ground.
381 – AL Wiring TOP 1

Line disruption on digital input 1
Short circuit or wire break on u Check wiring to plant.
transistor output 1, plant side
(TOP 1).

(TOP 2).

TIM-ID: 0000029153 - 005

transistor output 3, plant side 3
(TOP 3).

(TOP 4).
390 – AL MCR Exceeded

Speed limiter/MCR function: The maximum continuous rate was exceeded
Yellow alarm – engine power limited to permissible continuous power
DBR/MCR function: MCR u If the alarm remains, contact Service.
(maximum continuous rate) was
exceeded.
400 – AL Open Load Digital Input 1

Wiring faulty or no resistance 1. Check wiring (→ Page 189).
over switch. 2. Check target device input.
3. Contact Service.

TIM-ID: 0000029153 - 005
3. Contact Service.

3. Contact Service.

3. Contact Service.

3. Contact Service.

TIM-ID: 0000029153 - 005
3. Contact Service.

3. Contact Service.

3. Contact Service.
408 – AL Open Load Emerg. Stop Input ESI

Open circuit at input for emergency stop.
3. Contact Service.
410 – LO U-PDU
Injector voltage too low (limit value 1)
Cable damage or faulty power 1. Check wiring (→ Page 189).
supply. 2. Check supply.
TIM-ID: 0000029153 - 005
3. Contact Service.

411 – LOLO U-PDU
Injector voltage too low (limit value 2)
4. Contact Service.
412 – HI U-PDU
Injector voltage too high (limit value 1).
3. Contact Service.
413 – HIHI U-PDU

Injector voltage too high (limit value 2)
4. Contact Service.
414 – HI Level Water Fuel Prefilter

Water level in fuel prefilter too high (limit value 1)
TIM-ID: 0000029153 - 005
Water content in fuel too high or u Drain fuel prefilter.

water ingress in fuel tank.

415 – LO P-Coolant Intercooler
Coolant pressure in intercooler too low (limit 1)
Leak in coolant circuit. u Top up coolant.
416 – SS P-Coolant Intercooler

Coolant pressure in intercooler too low (limit 2)
Leak in coolant circuit. u Top up coolant.
417 – SD Level Water Fuel Prefilter

Fuel prefilter water level sensor signal error
Water level sensor of fuel 1. Check sensor and wiring, replace as necessary (→ Page 189).
prefilter is faulty. 2. Contact Service.
Short circuit or wire break.
438 – LO P-Fuel 2 (Common Rail)

Yellow alarm – DBR fuel limitation
HP fuel control block faulty or u Contact Service.
leakage in HP fuel system.
439 – HI P-Fuel 2 (Common Rail)

TIM-ID: 0000029153 - 005

Red alarm – DBR fuel limitation, start of injection readjusted towards late
HP fuel block jamming or HP u Contact Service.
fuel control block wiring faulty.

441 – AL System 2 Leaky
Pressure gradient in rail is too low during starting or too high during stopping
HP system leaky, air in system. u Contact Service.
444 – SD U-PDU
Injection power stage supply voltage faulty
Sensor defect of injector power u Replace engine governor.
stage or internal fault of engine
governor.
445 – SD P-Ambient Air

Ambient air pressure sensor signal error
Ambient air pressure sensor u Replace engine governor.
faulty.
446 – SD P-HD2
Rail pressure sensor signal error
Rail pressure sensor faulty. 1. Check sensor and wiring (B48), replace as necessary
High-pressure governor (→ Page 189).
emergency operation 2. Contact Service.
TIM-ID: 0000029153 - 005
448 – HI P-Charge Air

Charge-air pressure too high (limit value 1)
Fault at turbine bypass flap. u Contact Service.

449 – SS P-Charge Air
Charge-air pressure too high (limit value 2)
Fault at turbine bypass flap. u Contact Service.
450 – SD Idle/End-Torque Input [%]

Start/end torque signal error
Input signal for start/end torque 1. Check signal transmitter and wiring, replace as necessary
faulty. (→ Page 189)
3. Contact Service.
454 – SS Power Reduction Active

Power reduction has been activated.
Red alarm – power reduction has been activated.
Engine operation outside u Observe additional messages.
standard limit values.
This message can be caused by
the following: Intake depression,
exhaust back pressure, charge-
air coolant temperature or
intake air temperature outside
the limit values
470 – SD T-ECU
Engine governor, temperature, signal error
TIM-ID: 0000029153 - 005

Temperature sensor for engine 1. Check sensor and wiring, replace as necessary (→ Page 189).
governor faulty. 2. Restart engine (→ Page 29).

472 – AL Stop SD
Engine stops
Engine stop, since all shutdown 1. Check wiring (→ Page 189).
channels detect "sensor defect". 2. Contact Service.
474 – AL Wiring FO
Wiring fault at FO
Line break or short circuit at FO 1. Check wiring (→ Page 189).
channel. 2. Contact Service.
478 – AL Comb. Alarm Yel (Plant)

Combined yellow alarm from the system
Various causes possible. u Observe additional messages.
479 – AL Comb. Alarm Red (Plant)

Combined red alarm from the system
Red alarm
Various causes possible. u Observe additional messages.
480 – AL Ext. Engine Protection

TIM-ID: 0000029153 - 005
External engine protection function active

The external engine protection 1. Check plant signal.
function is active 2. Contact Service.
Monitoring of plant signal by
governor active (plant side).

Speed of 2nd secondary turbocharger too high (limit value 1)
Obstructed charge-air circuit or u Reduce power.

Speed of 2nd secondary turbocharger too high (limit value 2)

Speed of the 3rd secondary turbocharger too high (limit value 1)

Speed of the 3rd secondary turbocharger too high (limit value 2)
500 – AL Wiring POM Starter 1

TIM-ID: 0000029153 - 005
Wiring faulty, connection of starter 1 at POM
Missing consumer. u Check connection between POM and starter.
Short circuit or wire break

501 – AL Wiring POM Starter 2
Wiring faulty, connection of starter 2 at POM
Missing consumer. u Check connection between POM and starter.
Short circuit or wire break
502 – AL Open Load POM Battery-Charging Generator

Open circuit at battery-charging generator connection to POM
Wiring faulty or no resistance u Check connection between POM and battery-charging
over switch. generator.
503 – AL Battery Not Charging

No battery charge
Battery is not charged by u Check battery-charging generator and wiring (→ Page 189).
battery-charging generator.
504 – AL CAN POM Node Lost

POM missing on CAN bus
If alarm 508 also appears, the u Check connection and POM.
resistance in the POM wiring is
missing.
506 – AL Low Starter Voltage

TIM-ID: 0000029153 - 005
The battery voltage is too low for the starting process
Battery flat or wiring defective. u Check starter battery and wiring (→ Page 189).

507 – AL POM Fault
A general POM fault occurred
Defect in POM. u Replace POM.
508 – AL Wrong POM ID

POM sends a different ID number than expected
If alarm 504 also appears, the u Check POM wiring harness.
resistance in the POM wiring is
missing.
510 – AL Override applied

Override was activated.
Override suppresses other u Deactivate override button again.
alarms.
515 – AL Starter Not Engaged

Yellow alarm – start termination possible
Starter on POM could not be 1. Repeated start attempt.
engaged. 2. Check POM, starter and wiring (→ Page 189).
3. Contact Service.
519 – Oil Level Calibration Error

TIM-ID: 0000029153 - 005
Error writing calibration value into flash or SD of level sensor.
Oil level sensor or wiring faulty. 1. Check sensor and wiring, replace as necessary (→ Page 189).
2. Contact Service.

536 – AL Wiring PWM_CM1
Wiring problem at PWM_CM1 channel
Cable break or short circuit on 1. Check wiring to connected device or check connected device
channel PWM_CM1. itself (actuator/sensor) and replace if necessary (→ Page 189).
2. Contact Service.
549 – AL Voltage interruption

Alarm from the emergency stop counter function
Engine governor power has been u Instruct operators to switch off the power supply only after the
disconnected with the engine engine has come to a standstill.
still running. This may lead to
overpressure in the HP system
which can damage the engine.

2. Contact Service.
576 – AL ESCM Override

Engine overload.
TIM-ID: 0000029153 - 005
Violation of corrected MCR or u Reduce power.

DBR/MCR curve.

577 – SD T-Lube Oil Pan
Oil pan temperature sensor signal error
Oil pan temperature sensor u Check sensor and wiring, replace as necessary (→ Page 189).
faulty.

2. Contact Service.
582 – AL Emergency Stop Failed

Emergency stop command from locomotive control system was not executed
Flashing pre-alarm and alarm
With the emergency stop signal u Contact Service.
active, the engine speed must
be reduced to standstill within a
parameterizable time.
586 – LO P-Oil Refill Pump

Oil pressure in refill pump too low (limit value 1)
Insufficient oil in oil refill tank. 1. Check oil level, top up as necessary (→ Page 154).
TIM-ID: 0000029153 - 005
2. Contact Service.

2. Contact Service.
588 – SD P-Oil Refill Pump

Refill pump oil pressure sensor signal error
Pressure sensor faulty. 1. Check sensor and wiring, replace as necessary (→ Page 189).
593 – AL T-Lube Oil Pan Low

Lube oil temperature in oil pan too low.
Preheating time not long 1. Extend preheating period.
enough. 2. Contact Service.
594 – AL L1 PRV Defect

Yellow alarm – warning pressure relief valve, first rail

TIM-ID: 0000029153 - 005
Red alarm – pressure relief valve, first rail.


596 – AL Test Parameters
The parameter set is used for u Contact Service.
trials. The alarm remains set
until a series parameter set is
loaded.

2. Contact Service.

Yellow alarm – warning pressure relief valve, second rail.
HP fuel block jamming or HP 1. Check wiring and HP fuel control block (→ Page 189).

Red alarm breather valve, second rail.
HP fuel block jamming or HP 1. Check wiring and HP fuel control block (→ Page 189).
600 – SD T-Exhaust A+B

TIM-ID: 0000029153 - 005
Exhaust temperature sensor signal error, A- and B-side

Exhaust temperature sensor on 1. Check sensor and wiring, replace as necessary (→ Page 189).
A- and B-side faulty. 2. Contact Service.

601 – SD ETC1+ETC2
ETC speed sensor 1 and 2 signal error
ETC speed sensors 1 and 2 1. Check sensor and wiring, replace as necessary (→ Page 189).
602 – AL CAN Engine Start Lock

Start interlock signal from plant pending.
Start interlock initiated by plant. u The alarm is reset by canceling the engine start command or
the CAN request.
606 – AL Double Nodes Lost CAN 1+2

ECU does not detect monitored CAN bus device.
A node has failed on both CANs. 1. Check wiring and power supply of plant (→ Page 189).
Short circuit or wire break. 2. Acknowledge alarm.
4. Contact Service.

TIM-ID: 0000029153 - 005
2. Contact Service.

2. Contact Service.
610 – AL Wiring HP Fuel Control Block 1

Wiring faulty at HP fuel control block 1
Cable break or short circuit on 1. Check wiring (→ Page 189).
PWM channel, HP fuel control 2. Contact Service.
block.
611 – AL Wiring HP Fuel Control Block 2

Wiring faulty at HP fuel control block 2
PWM channel, HP fuel control 2. Contact Service.
block 2.
612 – AL Wiring Pressure Regulating Valve 1

Wiring faulty, pressure regulating valve 1
PWM channel, pressure 2. Contact Service.
TIM-ID: 0000029153 - 005
regulating valve.

613 – AL Wiring Pressure Regulating Valve 2
Wiring faulty, pressure regulating valve 2
PWM channel, pressure 2. Contact Service.
regulating valve 2.
614 – AL L1 P-Fuel Add. Filter Diff.

Fuel prefilter differential pressure too high
Fuel prefilter not operating 1. Replace fuel prefilter.
615 – AL EIL Protection

Alarm for Protection module
Incorrect or manipulated EIL. 1. Replace EIL.
2. Contact Service.
616 – AL EIL Error

ECU cannot detect EIL
Incorrect or manipulated EIL. 1. Replace EIL.
2. Contact Service.
TIM-ID: 0000029153 - 005

625 – SD P-Fuel before Add. Filter
Fuel pressure sensor before additional filter signal error
Analog input signal for fuel 1. Check pressure transmitter and wiring, replace as necessary
pressure before additional filter (→ Page 189).
faulty. 2. Fault is rectified when engine is restarted (→ Page 29).

2. Contact Service.

2. Contact Service.

TIM-ID: 0000029153 - 005

2. Contact Service.

629 – AL EGR Shutoff Flap A Defect
EGR shutoff flap A is faulty
Actuator fault at exhaust gas 1. Replace actuator or flap.
recirculation shutoff flap A or 2. Contact Service.
flap mechanical system is
defective.
630 – AL EGR Shutoff Flap B Defect

EGR shutoff flap B is faulty
Actuator fault at exhaust gas 1. Replace actuator or flap.
recirculation shutoff flap B or 2. Contact Service.
flap mechanical system is
defective.
631 – AL Bypass Flap Defect

Bypass flap is faulty.
Actuator fault at bypass flap or 1. Replace actuator or flap.
flap mechanical system 2. Contact Service.
defective.
632 – AL Dispenser Flap Defect

Dispenser flap faulty
TIM-ID: 0000029153 - 005
Actuator fault at dispenser flap 1. Replace actuator or flap.

or flap mechanical system 2. Contact Service.
defective.

633 – SD P-Ambient Air (HDT2800)
Moisture sensor signal error (TRICAN HDT2800)
Moisture sensor (TRICAN 1. Check sensor and wiring, replace as necessary (→ Page 189).
HDT2800) defective. 2. Contact Service.
634 – SD T0-Ambient Air (HDT2800)

635 – SD Air Humidity (HDT2800)

636 – SD Level Lube Oil J1939

Oil level sensor J1939 signal error
Oil level sensor J1939 faulty. 1. Check sensor and wiring, replace as necessary (→ Page 189).
2. Contact Service.
637 – SD T-Lube Oil Pan J1939

TIM-ID: 0000029153 - 005
Oil temperature sensor J1939 signal error
Oil temperature sensor J1939 1. Check sensor and wiring, replace as necessary (→ Page 189)
defective. 2. Contact Service.

640 – SD Smart NOx Oxidation Factor O2
Signal error, Smart NOx Sensor (Oxidation Factor O2)
Smart NOx sensor (oxidation 1. Check sensor and wiring, replace as necessary (→ Page 189).
factor O2) faulty. 2. Contact Service.
643 – SD P-Fuel b.o.F.

Fuel pressure sensor before optional filter signal error
Fuel pressure sensor before 1. Check sensor and wiring (B34.3), replace as necessary
optional filter faulty. (→ Page 189).
3. Contact Service.
644 – AL L1 P-Fuel b.o.F.

Fuel supply pressure before optional filter too low (limit value 1)
Leaking or obstructed fuel lines u Check filter, fuel low-pressure side
or fuel tank empty.
645 – AL L2 P-Fuel b.o.F.

Fuel supply pressure before optional filter too low (limit value 2)
Leaking or obstructed fuel lines u Check filter, fuel low-pressure side
or fuel tank empty.
TIM-ID: 0000029153 - 005

647 – SD P-Exhaust Lambda
Exhaust gas sensor near lambda sensor signal error
Exhaust gas sensor near lambda 1. Check sensor and wiring (B91), replace as necessary
sensor faulty (→ Page 189).
3. Contact Service.
648 – SD P-Charge Air B

Charge-air pressure sensor, B-side, signal error
Charge-air pressure sensor on B- 1. Check sensor and wiring (B10.11), replace as necessary
side faulty (→ Page 189).
662 – SD Smart NOx Heating Element

Smart NOx sensor (heating element) signal error
Smart NOx heating element 1. Check sensor and wiring, replace as necessary (→ Page 189).
faulty 2. Contact Service.
663 – SD Smart NOx Concentration

Smart NOx sensor (NOx concentration) signal error
Smart NOx sensor (NOx 1. Check sensor and wiring, replace as necessary (→ Page 189).
TIM-ID: 0000029153 - 005
concentration) faulty 2. Contact Service.


693 – AL Engine Brake Valve Fault
Engine brake valve faulty
At least one engine brake valve 1. Check valve and wiring, replace if necessary (→ Page 189).
is defective. 2. Contact Service.
718 – AL Intake Air Flap Defect

Intake air flap faulty
Actuator fault at intake air flap. 1. Replace actuator or flap.
2. Contact Service.
723 – SD T-Exhaust before DOC A

Exhaust temperature sensor before DOC A signal error
T-exhaust sensor before DOC A 1. Check sensor and wiring, replace as necessary (→ Page 189).
724 – SD T-Exhaust before DPF A

Exhaust temperature sensor before DPF A signal error
T-exhaust sensor before DPF A 1. Check sensor and wiring, replace as necessary (→ Page 189).
TIM-ID: 0000029153 - 005

725 – SD T-Exhaust after DPF A
Exhaust temperature sensor after DPF A signal error
T-exhaust sensor after DPF A 1. Check sensor and wiring, replace as necessary (→ Page 189).
726 – SD P-Delta Exhaust DPF A

P-Delta exhaust differential pressure at DPF A signal error
T-Delta exhaust sensor DPF A 1. Check sensor and wiring, replace as necessary (→ Page 189).
727 – AL L1 Delta T-LT Intercooler

T-max. coolant intercooler has exceeded L1
faulty (→ Page 189). 2. Check intercooler and coolant cooler.
3. Contact Service.
728 – AL L2 Delta T-LT Intercooler

T-max. coolant intercooler has exceeded L2
Red alarm
faulty. 2. Check intercooler and coolant cooler.
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3. Contact Service.

729 – AL L1 T-Exhaust Before DOC
L1 T-exhaust before DOC violated
3. Contact Service.
730 – AL L2 T-Exhaust Before DOC

L2 T-exhaust before DOC violated
Red alarm
3. Contact Service.
731 – AL L1 T-Exhaust Before DPF

L1 T-exhaust before DPF violated
3. Contact Service.
732 – AL L2 T-Exhaust Before DPF

L2 T-exhaust before DPF violated
Red alarm
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3. Contact Service.

733 – AL L1 T-Exhaust After DPF
L1 T-Exhaust after DPF violated
3. Contact Service.
734 – AL L2 T-Exhaust After DPF

L2 T-Exhaust after DPF violated
Red alarm
3. Contact Service.
735 – AL L1 P-DPF Difference

L1 P-DPF differential pressure violated
Excessive pressure loss in DPF 1. Check DPF.
due to contamination. 2. Contact Service.
736 – AL L2 T-DPF Difference

L2 P-DPF differential pressure violated
Red alarm
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737 – AL L1 P-DPF Differential Pressure Standard

L1 P-DPF differential pressure standard violated

Red alarm

Red alarm

Red alarm
741 – AL DPF Hard TM Termination

DPF hard TM terminated
Red alarm
Hard thermal management was 1. Check DPF.
terminated due to unfavorable 2. Contact Service.
operating conditions.
742 – AL DPF Frequent Hard TM

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DPF frequent hard TM
Hard thermal management is 1. Check DPF.
requested too often by engine 2. Contact Service.
governor.

743 – AL DPF Hard TM Suppression
Speed drop
Red alarm is activated if engine speed drops during starting sequence.
Hard thermal management was 1. Check DPF.
suppressed too often due to 2. Contact Service.
missing enable from plant.
744 – AL DPF Flash Read Error

Flash reading error during initialization of the starting values for the DPF function
Functional error in the flash 1. Replace flash memory.
memory. 2. Contact Service.
745 – AL Emission Fault 1

Emission fault 1
NOx-, tricane or exhaust gas 1. Reduce power.
temperature sensor defective. 2. Check sensors and wiring (→ Page 189).
3. Contact Service.
746 – AL Emission Fault 2

Emission fault 2
Red alarm
NOx-, tricane, exhaust back 1. Check sensors and wiring (→ Page 189).
pressure, p5 or lambda sensor 2. Check actuators.
defective. 3. Contact Service.
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Flap actuator faulty.

Malfunction in NOx controller.

7 Task Description
7.1 Engine
7.1.1 Engine – Barring manually
Preconditions

Barring device F6787910 1
Ratchet F30006212 1
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – Danger to life!
• Before barring the engine, ensure that nobody is in the danger zone.
Barring engine manually (lateral

installation)
1. Remove cover from flywheel housing.
2. Engage barring device (2) in ring gear and
install on flywheel housing.
• Use barring device F6787910.
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.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
5. For barring device removal follow reverse
sequence of working steps.
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MS150112/01E 2014-10 | Task Description | 99

7.1.2 Barring engine with starting system
DANGER
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
Barring engine with starting sys-

tem
1. Release latch (1) of connector X3 (2).
Note: Seal unused connectors with the supplied
protective cap.
2. Remove connector from engine governor.
3. Turn engine in unloaded condition: Press
START button.
4. Let the crankshaft rotate until oil pressure
is indicated.
5. Engine start is interrupted automatically af-
ter the max. permissible time.
6. Repeat this procedure after approx. 20 sec-
onds if required.
7. Fit connector X3 (2) on engine governor
and close latch (1).
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100 | Task Description | MS150112/01E 2014-10

7.1.3 Engine – Test run
DANGER
• Before cranking the engine with starter system, make sure that there are no persons in the en-
gine's danger zone.
WARNING
Engine – Test run

1. Start engine (→ Page 29).
2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 28).
4. Stop engine (→ Page 30).
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7.2 Auxiliary PTO
7.2.1 Auxiliary PTO – Replacement
Grease (Kluthe Hakuform 30-10/emulsifier) X00059351 1
Engine oil
O-ring (→ Spare Parts Catalog)
Screw (→ Spare Parts Catalog)
NOTICE
Contamination of components.
Damage to component!
• Check components for special cleanliness.
Replacing auxiliary PTO

1. Remove auxiliary PTO (3) by releasing the
screws (1) on the gearcase.
2. Before installing the new PTO, thoroughly
clean the contact surfaces and coat with
grease.
3. Insert auxiliary PTO (3) in gearcase bore.
4. Insert screws (1) and washers (2) and tight-
en crosswise.
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7.3 Cylinder Liner
7.3.1 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 115).
2. Remove injector (→ Page 118).
Positioning crankshaft at BDC

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

Findings Measure
• Thin carbon coating around carbon scraper ring No actions required.
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits on entire circumference between top piston ring
and bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark on entire circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Dark areas with even or varying degrees of discoloration Further endoscopic examina-
• Beginning and end of the discoloration are not sharply defined and tion required as part of mainte-
do not cover the entire stroke area nance work.
• Dark areas in the upper section of the cooling bore, remaining cir-
cumference are faultless
• Piston rings are faultless
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• On the entire circumference, apart from light areas of discoloration Cylinder liner must be replaced,
(do not impair operation) clearly darker stripes that start at the top contact Service.
piston ring
• Heat discoloration in the direction of stroke and honing pattern
damage
• Heat discoloration of piston rings

1. Compile endoscopic report using the table.
2. Use technical terms to describe the liner surface (→ Page 105).
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 118).
2. Install cylinder head cover (→ Page 115).
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7.3.2 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 ex-
amination report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
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clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.

Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough
investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To
avoid unnecessary disassembly work, it is recommended that another inspection be carried out after
further operation of the engine.
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7.4 Crankcase Breather
7.4.1 Crankcase breather – Oil mist fine separator replacement
Preconditions

Engine oil
Oil mist fine separator (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Replacing oil mist fine separator

1. Remove screws (1) and take off together
with holder (2).
2. Replace oil mist fine separator (3).
3. Replace O-ring (4) if necessary.
4. Replace further oil mist fine separators in
the same way.
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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 115).
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 115).
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7.5.2 Valve projection – Measurement
Preconditions

Depth gauge, 200 mm Y20000918 1
Preparatory steps
1. Remove cylinder head covers (→ Page 115).
3. Remove sleeves (arrow).
4. Install barring device (→ Page 99).
5. Rotate crankshaft with barring device in en-

gine direction of rotation until marking
“OT” and pointer are aligned.
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Measuring valve projection
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. Measure valve projection for each valve in two crankshaft positions (firing TDC and overlap TDC for cyl-
inder A1) according to the diagram. Diagram (→ Page 112).
3. Release adjusting screw (1) and remove
valve bridge. Do not remove rocker arm (2).
4. Measure distance between valve stem end

and cylinder head top at the spark plug
bore with depth gauge (see figure).
• The specified value for a new cylinder
head: 93.8 mm.
• Admissible wear: 3 mm.
• If the measured value is > 96.8 mm,
have the relevant cylinder head replaced
by specialist personnel ahead of sched-
ule.
5. Install valve bridge.
6. Adjusting valve clearance (→ Page 112)
Final steps
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1. Remove barring device (→ Page 99).

2. Check condition of O-rings at the sleeves, replace if damaged.

3. Install sleeves (arrow).
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7.5.3 Valve clearance – Check and adjustment
Preconditions
☑Coolant temperature max. 40 °C.
☑Valves are closed.

Feeler gauge Y20098771 1
Allen key F30002815 1
Torque wrench, 60-320 Nm F30452768 1
Socket wrench, 24 mm F30039526 1
Engine oil
Preparatory steps
2. Install barring device (→ Page 99).
Note: The OT mark (1) (if fitted) on the flywheel
must not be used for reference.
3. Rotate crankshaft with barring device in en-
gine direction of rotation until "OT-A1"
mark and pointer are aligned.
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Diagram for 12V engines (two
crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
Checking valve clearance at two crankshaft positions

1. Check OT/TDC position of piston in cylinder A1:
• If rocker arms on cylinder A1 are unloaded, 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 0.1 mm, 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 provid-
ed.
Note: Feeler gauge must just pass through the
gap.
4. Pull feeler gauge (3) between valve bridge
and rocker arm.
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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.
Name Size Type Lubricant Value/Standard
Locknut M16 x 1.5 Tightening torque (Engine oil) 90 Nm +9 Nm
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 99).
3. Enable engine start.
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7.5.4 Cylinder head cover ‒ Removal and installation
Preconditions

Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Removing cylinder head cover

1. Clean cylinder head covers (1) if severely
soiled prior to removal.
2. Remove screws (3, 4) with washers (2, 5).
3. Take cylinder head cover (1) with O-ring (6)
off cylinder head (7).
Installing cylinder head cover

1. Clean mounting surface.
2. Check O-ring (6) for damage, replace if necessary.
3. Coat O-ring (6) with assembly compound.
4. Place cylinder head cover (1) with O-ring (6) on cylinder head (7).
5. Install cylinder head cover (1) with screws (3, 4) and washers (2, 5).
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7.6 Injection Pump / HP Pump
7.6.1 HP pump – Relief bore check
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
HP pump – Relief bore check

1. Visually inspect relief bore (1) for fuel dis-
charge.
2. For jacketed HP lines, leakage is indicated
by the yellow combined alarm.
3. If fuel discharge is found or indicated, con-
tact Service.
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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 118).
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7.7.2 Injector – Removal and installation
Preconditions

Installation/removal device F6789889 1
Milling cutter F30452739 1
Torque wrench, 0.5-5 Nm 0015384230 1
Assembly paste (Optimoly Paste White T) 40477 1
Engine oil
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Preparatory steps
1. Shut off fuel supply to engine.
Removing injector
1. Disconnect cable connector on injector.
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2. Unscrew union nuts (2,5) and remove HP
line (3) from rail (4) and cylinder head.
Note: The injector accumulator will be emptied
when removing the adapter.
3. Remove adapter (1).
4. Remove screw (1).

5. Install installation/removal device on cylin-
der head.
6. Remove injector (2) and hold-down
clamp (6) with installation/removal device.
7. Remove installation/removal device.
8. Remove sealing ring (5) from injector, or
withdraw from cylinder head.
9. Remove O-rings (3) and damper ring (4)
from injector.
10. Clean all mating and sealing surfaces.
11. If carbon residue is present: Clean sealing
face on cylinder head and protective sleeve
with milling cutter.
12. Cover all connections and bores, or seal
with suitable plugs.
Installing injector
1. Remove plug before installing the injec-
tor. (Do not remove the plug from the HP
line before installing the adapter.)
2. Coat injector with assembly paste at the
seat of the nozzle clamping nut.
3. The new sealing ring (arrow) is supplied
with the injector.
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4. Secure new sealing ring (5) on injector (2)
with grease.
5. Fit new O-rings (3) (included in the scope
of supply of the injector) and damping ring
(4) onto the injector (2) and coat with
grease.
6. Insert injector (2) together with hold-down
clamp (6) into cylinder head, ensuring that
the high-pressure fuel line connection is
aligned correctly.
7. Press in injector (2) and hold-down
clamp (6) with installation/removal device.
8. Remove installation/removal device.
9. Coat screw head mating face (1) and
thread with engine oil.
10. Insert screw (1) and tighten with torque wrench to the specified initial tightening torque.
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
Note: Ensure special cleanness.
11. Coat thread and sealing cone of adapter (1)
with engine oil.
12. Install adapter (1) and use torque wrench to tighten to the specified initial tightening torque.
Adapter Preload torque (Engine oil) 5 Nm to 10 Nm
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13. Tighten screw on hold-down clamp (→ Step 10) with torque wrench to specified tightening torque.
Screw M12 Tightening torque (Engine oil) 100 Nm + 10 Nm
14. Tighten adapter (1) with torque wrench to the specified tightening torque.
Adapter Tightening torque (Engine oil) 100 Nm + 10 Nm
Note: Ensure special cleanness.
15. Coat thread and sealing cone of HP line (3) with engine oil.

16. Use torque wrench to tighten union nuts (2,5) on HP line (3) to specified tightening torque. Tightening
sequence:
1 Nut on adapter (2)
2 Nut on rail (5)
Union nut / thrust Tightening torque (Engine oil) 40 Nm + 5 Nm
screw
17. Fit cable connector onto injector.
Note: The CDC parameters must be reset, other-
wise the emission certification of the en-
gine is no longer applicable.
18. Reset CDC parameters (→ Page 190).
Final steps
2. Open fuel supply to engine.
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7.8 Fuel System
7.8.1 Fuel system – Venting
Preconditions

Diesel fuel
WARNING
Fuels are flammable and explosive.
Danger to life! Risk of burns!
• Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and goggles / safety mask.
NOTICE
Risk of severe component damage and other severe damage!
• Do not smoke.
Venting LP fuel system

1. Open threaded vent plug (1) and connect a
suitable hose.
2. Provide suitable container to collect escap-
ing fuel.
3. Unlock fuel priming pump (2), screw out
handle by turning it counterclockwise.
4. Operate the pump with the handle (2) until
bubble-free fuel emerges from the vent
plug (1).
5. Close vent plug (1).
6. Screw in handle by turning it clockwise.
7. Verify that fuel priming pump (2) is locked:
handle must be tightened.
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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
Danger to life! Risk of burns!
• Do not smoke.
• Wear protective clothing, protective gloves, and goggles / safety mask.
NOTICE
Risk of severe component damage and other severe damage!
• Do not smoke.
Fuel filter – Replacement

1. Provide suitable container to collect escap-
ing fuel.
2. Remove easy-change filter (2) with filter
wrench.
3. Clean sealing face on filter head (1).
4. Coat seal on easy-change filter (2) lightly
with engine oil (arrow).
5. Screw on easy-change filter (2) by hand un-
til the seal makes contact with the filter
head and tighten by hand.
6. Replace other easy-change filters in the
same way.
7. Vent fuel system (→ Page 122).
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7.9.2 Additional fuel filter – Replacement
Preconditions

Engine oil
Easy-change filter (→ Spare Parts Catalog) 4
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Supplementary fuel filter – Re-

placement
1. Remove easy-change filter (2) with filter
wrench.
2. Clean sealing surface on filter head (1).
3. Coat seal on easy-change filter (2) slightly
with engine oil (arrow).
4. Screw on easy-change filter (2) by hand un-
til the seal makes contact with the filter
head and tighten manually.
5. Replace further easy-change filters in the
same way.
6. Vent fuel system (→ Page 122)
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7.10 Exhaust Turbocharger
7.10.1 Exhaust turbocharger – Turbine housing check
Turbine housing (→ Spare Parts Catalog)
Exhaust turbocharger (low-pressure charger)

u Check turbine housing (→ Page 126).
Exhaust turbocharger (high pressure)

u Check turbine housing (→ Page 134).
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7.10.2 Exhaust turbocharger (LP) – Turbine housing check
Preconditions
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

Socket for lambda sensor / NOx sensor F30453932 1
Engine oil
Assembly paste (Ultra-Therm MTU) 50547 1
WARNING
Component is hot.
Risk of burning!
• Wear protective gloves.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
Preparatory steps, general

1. Drain engine coolant (→ Page 164).
2. Drain charge-air coolant (→ Page 174).
Preparatory steps – exhaust tur-

bocharger (LP), right side
1. Loosen screws on pipe half-clamps (2, 3)
and remove coolant vent lines (1, 4) from
heat shield and holders.
2. Remove pipe half-clamps (2, 3) with cool-
ant vent lines (1, 4) from heat shield and
holders.
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3. Remove NOx sensor (1) from exhaust el-
bow.
Preparatory steps - exhaust tur-

bocharger (LP), left side
1. Loosen screws on holders (2, 3).
2. Remove holders (2, 3) with coolant vent
lines (1, 4) from heat shield.
3. Remove temperature sensor (1), lambda

sensor (2) and test lead for sensor
B91.3 (3) from exhaust elbow.
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Note: The following activity steps are only described for an exhaust turbocharger (LP). The description applies
mirror-inverted to the other side. Checking of the turbine housing of the HP exhaust turbocharger re-
quires special steps (→ Page 134).
Removing heat shield
1. Remove screws (1) and take off with hold-
er (2) and washers.
er (4) and washers.
3. Remove screws (2, 3) and take off with

heat shield (1) and washers.
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Removing exhaust elbow
Note: Mark position of clamp.
1. Unscrew screws (4) and remove from con-
sole with spacer sleeves (5).
2. Release clamp (2) and take off with sealing
ring (3) and exhaust elbow (1) from turbine
housing.
Checking turbine housing

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

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1. Install exhaust elbow (1) with clamp (2) and sealing ring (3) on turbine housing and tighten to specified
tightening torque.
Clamp Tightening torque (Assembly paste (Ul- 27 Nm +2 Nm
tra-Therm MTU))
2. Coat threads of screw (4) with assembly paste prior to installation.
3. Install screws (4) and spacer sleeves (5) on console and tighten to specified tightening torque.
Screws Tightening torque (Assembly paste (Ul- 42 Nm +4 Nm
tra-Therm MTU))
Installing heat shield
1. Install heat shield (1) with washers and screws (2, 3) and tighten to specified tightening torque.
Screws Tightening torque (Engine oil) 42 Nm +4 Nm
2. Install holder (4) with washers and
screws (3) and tighten.
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Final steps – exhaust turbo-
charger (LP), right side
1. Install NOx sensor (1) on exhaust elbow and use a torque wrench and socket for NOx sensor to tighten
to specified tightening torque.
Sensor M20 x 1.5 Tightening torque 50 Nm ±10 Nm
2. Install pipe half-clamps (2, 3) and coolant
vent lines (1, 4) on heat shield and holder.
3. Tighten screws.
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Final steps - exhaust turbocharg-
er (LP), left side
1. Install NOx sensor (1) on exhaust elbow and use a torque wrench and socket for lambda sensor to tight-
en to specified tightening torque.
Sensor M18 x 1.5 Tightening torque 50 Nm ±10 Nm
2. Install test lead for pressure sensor B91.3 (2) on exhaust elbow and tighten union with union nut.
3. Install threaded adapter (1) of temperature sensor B4 on exhaust elbow and use torque wrench to tight-
en nut (2) to specified tightening torque.
TIM-ID: 0000026820 - 005

Threaded adapter M14 x 1.5 Tightening torque 40 Nm ±5 Nm
4. Insert temperature sensor in threaded adapter (1).
5. Tighten union nut (3) of temperature sensor B4 with torque wrench to specified tightening torque, while
countering the nut (2) of threaded adapter (1) at the same time.
Union nut M10 Tightening torque 35 Nm ±5 Nm

6. Install coolant vent lines (1, 4) and hold-
er (2, 8) on heat shield and tighten screws.
Final steps, general

1. Fill with engine coolant (→ Page 167).
2. Fill charge-air coolant circuit (→ Page 177).
TIM-ID: 0000026820 - 005

7.10.3 Exhaust turbocharger (HP) – Turbine housing check
Preconditions

Engine oil
Assembly paste (Ultra-Therm MTU) 50547 1
WARNING
Component is hot.
Risk of burning!
WARNING
Preparatory steps
3. Loosen screws of holders (1, 3).
4. Remove holders (1, 3) with coolant vent
lines (2, 4) from heat shield.
TIM-ID: 0000026621 - 004

Note: The procedure is only described for the exhaust turbocharger (HP). Checking of the exhaust turbocharg-
er turbine housing (LP) requires special steps (→ Page 126).
Removing heat shield
er (2) and washers.
2. Remove screws (2) and take off with heat

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

tion
u Release clamps (1) and remove insula-
tion (2).
TIM-ID: 0000026621 - 004

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

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

Note: Cracks are only permissible in the direction
of circumference of the spiral.
u Check turbine housing endoscopically from
the inside for cracks.
Result: If the crack is larger than the maximum
permissible crack length (x = 30 mm) or if
transverse cracks are present, contact
Service.
TIM-ID: 0000026621 - 004

Installing exhaust line
1. Install exhaust Y-pipe (3) with clamp (2)
and sealing ring (1) on turbine housing.
2. Tighten nut of clamp (2) with torque wrench to specified tightening torque.
Nut Tightening torque (Assembly paste (Ul- 27 Nm +2 Nm
tra-Therm MTU))
Installing exhaust Y-pipe insula-

tion
u Install insulation (2) on exhaust Y-pipe and
secure with clamps (1).
TIM-ID: 0000026621 - 004

Installing heat shield
1. Install heat shield (1) with washers and screws (2) and tighten to specified tightening torque.
Screws Tightening torque (Engine oil) 42 Nm +4 Nm
TIM-ID: 0000026621 - 004

Final steps
1. Install coolant vent lines (2, 4) and hold-
ers (1, 3) on heat shield and tighten
screws.
3. Fill charge-air coolant (→ Page 177).
TIM-ID: 0000026621 - 004

7.11 Charge-Air Cooling
7.11.1 Intercooler – Leak check
DANGER
WARNING
WARNING
Air jet from compressed-air gun.
Risk of injury to eyes and organs! Risk of hearing damage!
• Never direct a compressed-air jet at persons.
• Wear goggles/safety mask and ear protectors.
WARNING
Condensation contains acid.
Risk of chemical burns!
• Wear protective goggles.
Intercooler – Leak check

1. With the engine at standstill, open the plug
screws in the charge-air elbows on the left
and right engine sides on driving end (ar-
rows).
2. If necessary, use a suitable tool to remove
obstructions and check the openings for
coolant discharge.
Result: If a large amount of coolant is discharged,
contact Service.
TIM-ID: 0000018644 - 005
Emergency measures prior to engine start with a leaking intercooler

2. Bar engine manually (→ Page 99).
3. Bar engine with starting system to blow out combustion chambers (→ Page 100).
Note: Install injectors in their original installation position.

7.12 Exhaust Gas Recirculation
7.12.1 EGR cooler – Overview
1 Coolant ventilation 5 Exhaust gas recirculation 9 EGR cooler

2 Screw after EGR cooler 10 Exhaust gas recirculation
3 Washer 6 Washer previous to EGR cooler
4 Coolant line 7 Screw with EGR shut-off flap
8 Intercooler 11 Coolant line
TIM-ID: 0000031494 - 005

7.12.2 EGR cooler – Cleaning
Preconditions

Cleaning agent (Hakupur 312) 30390 1
WARNING
NOTICE
Contamination of components.
Damage to component!
• Check components for special cleanliness.
Cleaning EGR cooler

1. Clean all parts as shown in overview drawing (→ Page 141) with cleaning agent (Hakupur 312).
2. Blow out all parts with compressed air.
TIM-ID: 0000045524 - 001

7.12.3 EGR cooler ‒ Check
Oilstone 8205893261/00 1
Crocus cloth (→ Tools Catalog)
EGR cooler (→ Spare Parts Catalog)
WARNING
Checking EGR cooler

Item Findings Action
Visually inspect all components Damaged • Recondition
for damage. • Replace
Check all sealing, mating and con- • Damaged • Recondition:
tact faces for damage and uneven- • Uneven Smooth with oilstone or cro-
ness. cus cloth.
• Replace
Check all threads for ease of Sluggish • Recondition
movement. • Replace EGR cooler
Table 3: Checking EGR cooler: Findings – Action

TIM-ID: 0000045523 - 002

7.12.4 Exhaust flaps – Overview
1 EGR shutoff flap 2 Donor cylinder flap
TIM-ID: 0000027110 - 005
1 Bypass flap

7.12.5 Exhaust flaps – Actuator function check
Preconditions
WARNING
Exhaust flaps close rapidly.
Risk of crushing hands!
• Using a suitable tool, check exhaust flaps by pressing the actuating linkage to its limit several
times and releasing it.
WARNING
Component is hot.
Risk of burning!
Checking actuator function – mechanical

Note: For installation position of exhaust flaps, refer to overview (→ Page 144).
1. Remove guard plates of exhaust flaps.
2. Check operability and ease of movement of
exhaust flaps and control linkage by mov-
ing the assembly at the points (arrows) and
make sure that there is no excessive play.
Result: If exhaust flap is jamming, sluggish or has
too much play, contact Service.
3. Check whether the internal spring pulls the
flap into the F-position:
• Fail-safe position for bypass flap and
EGR shutoff flap: opened.
• Fail-safe position for donor cylinder flap:
closed.
Result: If the bypass flap/EGR shutoff flap is
closed or the donor cylinder flap is opened,
contact Service.
Checking operation of actuators – electrically

1. Switch on ECU.
TIM-ID: 0000027108 - 005
2. Learning cycle is carried out.

Result: If the exhaust flaps don't move, contact Service.

7.12.6 Exhaust flaps – Overview
1 EGR shutoff flap 2 Donor cylinder flap
TIM-ID: 0000044519 - 001
1 Bypass flap

7.12.7 Exhaust flaps – Checking coupling rods operability and play
Preconditions
WARNING
Exhaust flaps / air flaps close rapidly.
Risk of crushing!
• Using a suitable tool, check exhaust flaps / air flaps by pressing the actuating linkage to its limit
several times and releasing it.
WARNING
Component is hot.
Risk of burns!
Checking coupling rods (bypass and EGR flap) – mechanically

coupling rod (1) by moving it at the speci-
fied points (arrows) and make sure that
there is no excessive play.
Result: Replace coupling rod (1) if it is jamming,
sluggish or features excessive play
(→ Page 149).
3. Check whether the internal spring pulls the
flap into the F-position:
• Fail-safe position for bypass flap and
EGR shutoff flap: opened.
• Fail-safe position for donor cylinder flap:
closed.
Result: If the bypass flap/EGR shutoff flap is
closed or the donor cylinder flap is open,
contact Service.
Checking coupling rod (donor cylinder flap) – mechanically

TIM-ID: 0000044535 - 002

coupling rod (1) by moving it at the speci-
fied points (arrows) and make sure that
there is no excessive play.
Result: Replace coupling rod (1) if it is jamming,
sluggish or features excessive play
(→ Page 149).
TIM-ID: 0000044535 - 002

7.12.8 Exhaust flaps – Coupling rod replacement
Preconditions

Ratchet adapter F30027340 1
Assembly paste (Ultra-Therm MTU) 50547
Coupling rod (→ Spare Parts Catalog) 1
Coupling rod (→ Spare Parts Catalog) 2
Locknut (→ Spare Parts Catalog)
Locking screw (→ Spare Parts Catalog)
Washer (→ Spare Parts Catalog)
WARNING
Risk of crushing!
WARNING
Component is hot.
Risk of burns!
Removing coupling rods (bypass and EGR shutoff flaps)

2. Remove locknuts (2).
3. Take off washers (1).
4. Remove locking screws (5) and (4).
Result: Lever detached from actuator output shaft.
5. Remove coupling rod and lever.
6. Remove washers (3).
TIM-ID: 0000044549 - 003

Installing coupling rods (bypass and EGR shutoff flaps)
1. Insert coupling rod and washers (3).
2. Tighten lever with locking screw (5) and locknut (4) on output shaft to the specified tightening torque.
Nut / screw Tightening torque (Assembly paste (Ul- 6 Nm + 2 Nm
tra-Therm MTU))
3. Tighten washers (1) and locknuts (2) to the specified tightening torque.
Nut Tightening torque (Assembly paste (Ul- 16 Nm ± 2 Nm
tra-Therm MTU))
Note: Following each change to the mechanism of the exhaust recirculation system, an actuator test (teach-in
routine) with DiaSys® must be carried out. (→ Page 191).
Removing coupling rod (donor cylinder flap)

1. Remove guard plates of exhaust flap.
2. Remove locknuts (4).
3. Remove washers (3).
4. Remove locking screw (1) and locknut (2).
Result: Lever detached from actuator output shaft.
5. Remove coupling rod and lever.
6. Take off washers (5).
Installing coupling rod (donor cylinder flap)

1. Insert coupling rod and washers (5).
2. Tighten lever with locking screw (1) and locknut (2) on output shaft to the specified tightening torque.
TIM-ID: 0000044549 - 003

Nut / screw Tightening torque (Assembly paste (Ul- 6 Nm + 2 Nm
tra-Therm MTU))
3. Tighten washers (3) and locknuts (4) to the specified tightening torque.
Nut Tightening torque (Assembly paste (Ul- 16 Nm ± 2 Nm
tra-Therm MTU))

Note: Following each change to the mechanism of the exhaust recirculation system, an actuator test (teach-in
routine) with DiaSys® must be carried out. (→ Page 191).
TIM-ID: 0000044549 - 003

7.13 Starting Equipment
7.13.1 Starter – Condition check
Preconditions
Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 189).
TIM-ID: 0000000905 - 017

7.14 Lube Oil System, Lube Oil Circuit
7.14.1 Engine oil level – Check at sight glass
Preconditions
Engine oil level check at sight

glass
1. Make a preliminary visual check of oil lev-
el (2) at the sight glass (1).
2. A proper engine oil level check must al-
ways be carried out using the oil dipstick
(→ Page 154).
TIM-ID: 0000038098 - 002

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

gine start
1. Pull out dipstick from guide tube and wipe
it.
2. Insert dipstick into guide tube up to the
stop, pull out after approx. 10 seconds.
Check oil level on oil dipstick side marked
"5 Min. after Stop".
Note: After extended out-of-service periods, the
oil level may be up to 2 cm above the
"max." mark. This might be caused by en-
gine oil flowing from oil filter and heat ex-
changer back into the oil pan.
3. The oil level must reach the "max." mark or
exceed it by up to 2 cm.
4. If necessary, top up to "max." mark
(→ Page 155).
5. Insert oil dipstick into guide tube up to the
stop.
Checking engine oil level with the engine running

1. After the engine has run for approx. 10 minutes at a constant speed of 600 to 900 rpm, pull out oil
dipstick from guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, pull out after approx. 10 seconds. Check oil level on the
dipstick side marked "IDLE".
3. Oil level must not be lower than the "min" mark.
4. If necessary, top up to "max." mark (→ Page 155).
Checking oil level after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, pull out after approx. 10 seconds. Check oil level on oil
dipstick side marked "5 Min. after Stop".
3. Oil level must be between “min.” and “max.” marks.
4. If necessary, top up to "max." mark (→ Page 155).
5. Insert oil dipstick into guide tube up to the stop. TIM-ID: 0000026776 - 005

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

Ratchet F30027341 1
Ratchet F30450902 1
Engine oil
Sealing ring (→ Spare Parts Catalog)
WARNING
Hot oil.
Risk of burns! Risk of poisoning!
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
Oil change without semirotary hand 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 plugs (1) on driving and free
end and drain engine oil.
3. Fit drain plugs (1) on driving and free end
and with new sealing ring.
TIM-ID: 0000037912 - 003
Oil change using semirotary hand pump: Engine oil extraction

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

Draining residual oil from equip-
ment carrier (only with unsched-
uled engine oil change)
1. Provide a suitable container in which to col-
lect the engine oil.
2. Remove drain plug (1) and drain engine oil
from engine oil heat exchanger and from
engine oil filter.
3. Remove drain plugs (2, 3, 4) and drain en-
gine oil.
4. Replace engine oil filter (→ Page 158).
Note: Screw in drain plugs with new sealing ring.

5. Screw in drain plug (1) and tighten to specified tightening torque using a torque wrench.
Screw M18 x 1.5 Tightening torque (Engine oil) 50 Nm +10 Nm
6. Screw in drain plugs (2, 4) and tighten with torque wrench to the specified torque.
7. Screw in drain plug (3) and tighten to specified tightening torque using a torque wrench.
Filling with new engine oil

1. Open cover (1) on filler neck (2).
2. Pour oil in at filler neck (2) up to "max."
mark at oil dipstick.
3. Close cover (1) on filler neck (2).
TIM-ID: 0000037912 - 003

7.14.4 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 cen-
trifugal 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 engine oil for:
• Dispersing capacity (spot test);
• Water content;
• Fuel dilution.
TIM-ID: 0000000956 - 005

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

Filter wrench F30379104
Engine oil
Oil filter (→ Spare Parts Catalog)
WARNING
Hot oil.
Engine oil filter – Replacement

1. Stop engine and disable engine start.
2. After warning up and directly stopping the
engine, open the vent plug (1) on the oil
heat exchanger.
3. Wait 5 minutes until the oil system is vent-
ed and the oil has drained off.
Note: Always use a new sealing ring for the vent plug.
4. Screw the vent plug (1) back in.
TIM-ID: 0000028834 - 005

Screw M14 Tightening torque (Engine oil) 35 Nm +4 Nm

5. Remove engine oil filter using the filter
wrench.
6. Clean sealing surface on connecting piece.
Note: Only install engine oil filter with an integrat-
ed safety valve.
7. Check condition of the new oil filter sealing
ring and coat it with engine oil.
8. Screw the engine oil filter on and tighten by
hand.
9. Replace other engine oil filters in the same
way.
10. Bar the engine using the starting system
(→ Page 100).
TIM-ID: 0000028834 - 005

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

Cold cleaner (Hakutex 60) 50602 1
Filter sleeve 8591840001 1
Set of seals 23540304 1
WARNING
Hot oil.
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
TIM-ID: 0000038266 - 001

Cleaning centrifugal oil filter
and replacing filter sleeve
1. Release screw (1) and remove.
2. Remove clamp (3) and take off cover (2).
3. Carefully remove rotor assemble (12) from
housing (5).
4. Hold rotor assembly (12) firmly in position
with filter wrench and release knurled nut
(13).
5. Take off rotor cap (12).
6. Remove filter sleeve, stiffener plate and
sealing ring (10).
7. Measure thickness of oil residues on filter
sleeve.
8. If maximum layer thickness of oil residues
exceeds 30 mm, shorten maintenance in-
terval.
9. Take off standpipe (11) from lower rotor
section (9).
10. Wash hood (2), rotor cap (12), stiffener
plate, standpipe (11), rotor lower sec-
tion (9) and nozzles (7) with cold cleaner
and blow out with compressed air. Do not
use sharp-edged objects for cleaning.
11. Check nozzles (7) for obstructions.
12. Push standpipe (11) onto rotor lower sec-
tion (9).
13. Insert the new filter sleeve with stiffener
plate in rotor cap (12) with the smooth sur-
face facing the rotor cap.
14. Check sealing ring (10), fit new one if nec-
essary. Coat sealing ring with grease and
insert in groove of rotor cap (12).
15. Place rotor cap (12) onto standpipe (11).
16. Hold rotor assembly (12) firmly in position
with filter wrench and tighten curled nut
(13).
17. Lubricate bearings of rotor assembly (12),
insert in housing (5) and check for ease of
movement.
18. Check sealing ring (4), fit new one if neces-
sary. Fit sealing ring on housing (5).
19. Fit hood (2).
20. Tighten screw (1) by hand.
21. Install clamp (3) and tighten with torque wrench to the specified torque.
TIM-ID: 0000038266 - 001

Clamp Tightening torque 8 Nm +1 Nm
22. Tighten screw (1) with torque wrench to the specified tightening torque.
Screw Tightening torque 5 Nm +2 Nm

7.16 Coolant Circuit, General, High-Temperature Circuit
7.16.1 Engine coolant – Level check
Preconditions
WARNING
Checking engine coolant level at filler neck:

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

remote cooler:
Note: Engine coolant must be visible at marker
plate.
1. Check engine coolant level.
2. Top up engine coolant as necessary
(→ Page 167).
3. Check and clean cap.
4. Place cap on filler neck and close.
Checking engine coolant level via level sensor:

Note: Engine coolant level is automatically monitored by the engine control system.
1. Switch on engine control system and check readings on the display.
2. Top up engine coolant as necessary (→ Page 167).
TIM-ID: 0000000937 - 013

7.16.2 Engine coolant – Change
Coolant
Engine coolant change

TIM-ID: 0000000036 - 031

7.16.3 Engine coolant – Draining
Preconditions
WARNING
Coolant is hot and highly pressurized.
Risk of injury! Risk of scalding!
• Allow engine to cool down.
Preparatory steps
1. Provide a suitable container to collect the coolant.
2. Switch off preheating unit (external).
Engine coolant – Draining

1. Provide a suitable container to collect the coolant.
2. Turn cover on coolant expansion tank counterclockwise until the first stop and allow pressure to es-
cape.
3. Continue to turn cover counterclockwise and remove.
4. Extract remaining engine coolant in the coolant expansion tank via the filler neck.
5. Drain engine coolant at preheating unit (ex-
ternal).
6. Open drain valve (2) and drain engine cool-
ant at elbow on engine coolant pump.
7. Open drain valves (1) on A and B side of
crankcase and drain engine coolant.
Note: With the air compressor (optional) installed
at the drain point (A side), the drain valve is
inaccessible.
8. Open supply hose at air compressor.
TIM-ID: 0000030760 - 005

9. Drain remaining engine coolant at EGR
cooler, A and B side (arrow).
Final steps
1. Close all open drain points.
2. Fit cover on filler neck and close it.
TIM-ID: 0000030760 - 005

7.16.4 Exhaust flaps – Draining coolant from servomotors
Preconditions
WARNING
Component is hot.
Risk of burns!
WARNING
Preparatory steps
1. Provide a suitable receptacle to catch the coolant.
2. Drain the respective coolant circuit:
• Donor cylinder flap: Drain engine coolant (→ Page 164).
• Bypass flap/EGR shutoff flap: Drain charge-air coolant (→ Page 174).
Note: The procedure is described for one exhaust flap only but also applicable to the other exhaust flaps.
Overview of exhaust flaps (→ Page 144).
Draining coolant
Note: Collect coolant in a suitable container.
1. Release union nut (4) at the lower coolant
line (3).
2. Carefully pull coolant line (3) out of the un-
ion.
3. Release union nut (1) at the upper coolant
line (2).
4. Withdraw coolant line (2) slightly out of
threaded adapter.
Note: Wait until coolant no longer emerges from
the lines.
5. Retighten union nuts (1, 4) on coolant
lines (2, 3).
TIM-ID: 0000030758 - 003

7.16.5 Engine coolant – Filling
Preconditions

Engine coolant
WARNING
NOTICE
Filling cold coolant into a hot engine can result in thermal stress.
Danger of crack formation in engine!
• Only fill or top up coolant with the engine cold.
Preparatory steps
1. Turn cap (1) of coolant expansion tank (ex-
ternal) counterclockwise until the first stop
and allow pressure to escape.
2. Continue to turn cap (1) counterclockwise
and remove.
TIM-ID: 0000018688 - 006

Filling with engine coolant using
pump
1. Connect appropriate pump with hose to
drain valve (arrow).
2. Open vent points on EGR cooler (1, 7), dis-

tributor pieces (4, 6), exhaust turbocharg-
ers (2, 3) and oil heat exchanger (5).
3. Open drain valve and pump coolant into en-
gine at 0.5 bar minimum.
Result: When coolant emerges from the vent
points, close vent points one by one, pro-
ceeding from the lowest point upwards.
4. Fill expansion tank until overflow edge is
reached.
5. Close drain valve.
6. Check proper condition of cap and clean
sealing faces if required.
7. Fit cap on filler neck and close it.
8. Start engine (→ Page 29) and shut down af-
ter 10 seconds of operation without load
(→ Page 29).
9. Continue to turn cap counterclockwise and
remove.
10. Check engine coolant level (→ Page 162)
and top up engine coolant if necessary:
a) Fill coolant in expansion tank until the
coolant level at top edge of filler neck
remains constant.
b) Put on filler neck cap and close it.
c) Repeat the steps from "Start engine"
(→ Step 8) until no more engine coolant
needs to be topped up.
d) Disconnect pump and hose.
TIM-ID: 0000018688 - 006

Alternative: Filling engine cool-
ant via filler neck
1. Open vent points on EGR cooler (1, 7), dis-
tributor pieces (4, 6), exhaust turbocharg-
ers (2, 3) and oil heat exchanger (5).
2. Fill engine coolant in expansion tank via fill-
er neck until coolant level at top edge of
filler neck remains constant.
Result: When engine coolant emerges from the
vent points, close vent points one by one,
proceeding from the lowest point upwards.
3. Check cap to make sure it is in good condi-
tion and clean sealing faces, if required.
4. Fit cap on filler neck and turn until the first
stop to close.
5. Start engine (→ Page 29) and shut down af-
ter 10 seconds of operation without load
(→ Page 30).
6. Turn cap counterclockwise and remove.
7. Check engine coolant level (→ Page 162)
and top up engine coolant if necessary:
a) Repeat the steps from "Start engine"
(→ Step 5) until no more engine coolant
needs to be topped up.
b) Check cap to make sure it is in good
condition and clean sealing faces, if re-
quired.
c) Position filler neck cap and close it.
Final steps
1. Start the engine and run with no load for a few minutes.
2. Check engine coolant level (→ Page 162) and top up engine coolant if necessary.
TIM-ID: 0000018688 - 006

7.16.6 Engine coolant pump – Relief bore check
DANGER
WARNING
Engine coolant pump – Relief

bore check
1. Check relief bore (arrow) for oil and coolant
discharge.
2. Stop engine (→ Page 30) and disable en-
gine start, observe general safety instruc-
tions "Maintenance and Repair".
3. Clean 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 the number of drops is higher, contact
Service.
TIM-ID: 0000037916 - 003

7.16.7 Engine coolant – Sample extraction and analysis
Preconditions

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

tion 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 engine coolant for:
• Concentration of engine coolant addi-
tives
• pH value
6. Engine coolant change intervals (→ MTU
Fluids and Lubricants Specifications
(A001061/..)).
TIM-ID: 0000037917 - 003

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

1. Turn cap on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.
2. Continue to turn cap counterclockwise and remove.
Note: Charge-air coolant must be visible at mark-
er plate.
3. Check charge-air coolant level.
4. Top up charge-air coolant as necessary
(→ Page 177).
5. Check that cap is in serviceable condition.
6. Clean sealing surfaces as necessary.
7. Fit cap and close tight.
Checking charge-air coolant level by means of level sensor:

Note: Coolant level is automatically monitored by engine control system.
1. Switch on engine control system and check readings on the display.
2. Top up charge-air coolant as necessary (→ Page 177).
TIM-ID: 0000000042 - 008

7.17.2 Charge-air coolant – Change
Coolant
Charge-air coolant – Change

2. Fill with charge-air coolant (→ Page 177).
TIM-ID: 0000000041 - 011

7.17.3 Charge-air coolant – Draining
Preconditions

WARNING
Component is hot.
Risk of burns!
WARNING
Charge-air coolant – Draining

1. Provide a suitable container in which to collect the charge-air coolant.
2. Turn cover on coolant expansion tank counterclockwise until the first stop and allow pressure to es-
cape.
3. Continue to turn cover counterclockwise and remove.
4. Extract remaining charge-air coolant in the coolant expansion tank via the filler neck.
5. Open drain valve (2) and drain charge-air
coolant at charge-air coolant pump.
6. Unscrew drain screw (1) and drain charge-
air coolant at thermostat housing.
TIM-ID: 0000026956 - 006

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

cooler (low pressure) A-side (arrows).

cooler (low pressure) B-side (arrow).
TIM-ID: 0000026956 - 006

Note: • The procedure is only described for one
exhaust flap, but also applies to the re-
maining exhaust flaps. Exhaust flap over-
view (→ Page 144).
• Collect emerging engine coolant in a
suitable container.
10. Loosen the union nut (4) of the lower cool-
ant line (3).
11. Carefully pull the coolant line (3) out of the
union.
12. Loosen the union nut (1) of the upper cool-
ant line (2).
13. Pull the coolant line (2) somewhat out of
the union.
Note: Wait until no more coolant comes out of
the lines.
14. Tighten the union nuts (1, 4) of the coolant
lines (2, 3) again.
Final steps
1. Close all drain valves and screw in drain plugs with new sealing rings.
TIM-ID: 0000026956 - 006

7.17.4 Charge-air coolant – Filling
Preconditions

Charge-air coolant
WARNING
NOTICE
Filling cold coolant into a hot engine can result in thermal stress.
Danger of crack formation in engine!
• Only fill or top up coolant with the engine cold.
Preparatory steps
1. Turn cap (1) of coolant expansion tank (ex-
ternal) counterclockwise until the first stop
and allow pressure to escape.
2. Continue to turn cap (1) counterclockwise
and remove.
TIM-ID: 0000026958 - 005

Filling with engine coolant
through filler neck
1. Open vent points at intercooler (high pres-
sure) (5), intercooler (low-pressure) (1, 4)
and distributors (2, 3).
2. Fill charge-air coolant in expansion tank via
filler neck until charge-air coolant level at
top edge of filler neck remains constant.
4. Set cap onto filler neck and turn until the
first stop to close.
6. After 10 seconds of running the engine
without load, shut down the engine
(→ Page 30).
7. Turn cap counterclockwise and remove.
8. Check charge-air coolant level
(→ Page 172) and top up if required:
a) Repeat the steps from "Start engine"
(→ Step 5) until charge-air coolant no
longer needs to be topped up.
b) Check proper condition of cap and
clean sealing faces if required.
c) Position filler neck cap and close it.
Alternative: Filling with charge-

air coolant using pump
1. Connect suitable pump with a hose to one
of the drain valves (1, 2).
TIM-ID: 0000026958 - 005

2. Open vent points at intercooler (high pres-
sure) (5), intercooler (low pressure) (1, 4)
and distributors (2, 3).
3. Open drain valve and pump charge-air cool-
ant into engine at 0.5 bar minimum.
4. Fill expansion tank until overflow edge is
reached.
5. Close drain valve.
9. After 10 seconds of running the engine
without load, shut down the engine
(→ Page 30).
10. Turn cap on coolant expansion tank coun-
terclockwise until the first stop and allow
pressure to escape.
11. Continue to turn cap counterclockwise and
remove.
12. Check charge-air coolant level
(→ Page 172) and top up if required:
a) Fill charge-air coolant into expansion
tank until the coolant level at top edge
of filler neck remains constant.
b) Fit cap on filler neck and close it.
c) Repeat the steps from "Start engine"
(→ Step 8) until charge-air coolant no
longer needs to be topped up.
d) Disconnect pump and hose.
Final steps
1. Start the engine and run with no load for a few minutes.
2. Check charge-air coolant level (→ Page 172) and top up if required.
TIM-ID: 0000026958 - 005

7.17.5 Checking charge-air coolant pump pressure relief port
DANGER
WARNING
Checking charge-air coolant

pump pressure relief port
1. Check pressure relief port (arrow) for oil
and coolant discharge.
Note: Observe safety regulations when carrying
out maintenance and repair work
(→ Page 8).
2. Shut down engine (→ Page 30) and disable
engine start.
3. Clean the pressure relief port with a wire if
it is dirty.
• Permissible coolant discharge: up to
10 drops per hour
• Permissible oil discharge: up to 5 drops
per hour
Result: If discharge is greater, contact Service.
TIM-ID: 0000026960 - 009

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 B Cracks on entire circumference Replace (→ Page 184)
Drive belt C Chunking
Drive belt Belt is oily, shows signs of over-
heating
TIM-ID: 0000000920 - 011

7.19 Battery-Charging Generator
7.19.1 Checking battery-charging generator
Preconditions
WARNING
Air jet from compressed-air gun.
Risk of injury to eyes and organs! Risk of hearing damage!
• Never direct a compressed-air jet at persons.
• Wear goggles/safety mask and ear protectors.
Checking battery-charging generator

Ventilation area (arrow) Clean None
Ventilation area (arrows) Contaminated Clean
Cleaning battery-charging generator

Note: Dry-clean battery-charging generator only. Do not insert sharp objects into the ventilation holes.
1. Remove coarse dirt from battery-charging generator.
2. Blow out ventilation area (arrow) with compressed air until all dust is cleared.
TIM-ID: 0000030224 - 003

7.19.2 Battery-charging generator drive – Drive belt tension adjustment
Preconditions

Ratchet F30027341 1
Ratchet F30027340 1
WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
Adjusting belt tension

1. Remove protective cover.
2. Slacken screws (1) and (2) by half a turn.
Result: Belt tensioner moves against the drive belt
and tensions it.
TIM-ID: 0000000945 - 007
Screw M10 Tightening torque 60 Nm +5 Nm

Screw M10 Tightening torque 42 Nm
5. Install protective cover.

7.19.3 Battery-charging generator drive – Drive belt replacement
Preconditions

Ratchet F30027341 1
Ratchet F30027340 1
Drive belt (→ Spare Parts Catalog)
WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
Battery-charging generator drive – Drive belt replacement

2. Slacken screws (2) and (3) by half a turn.
3. Place socket adapter or box wrench on
screw (1) and press belt tensioner in the di-
rection indicated by the arrow as far as it
will go.
4. Tighten screw (3).
5. Remove the used drive belt.
6. Fit new drive belt.
7. Slacken screw (3) by half a turn.
Result: Belt tensioner moves against the drive belt
and tensions it.
TIM-ID: 0000022970 - 005
Screw M10 Tightening torque 60 Nm +5 Nm

Screw M10 Tightening torque 42 Nm
10. Install protective cover.
11. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 183).

7.20 Fan Drive
7.20.1 Fan drive – Drive belt check / adjustment
Preconditions

Optibell 2 belt tension tester Y4345711 1
Preparatory steps
2. Check belt condition visually (→ Page 181).
Result: For drive belt replacement, (→ Page 187).
Checking V-belt tension

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 operation with fan Belt tension adjustment
60 Hz ± 1 Hz 56 Hz ± 1 Hz
TIM-ID: 0000045460 - 001

Adjusting drive belt tension
1. Release screws (2) until fan coupling can
be moved.
2. Tighten stud (1) until the required frequen-
cy is achieved.
3. Tighten all screws (2) with torque wrench to specified tightening torque.
Screw Tightening torque 100 Nm ± 10 Nm
TIM-ID: 0000045460 - 001

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 185).
TIM-ID: 0000007457 - 004

7.21 Engine Mounting / Support
7.21.1 Engine mounting – Check
Preconditions

Torque wrench, 80 to 400 Nm F30027338 1
Ratchet F30027341 1
Engine oil
Checking general condition

Visually inspect mounts. • Damage Replace (→ Contact Service.)
• Brittleness
• Deformation
• Crack formation
• Swelling
visible
Check securing screws for firm

seating
1. Check securing screws (1, 2) for firm seat-
ing.
2. Tighten loose threaded connections with torque wrench to specified tightening torque.
TIM-ID: 0000037198 - 003

Screw M16 Control torque (Engine oil) 250 Nm +25 Nm

7.22 Wiring (General) for Engine/Gearbox/Unit
7.22.1 Еngine cabling ‒ Check
Preconditions

Solvent (isopropyl alcohol) X00058037 1
Еngine cabling ‒ 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 if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check that cable clamps are firm, tighten loose cable clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical line components for damage:
• Connector housing
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
8. Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
9. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 022

7.23 Accessories for (Electronic) Engine Governor / Control System
7.23.1 Resetting CDC parameter and entering IIG with DiaSys®
Preconditions
Note: If the parameters for the drift correction (CDC) are not reset, the emission certification becomes invalid.
Resetting parameters for drift correction (CDC) with DiaSys®

1. Use DiaSys® to reset the CDC parameters (→ Dialog system DiaSys® E531920/..).
2. If no DiaSys® is available, contact Service.
Entering the codes for the injectors (IIG) with DiaSys®

1. Use DiaSys® to enter the IIG (→ Dialog system DiaSys® E531920/..).
2. If no DiaSys® is available, contact Service.
TIM-ID: 0000045613 - 001

7.23.2 Actuators – Visual inspection and test
Preconditions
WARNING
Risk of crushing!
WARNING
Component is hot.
Risk of burns!
Checking actuators visually

Corrugated pipe (1) Damaged, holes or cracks. Replace
Coolant connections (2, 3) Traces of coolant leaks. Replace
Output shaft (4) Damaged Replace
TIM-ID: 0000044543 - 002

Connector (1) Damaged Replace
Actuator cable connection (2) Damaged, protective cap not seat- Replace, fit protective cap correct-
ed correctly. ly.
Actuator general condition Heavily contaminated by black ex- Replace
haust.
Checking actuators with DiaSys®

1. Switch on ECU.
2. Carry out actuator test with DiaSys® (teach-in routine) (→ manufacturer's documentation).
TIM-ID: 0000044543 - 002

7.23.3 Engine governor and connectors – Cleaning
Preconditions

Isopropyl alcohol X00058037 1
Note: Always use test connectors to enter the connectors. Never use test leads for this purpose. Otherwise
the contacts could be bent.
Engine governor and connectors – Cleaning

1. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol.
2. Remove dirt from the connector and cable surfaces with isopropyl alcohol.
3. Check legibility of cable labels. Clean or replace illegible labels.
Cleaning severely contaminated connectors on the engine governor

Note: Seal unused connectors with the supplied protective cap.
1. Release the latch and pull off connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and lock them.
TIM-ID: 0000000047 - 010

7.23.4 Engine governor plug connections – Check
Preconditions
☑Engine stopped and starting disabled.
NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.
Checking plug connections at engine governor

1. Check all plug connections for secure seating.
2. Latch loose connectors.
TIM-ID: 0000000048 - 008

7.23.5 NOx sensor – Replacement
Preconditions

Assembly compound (Molykote P 37) 50564 1
NOx sensor (→ Spare Parts Catalog) 1
WARNING
Component is hot.
Risk of burning!
NOTICE
High voltage.
Risk of damage to components!
• Switch off ignition before replacing components.
NOTICE
Ceramic cell breakage due to shock or impact.
• Avoid shocks and impacts.
• Exercise extreme care when handling sensors.
Removing NOx sensor

1. Observe the following general information:
• Layout and position of sensor
(→ Page 17).
2. Disconnect and remove connector (1) from
control unit.
3. Remove sensor (2).
4. Remove control unit.
TIM-ID: 0000025205 - 010

Note: Always only replace NOx sensor together with control unit.
Installing NOx sensor
Note:
1. Install control unit.
Note: If the sensor was subjected to shock or im-
pact load, it is considered to be defective
and may not be used.
2. Remove protective cap on thread only just
before installation.
Note: Do not wipe off the thread lubricant applied
by the manufacturer.
3. Coat sensor thread with specified assembly
compound as required.
4. Screw in sensor by hand.
5. Tighten nut (2) to specified torque using a torque wrench.

Nut M20 x 1.5 Tightening torque (Assembly compound 50 Nm ±10 Nm
(Molykote P 37))
6. Fit connector (1) and lock it.
TIM-ID: 0000025205 - 010

7.23.6 Lambda sensor – Replacement
Preconditions

Assembly compound (Molykote P 37) 50564 1
Lambda sensor (→ Spare Parts Catalog) 1
WARNING
Component is hot.
Risk of burning!
NOTICE
Ceramic cell breakage due to shock or impact.
• Avoid shocks and impacts.
• Exercise extreme care when handling sensors.
NOTICE
High voltage.
• Switch off ignition before replacing components.
Removing Lambda sensor

1. Observe the following general information:
• Layout and position of sensor
(→ Page 17).
2. Disconnect and remove connector (1).
3. Remove sensor (2).
TIM-ID: 0000025194 - 010

Installing Lambda sensor
Note: If the sensor was subjected to shock or im-
pact load, it is considered to be defective
and may not be used.
1. Remove protective cap on thread only just
before installation.
Note: Do not wipe off the thread lubricant applied
by the manufacturer.
2. Coat sensor thread with specified assembly
compound as required.
3. Screw in sensor by hand.
4. Tighten nut (2) to specified torque using a torque wrench.

Nut M18 x 1.5 Tightening torque (Assembly compound 40 Nm to 60 Nm
(Molykote P 37))
5. Fit connector (1) and lock it.
TIM-ID: 0000025194 - 010

8 Appendix A
8.1 Abbreviations
Abbre- Meaning Explanation
viation
A/D Analog/Digital Transformer: transforms sensor voltages into numer-
ic values
ADEC Advanced Diesel Engine Controller Engine management system
AFRS Air Filter Restriction Sensor
AGR Abgasrückführung Exhaust gas recirculation (EGR)
AL Alarm
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger (ETC)
ATS Air Temperature Sensor
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica-
tion No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Drift correction setting with DiaSys in engine gover-
nor
CEL Check Engine Light 1st function: Warning lamp (rectify fault as soon as
possible)
2nd function: Read out fault codes
CCT Circuit
CLS Coolant Level Sensor Monitors coolant level
CM Current Measurement Current measured value
CPS Coolant Pressure Sensor Monitors coolant pressure
CR Common Rail
CTS Coolant Temperature Sensor Monitors coolant temperature
DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel
DDL Diagnostic Data Link Diagnostic lines
DDR Diagnostic Data Reader Diagnostic unit
Dia Electronic dialog system
Sys®
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards
TIM-ID: 0000000858 - 014
(DIN = “Deutsche Industrie-Norm”)

DL Default Lost Alarm: Default CAN bus failure
DMC Data Matrix Code
DOC Diesel Oxidation Catalyst Oxidation catalyst before the diesel particulate filter
DPF Diesel Particulate Filter
DT Diagnostic Tool Diagnostic unit
ECM Electronic Control Module Electronic control unit of the DDEC system
ECU Engine Control Unit Engine governor
MS150112/01E 2014-10 | Appendix A | 199

viation
EDM Engine Data Module Memory module for engine data
EE- Electrically Erasable Programmable Read
PROM Only Memory
EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal
EGR Exhaust Gas Recirculation
EIL Engine Ident Label
EIM-ID Emission Identification Number
EMU Engine Monitoring Unit
ESCM Extreme Site Condition Management Power reduction with extreme site conditions
ESD Einzelspeicherdruck Individual fuel accumulator pressure
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
EUI Electronic Unit Injector Electronic injection nozzle unit
FO Frequency Output
FPS Fuel Pressure Sensor Monitors fuel pressure
FRS Fuel - Differential Pressure Sensor
FTS Fuel Temperature Sensor Monitors fuel temperature
FWCP Fire Water Control Panel Control cabinet
GND Ground
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HP High Pressure
HT High Temperature
IDM Interface Data Module Memory module for interface data
IIG Initiale Injektorgleichstellung Initial input of injector code with DiaSys in engine
governor
INJ Injector
ISO International Organization for Standardiza- International umbrella organization for all national
tion standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
L1 Limit 1 Limit value, limit 1
L2 Limit 2 Limit value, limit 2
LED Light Emitting Diode
LLK Ladeluftkühlung Charge-air cooling/cooler (CAC)
LP Low Pressure
TIM-ID: 0000000858 - 014
LO Low Alarm: Measured value lower than 1st minimum limit

value
LOLO Low Low Alarm: Measured value lower than 2nd minimum lim-
it value
LSG Limit Speed Governor
LSU Lambda Sonde Universal
LT Low Temperature
MCR Maximum Continuous Rating Torque limitation curve
200 | Appendix A | MS150112/01E 2014-10

viation
N/A Not Applicable
NN Normalnull Reference area for heights above sea level
OEM Original Equipment Manufacturer
OI Optimized Idle
OLS Oil Level Sensor Monitors oil level
OPS Oil Pressure Sensor Monitors oil pressure
OTS Oil Temperature Sensor Monitors oil temperature
OT Oberer Totpunkt Top Dead Center (TDC)
PAN Panel Control panel
PIM Peripheral Interface Module
PWM Pulse Width Modulation Modulated signal
P-xyz Pressure-xyz Pressure measuring point xyz
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
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 / Security Shutdown Safety system alarm
TBS Turbocharger Boost Sensor Monitors charge-air pressure
TCI Turbo Compressor Inlet
TCO Turbo Compressor Outlet
TD Transmitter Deviation Alarm: Sensor comparison fault
TPS Throttle Position Sensor
TRS Timing Reference Sensor
T-xyz Temperature-xyz Temperature measuring point xyz
U_PDU Voltage Power Driver Unit Supply voltage of solenoid valve final stages
UDV Überdruckventil Pressure relief valve
UT Unterer Totpunkt Bottom Dead Center (BDC)
VNT Variable Nozzle Turbine
VSG Variable-Speed Governor
VSS Vehicle Speed Sensor
TIM-ID: 0000000858 - 014
WZK Wekrkzeugkatalog Tool Catalog (TC)

ZKP Zuordnung - Kategorie - Parameter Number assigned to a parameter that describes the
function and assignment
MS150112/01E 2014-10 | Appendix A | 201

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 person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015
202 | Appendix A | MS150112/01E 2014-10

9 Appendix B
9.1 Special Tools
Allen key
Part No.: F30002815
Qty.: 1
Used in: 7.5.3 Valve clearance – Check and adjustment
(→ Page 112)
Barring device
Part No.: F6787910
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 99)
Barring device
Part No.: F6555766
Qty.: 1
Used in: 7.3.1 Cylinder liner – Endoscopic examination
(→ Page 103)
DCL-ID: 0000029808 - 003
Crocus cloth
Part No.:
Qty.:
Used in: 7.12.3 EGR cooler ‒ Check (→ Page 143)
MS150112/01E 2014-10 | Appendix B | 203

Depth gauge, 200 mm
Part No.: Y20000918
Qty.: 1
Used in: 7.5.2 Valve projection – Measurement (→ Page 109)
Endoscope
Part No.: Y20097353
Qty.: 1
(→ Page 103)
Qty.: 1
Used in: 7.10.2 Exhaust turbocharger (LP) – Turbine housing
check (→ Page 126)
Qty.: 1
Used in: 7.10.3 Exhaust turbocharger (HP) – Turbine housing
Feeler gauge
Part No.: Y20098771
Qty.: 1
(→ Page 112)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.9.1 Fuel filter – Replacement (→ Page 123)
Qty.: 1
DCL-ID: 0000029808 - 003
Used in: 7.9.2 Additional fuel filter – Replacement (→ Page 124)

Qty.:
Used in: 7.15.1 Engine oil filter – Replacement (→ Page 158)
Qty.: 1
Used in: 7.15.2 Centrifugal oil filter – Cleaning and filter-sleeve
replacement (→ Page 160)
204 | Appendix B | MS150112/01E 2014-10

Installation/removal device
Part No.: F6789889
Qty.: 1
Used in: 7.7.2 Injector – Removal and installation (→ Page 118)
Milling cutter
Part No.: F30452739
Qty.: 1
MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 7.14.4 Engine oil – Sample extraction and analysis
(→ Page 157)
Qty.: 1
Used in: 7.16.7 Engine coolant – Sample extraction and analysis
(→ Page 171)
Oilstone
Part No.: 8205893261/00
Qty.: 1
Used in: 7.12.3 EGR cooler ‒ Check (→ Page 143)
DCL-ID: 0000029808 - 003
MS150112/01E 2014-10 | Appendix B | 205

Optibell 2 belt tension tester
Part No.: Y4345711
Qty.: 1
Used in: 7.20.1 Fan drive – Drive belt check / adjustment
(→ Page 185)
Ratchet
Part No.: F30006212
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 99)
Ratchet
Part No.: F30027341
Qty.: 1
Used in: 7.14.3 Engine oil – Change (→ Page 155)
Qty.: 1
Used in: 7.19.2 Battery-charging generator drive – Drive belt
tension adjustment (→ Page 183)
Qty.: 1
Used in: 7.19.3 Battery-charging generator drive – Drive belt re-
placement (→ Page 184)
Qty.: 1
Used in: 7.21.1 Engine mounting – Check (→ Page 188)
Ratchet
Part No.: F30450902
Qty.: 1
DCL-ID: 0000029808 - 003
206 | Appendix B | MS150112/01E 2014-10

Ratchet
Part No.: F30027340
Qty.: 1
Qty.: 1
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 7.12.8 Exhaust flaps – Coupling rod replacement
(→ Page 149)
Qty.: 1
Used in: 7.23.5 NOx sensor – Replacement (→ Page 195)
Qty.: 1
Used in: 7.23.6 Lambda sensor – Replacement (→ Page 197)
Ratchet with extension

Part No.: F30006212
Qty.: 1
(→ Page 103)
Socket for lambda sensor / NOx sensor

Part No.: F30453932
Qty.: 1
DCL-ID: 0000029808 - 003
MS150112/01E 2014-10 | Appendix B | 207

Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
(→ Page 112)
Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 4.7 Plant – Cleaning (→ Page 32)
Torque wrench, 0.5-5 Nm

Part No.: 0015384230
Qty.: 1
Torque wrench, 10-60 Nm

Part No.: F30452769
Qty.: 1
DCL-ID: 0000029808 - 003
208 | Appendix B | MS150112/01E 2014-10

Part No.: F30452769
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1
Used in: 7.23.5 NOx sensor – Replacement (→ Page 195)
Qty.: 1
Used in: 7.23.6 Lambda sensor – Replacement (→ Page 197)

Part No.: F30047798
Qty.: 1

Part No.: F30044239
Qty.: 1
Used in: 7.15.2 Centrifugal oil filter – Cleaning and filter-sleeve
replacement (→ Page 160)
DCL-ID: 0000029808 - 003
MS150112/01E 2014-10 | Appendix B | 209

Part No.: F30027337
Qty.: 1

Part No.: F30027336
Qty.: 1
Used in: 7.12.8 Exhaust flaps – Coupling rod replacement
(→ Page 149)

Part No.: F30452768
Qty.: 1
DCL-ID: 0000029808 - 003
210 | Appendix B | MS150112/01E 2014-10

Part No.: F30452768
Qty.: 1
(→ Page 112)
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1
Torque wrench, 80 to 400 Nm

Part No.: F30027338
Qty.: 1
Used in: 7.21.1 Engine mounting – Check (→ Page 188)
DCL-ID: 0000029808 - 003
MS150112/01E 2014-10 | Appendix B | 211

9.2 Index
Numerics D
12V 4000 C64 engine data 20 Display
– Fault messages display 37
A Drive belt
Abbreviations 199 – Condition check 181
Actuators
– Function check 145 E
– Function test 191 ECU9
– Overview 17 – Fault messages 38
– Visual inspection 191 EGR cooler
Additional fuel filter – Check 143
– Replacement 124 – Cleaning 142
After stopping the engine 31 – Overview 141
Auxiliary PTO Engine
– Replacement 102 – Barring
– With starting system 100
B – Barring manually 99
Battery-charging generator – Main dimensions 25
– Check 182 – Mounting check 188
– Drive belt replacement 184 – Overview 16
– Drive belt tension adjustment 183 – Starting in manual mode 29
– Stopping in manual mode 30
C – Test run 101
CDC – troubleshooting 35
– Reset 190 Engine cabling
Centrifugal oil filter – Check 189
– Cleaning 160 Engine coolant
Charge-air coolant – Change 163
– Change 173 – Check
– Check – Level at external cooler 162
– Level at filler neck 172 – Level at filler neck 162
– Level via level sensor 172 – Level via level sensor 162
– Draining 174 – Draining 164
– Filling 177 – Filling 167
Charge-air coolant pump – Sample extraction and analysis 171
– Pressure relief port check 180 Engine coolant pump
Connectors – Relief bore check 170
– Cleaning 193 Engine driving end
Contact persons 202 – Definition 15
Coolant Engine free end
– Change 163, 173 – Definition 15
Coupling rods Engine governor
– Check 147 – Cleaning 193
– Replacement 149 – Plug connections
Crankcase breather
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– Check 194
– Oil mist fine separator Engine mounting
– Replacement 107 – Check 188
Cylinder Engine oil
– Designation 15 – Analysis 157
Cylinder head cover – Change 155
– Removal and installation 115 – Level check with oil dipstick 154
Cylinder liner – Sample extraction 157
– Endoscopic examination 103 Engine oil filter
– Instructions and comments on endoscopic and visual – Replacement 158
examination 105
212 | Appendix B | MS150112/01E 2014-10

Engine oil level M
– Check at sight glass 153 Maintenance Schedule
– Check with oil dipstick 154 – Maintenance task reference table [QL1] 33
Engine sides MTU contact persons 202
– Designation 15
Engine – Overview 16 N
Exhaust flaps NOx sensor
– Actuator check 145 – Replacement 195
– Draining coolant 166
– Overview 144, 146 O
Exhaust flaps (exhaust gas recirculation) 146 Operational checks 28
Exhaust turbocharger
– Check P
– Turbine housing (high-pressure) 134 Parameters for drift correction (CDC)
– Turbine housing (low-pressure) 126 – Reset 190
– Turbine housing check 125 Plant
– Cleaning 32
F Pump
Fan drive – Charge-air coolant
– Drive belt check / adjustment 185 – Pressure relief port check 180
– Drive belt replacement 187 – Engine coolant
Fault messages – Relief bore check 170
– Display 37 Putting into operation
– List 38 – Preparations after long out-of-service periods
Filter (>3 months) 26
– Replacement
– Fuel 123 R
Filter sleeve Recommissioning
– Replacement 160 – Preparation after scheduled out-of-service period 27
Firing order 24
Flaps S
– Overview 144 Safety notices, standards 13
Fuel filter Safety regulations
– Replacement 123 – Auxiliary materials 11
Fuel system – Environmental protection 11
– Venting 122 – Fire prevention 11
– Fluids and lubricants 11
H – Organizational requirements 6
Hotline 202 – Personnel requirements 6
HP pump Safety requirements
– Relief bore check 116 – Important requirements 5
– Maintenance work 8
I – Operation 7
IIG – Repair work 8
– Input 190 – Safety notices, standards 13
Injector 118 – Startup 7
– Removal and installation 118 Sensors
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– Replacement 117 – Overview 17

Injector coding (IIG) – Replacement
– Input 190 – Lambda 197
Injectors – NOx 195
– Overview 17 Service partners 202
Intercooler Spare parts service 202
– Leak check 140 Starter
– Condition check 152
L
Lambda sensor T
– Replacement 197 Transport 14
Troubleshooting 35
MS150112/01E 2014-10 | Appendix B | 213

Turbine housing
– Check 125
V
Valve clearance
– Adjustment 112
– Check 112
Valve gear
– Lubrication 108
Valve projection
– Measurement 109
W
Wiring
– Check
– On engine 189
DCL-ID: 0000029808 - 003
214 | Appendix B | MS150112/01E 2014-10


Operating Instructions: Diesel Engine 12V 4000 C64 Application Group 5B

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6 Troubleshooting 7.11.1 Intercooler – Leak check 140

6.1 Troubleshooting 35 7.12 Exhaust Gas Recirculation 141

MS150112/01E 2014-10 | Table of Contents | 3

7.17 Low-Temperature Circuit 172 8 Appendix A

DCL-ID: 0000029808 - 003

4 | Table of Contents | MS150112/01E 2014-10

MS150112/01E 2014-10 | Safety | 5

Working clothes and personal protective equipment

TIM-ID: 0000040531 - 003

6 | Safety | MS150112/01E 2014-10

Safety requirements for operation

Malfunctions and emergency stop

Operation of electrical equipment

MS150112/01E 2014-10 | Safety | 7

Safety requirements during maintenance and repair work

Ensure that all retainers and dampers are installed correctly.

8 | Safety | MS150112/01E 2014-10

Safety requirements after completing maintenance and repair work

Hydraulic installation and removal

Working with batteries

MS150112/01E 2014-10 | Safety | 9

Working with laser equipment

Measuring component deviations

10 | Safety | MS150112/01E 2014-10

Environmental protection and disposal

Fluids and lubricants and auxiliary materials

coming into contact with ignition sources and do not smoke.

MS150112/01E 2014-10 | Safety | 11

Paints and varnishes

Acids/alkaline solutions/urea (AdBlue®, DEF)

• Observe the relevant safety data sheet for all materials.

12 | Safety | MS150112/01E 2014-10

MS150112/01E 2014-10 | Safety | 13

Placement after transport

14 | Safety | MS150112/01E 2014-10

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

MS150112/01E 2014-10 | General Information | 15

1 Oil heat exchanger 11 Engine mounting 21 Fuel priming pump

Engine model designation

C Application: Construction and Industrial, mobile

16 | General Information | MS150112/01E 2014-10

1 B13 - Crankshaft speed 3 F57 - Charge-air coolant

MS150112/01E 2014-10 | General Information | 17

TIM-ID: 0000045455 - 001

18 | General Information | MS150112/01E 2014-10

MS150112/01E 2014-10 | General Information | 19

GENERAL CONDITIONS (for maximum power)

20 | Technical Data | MS150112/01E 2014-10

COMBUSTION AIR / EXHAUST GAS

COOLANT SYSTEM (HT circuit)

COOLANT SYSTEM (LT circuit)

Thermostat: Fully open R °C 51

LUBE OIL SYSTEM

MS150112/01E 2014-10 | Technical Data | 21

GENERAL OPERATING DATA

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

WEIGHTS (basic design, dry engine)

22 | Technical Data | MS150112/01E 2014-10

MS150112/01E 2014-10 | Technical Data | 23