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Operating Instructions

Diesel engine
12 V 1600 R50

MS15033/03E

Engine model kW/cyl. Application group
12V1600R50 58 kW/cyl. 2A, continuous operation, unrestricted

Table 1: Applicability

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Table of Contents
1 Safety 7.1.2 Cylinder head cover – Removal and
installation 75
1.1 Important provisions for all products 5
1.2 Personnel and organizational requirements 6 7.2 Fuel System 76
7.2.1 Fuel system – Venting 76
1.3 Transportation 7
1.4 Safety regulations for startup and operation 8 7.3 Fuel Filter 78
1.5 Safety precautions when working on the 7.3.1 Fuel filter – Replacement 78
engine 10 7.3.2 Fuel prefilter – Condensate draining 80
1.6 Fire prevention and environmental 7.3.3 Fuel prefilter – Filter element replacement 81
protection, fluids and lubricants, auxiliary 7.4 Air Filter 82
materials 13 7.4.1 Air filter element – Removal and installation
1.7 Standards for safety notices in the text 15 (optional) 82
7.4.2 Air filter element and (optional) dust bowl ‒
2 General Information Cleaning 83
7.4.3 Air filter – Replacement (option) 84
2.1 Engine side and cylinder designations 16 7.5 Air Intake 85
2.2 Engine overview 17 7.5.1 Service indicator – Signal ring position check 85
2.3 Sensors and actuators – Overview 18
7.6 Exhaust Gas Aftertreatment 86
7.6.1 Regeneration procedure 86
3 Technical Data
7.7 Lube Oil System, Lube Oil Circuit 87
3.1 Firing order 22 7.7.1 Engine oil level – Check 87
3.2 Engine – Main dimensions 23 7.7.2 Engine oil – Change 88
3.3 12V1600R50 product data 24
7.8 Oil Filtration / Cooling 89
7.8.1 Engine oil filter – Replacement 89
4 Operation
7.9 Coolant Circuit, General, High-Temperature
4.1 Putting the engine into operation after Circuit 90
scheduled out-of-service-period 27 7.9.1 Engine coolant – Level check 90
4.2 Putting the engine into operation after 7.9.2 Engine coolant – Change 91
extended out-of-service periods (>3 months) 28 7.9.3 Engine coolant – Draining 92
4.3 Starting the engine 29 7.9.4 Engine coolant – Filling 94
4.4 Operational checks 30 7.9.5 Engine coolant pump – Relief bore check 96
4.5 Engine – Stop 31 7.10 Low-Temperature Circuit 97
4.6 After stopping the engine 32 7.10.1 Charge-air coolant level – Check 97
4.7 Plant – Cleaning 33 7.10.2 Charge-air coolant – Change 98
4.8 Engine – Barring manually 34 7.10.3 Charge-air coolant – Draining 99
7.10.4 Charge-air coolant – Filling 100
7.10.5 Charge-air coolant pump – Relief bore check 102
5 Maintenance
7.11 Belt Drive 103
5.1 Maintenance task reference table [QL1] 36 7.11.1 Coolant pump – Drive belt replacement 103
DCL-ID: 0000029795 - 004

6 Troubleshooting 7.12 Battery-Charging Generator 105
7.12.1 Battery-charging generator – Belt tensioner
6.1 Troubleshooting 37 and diverter pulley replacement 105
6.2 Fault messages of Engine Control Unit 7.12.2 Battery-charging generator – Drive belt
ECU 9 for Series 1600, rail applications 40 removal and installation 107

7.13 Drive Systems, Driving End and Free End
7 Task Description (Coupling) 108
7.13.1 Coupling – Radial clearance check 108
7.1 Valve Drive 72
7.1.1 Valve clearance – Check and adjustment 72 7.14 Wiring (General) for Engine/Gearbox/Unit 109

MS15033/03E 2016-02 | Table of Contents | 3

004 4 | Table of Contents | MS15033/03E 2016-02 .15 Accessories for (Electronic) Engine Governor / Control System 110 9 Appendix B 7.14.15.15.3 NOx sensor – Replacement 112 7.4 Lambda sensor – Replacement 114 8 Appendix A 8.1 Special Tools 120 7.2 MTU Contact/Service Partners 119 7. 7.1 Abbreviations 116 DCL-ID: 0000029795 .1 Engine governor and connector – Cleaning 110 9.1 Engine cabling – Check 109 8.2 Index 124 7.2 Engine governor – Checking plug-in connections 111 9.15.15.

Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu- lation authorities. TIM-ID: 0000040530 . All EU-certified engines delivered by MTU come with a second nameplate.1 Important provisions for all products Nameplate The product is identified by nameplate.008 MS15033/03E 2016-02 | Safety | 5 . Nameplate. 1 Safety 1. Emission control units/systems may only be maintained. • Remove the emission labels from the replaced part and destroy them. Please note the following when replacing components with emission labels: • The relevant emission labels must be affixed to the spare part. these labels must remain on the engine throughout its opera- tional life. The manufacturer does not accept any liability for violations of the emission regulations. military applications other than by US government agencies are ex- cepted from this proviso. • Do not transfer the emission labels from the replaced part to the spare part. ex- changed or repaired if the components used for this purpose are approved by the manufacturer. General information This product may pose a risk of injury or damage in the following cases: • Incorrect use • Operation. Engines used exclusively in land-based. model designation or serial number can be found on the product. model designation or serial number and must match with the infor- mation on the title page of this manual. maintenance and repair by unqualified personnel • Modifications or conversions • Noncompliance with the safety instructions and warning notices Emission regulations and emission labels Responsibility for compliance with emission regulations Modification or removal of any mechanical/electronic components or the installation of additional compo- nents including the execution of calibration processes that might affect the emission characteristics of the product are prohibited by emission regulations. When operating the machine in the EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi- cations. The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product. Replacing components with emission labels On all MTU engines fitted with emission labels.

Keep this manual handy in the vicinity of the product such that it is accessible to operating. assembly. maintenance. drugs or strong medication. These personnel must be instructed repeatedly. breathing mask. plant construction. repair. 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 • Technical personnel from the areas mechanical engineering. as- sembly. repair. e. assembly. Clothing and personal protective equipment Always wear appropriate personal protective equipment. installation. installa- tion. repair.008 6 | Safety | MS15033/03E 2016-02 . Personnel must receive instruction on product handling and maintenance based on this manual with a spe- cial emphasis on safety requirements and warnings. goggles. Personnel shall not report for duty under the influence of alcohol. safety shoes. installation. and transport personnel at all times. maintenance.g. Follow the instructions concerning personal protective equipment in the descrip- tions of the individual activities. This is important in the case of personnel who only occasionally perform work on or around the product. 1. and electrical engineering The operator must define the responsibilities of the personnel involved in operation. protective gloves. maintenance. ear protectors.2 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation. and transport in writing. or transportation. TIM-ID: 0000040531 .

• Only use transport and lifting devices approved by MTU. • If the engine is supplied with special aluminium foil packing. Transportation • Lift the engine only with the lifting eyes provided.3 Transportation Taking the engine's center of gravity into account For information on the center of gravity of the engine. 1. • Always transport the in installation position. TIM-ID: 0000000872 . • Lift engines by approx. If this is not the case. the lifting equipment must be re-adjusted. do not exceed max. permissible diagonal pull in longitudinal direction: 10 degrees. refer to engine installation/arrangement drawing. – Max. • Never set down the engine onto the oil pan unless expressly permitted by MTU on an engine-specific base.005 MS15033/03E 2016-02 | Safety | 7 . • Only set down engine on a firm. permissible diagonal pull in transverse direction: 10 degrees. level surface. Setting down the engine following transportation • Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. with no diagonal pull in transverse direction. lift the engine at the lifting eyes of the bear- ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck). • Secure the engine such as to preclude slipping and tipping when driving up or down inclines and ramps. • Secure the engine against tilting during transport. with no diagonal pull in longitudinal direction. 10 mm and verify that the lifting ropes / chains between engine and lifting equip- ment run vertically or in accordance with the specifications on the installation drawing. permissible diagonal pull: – Max.

during operation. • Check that all connections have been correctly allocated (e. • No persons wearing pacemakers or any other technical body aids are present. Immediately after putting the product into operation. Safety regulations during operation The operator must be familiar with the control and display elements. 8 | Safety | MS15033/03E 2016-02 . Always wear respiratory protection in the operating room during this period.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. direction). the product emits gases as a result of smoldering e. Smoking is prohibited in the area of the product. generator terminals or cables against accidental contact. • Respond by taking any necessary emergency action. violation of limit values and warning or alarm messages. • All loose parts have been removed from rotating machine components.012 to do so following a written procedure. • The exhaust system is leak-tight and that the gases are vented to atmosphere. i. Do not touch the product unless expressly instructed TIM-ID: 0000040533 . 1. The following requirements must be fulfilled before the product is started: • Wear ear protection. During operation. +/. Whenever the product is subsequently taken into operation ensure that: • All personnel is clear of the danger zone surrounding moving parts of the machine. emergency stop. • In the first few hours of operation. under voltage/high tension. Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched on. especially emergency stopping. the display instruments and monitoring units must be permanently observed with regard to present operating status. e.g. Do not inhale the exhaust gases of the product. Operation Do not remain in the operating room when the product is running for any longer than absolutely necessary. These gases may be hazardous to health. at regular intervals. • All safety equipment is in place.e. • All maintenance and repair work has been completed. Keep a safe distance away from the product if possible.polarity.g. make sure that all control and display instruments as well as the signaling and alarm systems work properly. • The service room is adequately ventilated. • Protect battery terminals. Operation of electrical equipment Parts of the electrical equipment are live. Malfunctions and emergency stop Practice emergency procedures. The following steps must be taken if a malfunction of the system is detected or reported by the system: • Inform supervisor(s) in charge.g. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled. The operator must be familiar with the consequences of any operations performed. lacquers or oil. • Analyze the message. • Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.

Follow the applicable warning instructions pertaining to such devices.012 MS15033/03E 2016-02 | Safety | 9 . TIM-ID: 0000040533 .

Elastomer components (e. fluids and lubricants. Safety regulations during maintenance and repair work Take special care when removing ventilation or plug screws from the product. When changing the oil or working on the fuel system. or air). Use the specified lifting equipment for all components. Adopt suitable measures to avoid that components/tools fall down. Lock-out the product to preclude undesired starting. always use suitable ladders and work platforms. couplings and V-belts) must not be painted.g. • Start interlock • Key switch • With hydraulic starting system: shut off supply line. engine mounts. fuel. unless: • It is expressly permitted to do so following a written procedure. When working high on the equipment. Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. They may only be installed after painting the engine or must be covered before painting work is carried out.g. ensure that the service room is adequately ventilated. then release the residual pressure. Use only proper and calibrated tools. risk of burning). TIM-ID: 0000040535 . shut off the lines first. Disconnect the control equipment from the product. Always seal connections with caps or covers if a line is removed or opened. Carry out work only on assemblies or plants which are properly secured. if fitted. Use the recommended special tools or suitable equivalents when instructed to do so. Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start- ers are fitted. Fit new seals when re-installing lines.5 Safety precautions when working on the engine Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. • Observe the safety data sheet. Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors. components carrying oil. Lock out circuit breakers. damping elements. 1. Make sure components or assemblies are placed on stable surfaces. • The product is running in the low load range and only for as long as absolutely necessary. Never work on en- gines or components that are held in place by lifting equipment. Do not blow out the interior of the flywheel housing or the starter with compressed air. Release residual pressure before removing or replacing a component in the supply line. Clean the flywheel housing inside with a class H dust extraction device. Attach “Do not operate” sign in the operating area or to control equipment. Keep fuel injection lines and connections clean. The following applies to starters with copper-beryllium alloy pinions: • Wear a respirator mask (filter class P3). Observe the specified tightening torques during assembly or disassem- bly. To depressurize pres- surized lines.g. e. Never carry out maintenance and repair work with the product in operation.012 Never use the product as a climbing aid. Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e. Use suita- ble collecting vessels of adequate capacity to catch fluids and lubricants. 10 | Safety | MS15033/03E 2016-02 . Disconnect the battery cables or actuate the battery isolating switch.

Remove any condensate from components which were chilled before assembly. Do not use product as ground terminal. jigs and fixtures to be used. Ensure that the grounding system is properly connected. Use only the specified jigs and fixtures for hydraulic removal/installation procedures. lines. permissible force-on pressure specified for the jig/fixture. or crossing cabling harnesses of the product. make sure that nobody is standing in the danger zone of the product. TIM-ID: 0000040535 . Check that all access ports/apertures which have been opened to facilitate working are closed again. exhaust pipe) from the product before performing necessary welding work. Before starting welding work: • Switch off the power supply master switch. coat the com- ponents with a suitable corrosion inhibitor. Safety regulations following maintenance and repair work Before barring the engine. Check that all safety equipment has been installed and that all tools and loose parts have been removed (especially the barring gear). • During the removal procedure. Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact with other components. Ensure that all retainers and dampers are installed correctly. No other maintenance or repair work must be carried out in the vicinity of the product while welding is going on. the pumps and the pipework at the relevant designated points. The welding current may otherwise induce an interference voltage in the cabling harnesses which could conceiv- ably damage the electrical system. screw on device with retracted plunger. Note cooling time for components which are heated for installation or removal (risk of burning).g. Do not attempt to bend or exert force on H.P. Pay particular attention to cleanliness at all times. Never position the welding power supply cable adjacent to. Cover the product when welding in its vicinity. particularly the fuel lines. • During the installation procedure. Welding work Welding operations on the product or mounted units are not permitted. Ensure that O-rings are not installed in a slanted/twisted condition. Do not place fuel or oil lines near hot components. Risk of explosion or fire due to oil vapors and highly flammable process materials. For a hydraulic installation/removal device with central expansion pressure supply.012 Observe the max. Before starting work. MS15033/03E 2016-02 | Safety | 11 . If necessary. Hydraulic installation and removal Check satisfactory function and safe operating condition of tools. screw on device with pushed-in plunger.g. Do not touch elastomeric seals (e. • Separate the electrical ground of electronic equipment from the ground of the unit. Remove components (e. Viton sealing rings) with your bare hands if they have a carbonized or resinous appearance. Never bend lines and avoid damaging lines. including rags and cable straps).g. Ensure that no unattached parts have been left in/on the product (e. • Disconnect the battery cables or actuate the battery isolating switch. screw spindle into shaft end until correct sealing is established. pay attention to the following: • Vent the installation/removal device.

in accordance with their class and usage. with protective devices for ensur- ing safe operation. Follow the safety in- structions in the manufacturer's user manual when working with laser equipment. When reconnecting. Avoid sparks and naked flames. Do not damage cabling during removal work. During hydraulic installation/removal of components.012 Measuring component dimensions Workpieces. protect them against moisture in particular. De-energize the appropriate areas prior to working on assemblies. Do not secure cables on lines carrying fluids. Gases released from the battery are explosive. components and measuring equipment lie in the specified tolerance range at a reference tem- perature of 20 °C. Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries. Battery pole reversal may lead to in- jury through the sudden discharge of acid or bursting of the battery body. Wear protective clothing. Do not place objects on the battery. Always use connector pliers to tighten union nuts on connectors. Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation). Check cor- rect execution of the emergency stop function in particular. ensure that no persons are in the direct vicinity of the component being pressed. Working on electrical and electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so. Do not use cable straps to secure cables. Do not allow battery acids to come into contact with skin or clothing.e. i. Before connecting the cable to the battery. ensure that cabling cannot be damaged during operation by: • Contact with sharp edges • Chafing on components • Contact with hot surfaces. 12 | Safety | MS15033/03E 2016-02 . Work with laser devices Work with laser devices shall be carried out by trained and qualified personnel only. Store spare parts properly prior to replacement. TIM-ID: 0000040535 . Subject the device as well as the product to a functional testing on completion of all repair work. goggles and protective gloves. Laser devices must be equipped. check the battery polarity. Package faulty electronic components or assemblies properly before dispatching for repair: • Moisture-proof • Shock-proof • Wrapped in antistatic foil if necessary.

Within the EU. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Before welding.010 Lead • Adopt suitable measures to avoid the formation of lead dust. When working with combustible indirect materials. MS15033/03E 2016-02 | Safety | 13 . lubricants and filters in accordance with local regulations. To avoid sparks in the vicinity of the battery. chilled or caustic materials. Oil or fuel on hot components can cause fires – therefore always keep the product in a clean condition. connect the ground lead last and remove it first. Always have a suitable extinguishing agent (fire extinguisher) on hand and familiarize yourself fully with its handling. avoid direct contact to the skin and do not inhale lead vapors. fluids and lubricants. TIM-ID: 0000040536 . • Switch on extraction system. Do not store combustible materials near the product. observe the information contained in the safety data sheet for the product. Noise Noise can lead to an increased risk of accidents if acoustic signals. auxiliary materials Fire prevention Flames. Rectify any fuel or oil leaks immediately. Wear protective gloves! Wash relevant areas after contact with used oil. Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A). The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere. Do not leave rags saturated with fluids and lubricants on the product. Environmental protection and disposal Dispose of used fluids. ensure area is well ventilated. When starting the engine with an external power source. • When working with lead or lead-containing compounds. Take special care when using hot. e. 1. • Wash relevant areas after contact with lead or lead-containing substances. connect the ground lead from the external power source to the ground lead of the engine or to the ground terminal of the starter. Used oil Used oil contains combustion residues that are harmful to health. warning shouts or sounds indicating dan- ger are drowned. cleaning agent. Auxiliary materials Process materials may also be hazardous or toxic.6 Fire prevention and environmental protection. batteries can be returned free of charge to the manufacturer where they will be properly recy- cled. naked light and smoking are prohibited. Do not carry out welding work on pipes and components carrying oil or fuel. When using consumables and auxiliary materials as well as other chemical substances. clean with a nonflammable fluid.g.

risks causing an explosion. • No smoking. TIM-ID: 0000040536 . • Store liquid nitrogen only in small quantities and always in specified containers without fixed covers. • When carrying out painting work outside the spray stands provided with fume extraction systems. closed shoes and safety goggles. • Hose couplings and connections must be securely attached. forcing flammable liquids (hazard class AI. • Carry out leak test in accordance with the specifications. Make sure that neighboring work areas are not adversely affected. then release the residual pressure. protective gloves. containers made of sheet metal. wear goggles or face mask.010 14 | Safety | MS15033/03E 2016-02 . Install pressure-reducing or safety valves set to the admissible pressure if this is not the case. • Wear protective clothing. Seek medical attention as soon as possible. valves and fittings or workpieces in any way. shut off the lines first. • Do not inhale vapors. Painting • Observe the relevant safety data sheet for all materials. • There must be no naked flames in the vicinity. rubber disk).g. plastic or glass) for drying purposes or to check for leaks risks bursting them. hands). • Assemblies or products which are to be connected must be designed to withstand this pressure. • Remove any wet clothing immediately. e. Acids/alkaline solutions/urea (AdBlue®. wash body areas with plenty of water. • If urea solution is swallowed. • Blowing compressed air into thin-walled containers (e. gloves and protective cloth- ing. Liquid nitrogen • Observe the relevant safety data sheet for all materials. DEF) • Observe the relevant safety data sheet for all materials. • After contact skin.g. • Avoid knocking or jolting the containers. • Always wear a mask providing protection against paint and solvent vapors. • When working with acids and alkaline solutions. Compressed air Observe special safety precautions when working with compressed air: • Unauthorized use of compressed air. ensure that the area is well ventilated. • Avoid body contact (eyes. • Provide the snout of the air nozzle with a protective disk (e. • Rinse eyes immediately with eyedrops or clean tap water. • Release residual pressure before removing or replacing pneumatic equipment in the supply line.g. rinse out mouth and drink plenty of water. • Wear goggles when blowing dirt off workpieces or blowing away swarf. To de- pressurize compressed-air lines. • Observe fire-prevention regulations. AII and B) out of con- tainers. • Make sure that working area is well ventilated. • Pay special attention to the pressure in the compressed air system or pressure vessel. • Work with liquid nitrogen may be carried out only by qualified personnel.

assembly. Consequences: Death. Consequences: Minor or moderate injuries! • Remedial action.7 Standards for safety notices in the text DANGER In the event of immediate danger. or transportation. serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. CAUTION In the event of a situation involving potential danger. Warning notices 1. • Additional product information. NOTICE In the event of a situation involving potentially adverse effects on the product. installation. Consequences: Material damage! • Remedial action. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera- tion. repair. TIM-ID: 0000040578 . Consequences: Death. 1. maintenance.005 MS15033/03E 2016-02 | Safety | 15 . 2. Warnings related to person- al injury shall be considered to include a warning of potential damage. The higher level warning notice is used if several hazards apply at the same time. serious or permanent injury! • Remedial action.

The numbering of other engine components also starts with 1 at driving end (4). The cylinders of each bank are numbered consecutively. TIM-ID: 0000002185 . 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen. 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). DIN ISO 1204 (KS = Kup- seite) plungsseite) Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4). starting with x=1 at driving end (4). 2 General Information 2.013 16 | General Information | MS15033/03E 2016-02 .1 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord. For cylinder designation (in accordance with DIN ISO 1204).

2.2 Engine overview 1 Exhaust outlet 9 Fuel filter 17 Engine governor 2 Air intake 10 Thermostat housing 18 Oil pan 3 Intermediate intercooler 11 Oil filter 19 Exhaust elbow 4 Lifting eye.004 x Application segment y Design index MS15033/03E 2016-02 | General Information | 17 . free end 21 Coupling 6 Oil dipstick 14 Cylinder head 22 Starter 7 EGR flap before EGR cooler 15 EGR cooler 8 Intercooler 16 Engine mount Engine model designation Key to the engine model designations 12 V 1600 Rxy 12 Number of cylinders V Cylinder arrangement: V engine 1600 Series R Application TIM-ID: 0000035484 . driving end 12 EGR flap before EGR cooler 20 Flywheel housing 5 Intermediate intercooler 13 Lifting eye.

1 Charge-air temperature before exhaust gas recirculation 6 B9. 2.3 Sensors and actuators – Overview Item Name Description 1 B48. left side 12 B6. right side 5 B9.2 NOx sensor.1 NOx sensor. left side 7 B5.3 Lube oil pressure before filter (option) 8 B88.1 Fuel pressure in HP system.1 Engine coolant temperature 18 | General Information | MS15033/03E 2016-02 .004 11 B4.1 Lube oil pressure after filter 4 B9.3 Charge-air temperature after exhaust gas recirculation.21 Exhaust temperature. left side (nitrogen oxide levels in exhaust gas) TIM-ID: 0000035485 .2 Charge-air temperature after exhaust gas recirculation. left side 2 B10 Charge-air pressure 3 B5. HP line. right side (nitrogen oxide levels in exhaust gas) 9 B89 Lambda sensor (residual oxygen content in exhaust gas) 10 B88.

Item Name Description 1 B90 Humidity. temperature of intake air 2 B91. right side 4 B26 Charge air coolant temperature 5 B93 Lube oil level and temperature (option) 6 A19 EIL (Engine Ident Label) 7 B1 Camshaft speed TIM-ID: 0000035485 . HP line.2 Fuel pressure in HP system.3 Exhaust gas pressure 3 B48. pressure.004 MS15033/03E 2016-02 | General Information | 19 .

ritght side 7 B13 Crankshaft speed 8 B44.22 Exhaust temperature. left side TIM-ID: 0000035485 . Item Name Description 1 B44. right side 5 B50 Crankcase pressure (option) 6 B4. left side 2 B44. right side 3 B44.1 Speed of HP turbocharger.4 Speed of LP turbocharger.3 Speed of LP turbocharger.2 Bypass flap of HP turbocharger.004 20 | General Information | MS15033/03E 2016-02 . left side 9 M52.2 Exhaust turbocharger (high pressure) speed. right side 4 M52.1 Bypass flap of HP turbocharger.

right side 2 B7 Lube oil temperature 3 M53.004 MS15033/03E 2016-02 | General Information | 21 . left side 4 B34. Item Name Description 1 M53.3 Engine coolant temperature in cylinder head TIM-ID: 0000035485 .1 EGR shut-off flap before cooler.2 Fuel pressure before filter (option) 6 B6.2 EGR shut-off flap before cooler.1 Fuel pressure after filter 5 B34.

. not reversible end) TIM-ID: 0000032242 . 3 Technical Data 3.002 22 | Technical Data | MS15033/03E 2016-02 .1 Firing order 12 V A1–B2–A5–B4–A3–B1–A6–B5–A2–B3–A4–B6 Direction of rotation Direction of rotation (as viewed on driving c.c.w.

3.003 MS15033/03E 2016-02 | Technical Data | 23 . 1327 mm TIM-ID: 0000035495 .2 Engine – Main dimensions Item Dimensions Length (B) approx. 1228 mm Height (A) approx. 1871 mm Width (C) approx.

Value has not yet been defined or will not be defined.3 12V1600R50 product data Legend DL Ref. Performance data ID 1 2 Rated engine speed A rpm 1800 1900 UIC rated power (fuel stop power ISO 3046) A kW 690 690 2. 25°C/45°C 2A continuous opera. min. N Not yet defined value. General conditions (for maximum power) TIM-ID: 0000035558 . limited suitability for design purposes. L mbar 50 50 Fuel temperature at engine inlet connection. L Limit value. 3. max (w/o power re.5% tolerance) ID Product type Application Engine speed Effective pow- er 1 12V1600R50 Rail main drive 1800 rpm 690 kW Ref. unrestricted (97/68/EC) 2 12V1600R50 Rail main drive 1900 1/min 690 kW Ref. max. max. Value which must not be fallen short of (lower limit. R Guideline value. value). Module does not apply to this type of product X Applicable. unrestricted (97/68/EC) Reference conditions ID 1 2 Intake air temperature °C 25 25 Charge air coolant temperature °C 50 50 Barometric pressure mbar 981 981 Site altitude above sea level m 400 400 1. BL Ref. Value is used for the design of an external system (plant). < The actual value must be smaller than the specified value. L °C 70 70 duction) 24 | Technical Data | MS15033/03E 2016-02 . value: Continuous power. 925 bhp EU Nonroad St IIIB tion. Module applies to this type of product > The actual value must be greater than the specified value. Continuously attainable power at standard conditions. Not continuously attainable in some applications (margin for load fluctuations). value: Fuel stop power. value) or exceeded (upper limit. 925 bhp EU Nonroad St IIIB tion.005 ID 1 2 Intake depression (new filter) A mbar 25 25 Intake depression. * Not sufficiently validated value (+/.Not applicable. 25°C/45°C 2A continuous opera. . not suitable for design purposes. A Design value. Maximum engine power.10% tolerance) ** Not sufficiently validated value (+/. Typical average value for information.

EN 590. 2 2 Number of exhaust valves per cylinder . L bar 2.7 Number of inlet valves per cylinder . max. max. 2 2 5.5 2. Coolant system (LT circuit) ID 1 2 Coolant pump: Inlet pressure.7 17. Combustion air / exhaust gas ID 1 2 Exhaust temperature after exhaust turbocharger R °C 435 415 7.5 Thermostat: Starts to open R °C 79 79 Thermostat: Fully open R °C 92 92 8. Coolant system (HT circuit) ID 1 2 Coolant temperature (at engine connection: outlet to cooling A °C 95 95 equipment) Coolant temperature after engine. Consumption ID 1 2 Specific fuel consumption (be) . limit 2 L °C 130 130 MS15033/03E 2016-02 | Technical Data | 25 . 12 12 Cylinder arrangement: V-angle Degrees 90 90 (°) Bore mm 122 122 Stroke mm 150 150 Displacement.Best point (+5%. Lube oil system ID 1 2 Lube oil temperature before engine. limit 2 L °C 112 112 Coolant pump: Inlet pressure.8MJ/kg) 4. total Liters 21 21 Compression ratio . 17. Model-related data (basic design) ID 1 2 Number of cylinders .75 1.5 Thermostat: Starts to open R °C 30 30 Thermostat: Fully open R °C 45 45 TIM-ID: 0000035558 . R g/kWh 192 191 42. 3.75 Displacement.005 10. L bar 2.5 2. cylinder Liters 1.

Weights / main dimensions ID 1 2 Dry engine weight (stand scope of delivery) R kg 2290 2290 22.L Liters 58 58 tion: max.” (standard oil system) (Op. engine side R Liters 15 15 Engine oil capacity.005 26 | Technical Data | MS15033/03E 2016-02 . engine side (without cooling equipment) R Liters 60 60 Charge-air coolant. Fuel system ID 1 2 Fuel pressure at engine inlet connection. +3 dB(A) tolerance) Engine surface noise w/o intake noise .65 -0. ISO 6798. R Liters 71 71 erating inclinations) Oil pan capacity at dipstick mark “min. (standard oil system )(Option: max. operating inclinations) Oil pan capacity at dipstick mark “max. +2 dB(A) tolerance) TIM-ID: 0000035558 .R dB(A) 99 99 sure level Lp. Acoustics ID 1 2 Exhaust noise. R dB(A) 107 107 1 m distance.” (standard oil system) L Liters 65 65 (Option: max.BL (free-field sound-pressure level Lp. max. initial filling (standard oil system) (Option: R Liters 75 75 max. ISO 6798. unsilenced .65 starting) 18. Oil and coolant capacity ID 1 2 Engine coolant capacity. 1 m distance. (when engine is L bar -0. min. operating inclinations) 19. 11. operating inclinations) Oil change quantity.BL (free-field sound pres. op.

Fuel prefilter Drain fuel prefilter (→ Page 80).1 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Coolant circuit Check engine coolant level (→ Page 90).003 MS15033/03E 2016-02 | Operation | 27 . 4 Operation 4. Coolant circuit Preheat engine coolant with coolant preheating unit (if fitted). Engine control system Switch on. Startup Item Action Lube oil system Check engine oil level (→ Page 87). TIM-ID: 0000032511 . Check charge-air coolant level (→ Page 97).

TIM-ID: 0000031877 . Change charge-air coolant (→ Page 98). Lube oil system Check engine oil level (→ Page 87). Engine control system Switch on. 4..) are available. Coolant circuit If engine is out of service for more than one year. Coolant circuit Preheat engine coolant with coolant preheating unit (if fitted). Coolant circuit Check engine coolant level (→ Page 90). ☑ MTU Preservation and Represervation Specifications (A001070/. change engine coolant (→ Page 91). Check charge-air coolant level (→ Page 97). Engine governor Check plug-in connections (→ Page 111).).2 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled.. Fuel system Vent (→ Page 76).003 28 | Operation | MS15033/03E 2016-02 . Putting the engine into operation after extended out-of-service periods (>3 months) Item Action Engine Depreserve (→ MTU Preservation and Represervation Specifications A001070/.

on manufacturer) • Tachometer indicates increasing speed. • After the starting procedure is completed. 4. TIM-ID: 0000035501 .3 Starting the engine Preconditions ☑ Engine is not connected to load. ☑ External start interlock is not active. Risk of damage to hearing! • Wear ear protectors. DANGER Rotating and moving engine parts. engine is running at idle speed. Risk of crushing. WARNING High level of engine noise when the engine is running.003 MS15033/03E 2016-02 | Operation | 29 . danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system. Starting engine Item Action Switchgear cabinet. Press start button. (depending • Automatic starting sequence is executed. make sure that there are no persons in the engine's danger zone. tor station etc. opera.

Air filter Check filter restriction indicator on the air filter (if fitted) (→ Page 85). exhaust color and vibrations (→ Page 37). danger of parts of the body being caught or pulled in! • Only run the engine at low power. pressures). Engine coolant pump Check relief bore (→ Page 96).4 Operational checks DANGER Rotating and moving engine parts.002 30 | Operation | MS15033/03E 2016-02 . Risk of damage to hearing! • Wear ear protectors. Engine oil Check engine oil level (→ Page 87). 4. Keep away from the engine's danger zone. Exhaust gas system Check exhaust color (→ Page 37). Risk of crushing. Engine operation Check engine visually for leaks and general condition. temperature. WARNING High level of engine noise when the engine is running. Check engine for abnormal running noises. TIM-ID: 0000035509 . Charge-air coolant pump Check relief bore (→ Page 102). Operational checks Item Action Control and display panels Check readings of operational data (speed.

TIM-ID: 0000035510 . Press stop button. Switchgear cabinet. allow it to idle until the engine temperatures decrease and constant levels are indicated. tor station etc. (depending • Automatic stopping procedure is performed.5 Engine – Stop Preconditions ☑ Engine is not connected to load NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress- es. opera. on manufacturer) • Engine at a standstill. therefore. damage to components is possible! • Before shutting down the engine. Stopping engine Item Action Temperature indications Wait until engine temperatures are constant. 4. Overheating of and.002 MS15033/03E 2016-02 | Operation | 31 .

Engine control system Switch off. Out-of-service-period > 1 month: • Preserve engine (→ MTU Preservation and Represervation Specifications A001070/.. • the antifreeze concentration is insufficient for the engine-room tempera- ture.. Risk of sensor damage! • Remove pressure sensors and shake off residual water. Drain charge-air coolant (→ Page 99) if: • freezing temperatures are expected and the engine is to remain out of service for an extended period.) are available. TIM-ID: 0000031879 . 4.).6 After stopping the engine Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/. Out-of-service-period > 1 week: tems • Seal engine's air and exhaust sides. Air intake and exhaust sys. • the coolant is not kept at a suitable temperature. After stopping the engine Item Measure Coolant circuit Drain engine coolant (→ Page 92). but engine coolant has no antifreeze addi- tive. Water remaining in the pressure sensors freezes at temperatures below 0 °C. • antifreeze concentration is 50 % and engine-room temperature is below -40 °C.004 32 | Operation | MS15033/03E 2016-02 . NOTICE Engine coolant with inadequate freeze protection. • the engine room is not heated.

4.7 Plant – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.
☑ No operating voltage is applied.

Special tools, Material, Spare parts
Designation / Use Part No. Qty.
High-pressure cleaning unit - 1
Cleaner (Hakupur 50/136) X00056700 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
Water jet from high-pressure cleaning unit.
Risk of eye injury, risk of scalding!
• Do not direct water jet at persons.
• Wear protective clothing, protective gloves, and goggles/safety mask.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors or
ECUs.

Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec-
tion).
2. Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning
units carefully and observe the safety precautions.
3. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 032

• 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 direct compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.

MS15033/03E 2016-02 | Operation | 33

4.8 Engine – Barring manually
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Barring device F6790714 1
Barring device F6797426 1
Adapter F30011619 1
Ratchet adapter F30027340 1

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 engine's
danger zone.

Barring engine manually – Var-
iant A
1. Remove screw (2) on flywheel housing.
2. Remove end cover (1).

TIM-ID: 0000045482 - 003

34 | Operation | MS15033/03E 2016-02

3. Engage barring device (1) in ring gear and in-
stall on flywheel housing (2).
4. Fit adapter and ratchet adapter on barring
device.
5. Rotate crankshaft in engine direction of rota-
tion. Apart from the normal compression re-
sistance, there should be no resistance.
6. For barring device removal, follow reverse se-
quence of working steps.

Barring engine manually – Var-
iant B
Note: Remove starter if necessary.
1. Remove screw (2) on flywheel housing.
2. Remove end cover (1).

3. Engage barring device (2) in ring gear and in-
stall on flywheel housing (1).
4. Fit adapter and ratchet adapter on barring
device.
5. Rotate crankshaft in engine direction of rota-
tion. Apart from the normal compression re-
sistance, there should be no resistance.
6. For barring device removal, follow reverse se-
quence of working steps.
TIM-ID: 0000045482 - 003

MS15033/03E 2016-02 | Operation | 35

at the latest. exhaust color (→ Page 30) and vibrations. (→ Page 103) W1019 X Check radial clearance. (→ Page 84) W1008 Replace engine oil filter when changing engine oil.003 36 | Maintenance | MS15033/03E 2016-02 . W1013 Replace drive belt. (→ Page 78) W1005 X Replace air filter. empty dust bowl. (→ Page 30) W0506 Check engine for abnormal running noises. (→ Page 81) Table 2: Maintenance task reference table [QL1] TIM-ID: 0000045401 .1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. ATTENTION! (→ Page 72) First adjustment after 1. W1326 X Replace battery-charging generator belt tensioner and (→ Page 105) diverter pulley. or when (→ Page 89) the interval (years) is reached. (→ Page 108) W1027 X Clean air filter. 5 Maintenance 5. (→ Page 114) W1675 Replace fuel prefilter or fuel prefilter element. adjust as necessary. Option Task Maintenance tasks W0500 Check engine oil level. (→ Page 83) W1207 Check valve clearance. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule. W0507 Drain water and contamination from fuel prefilter. The Mainte- nance Schedule is a stand-alone publication. (→ Page 87) W0503 X Check maintenance indicator of air filter. (→ Page 30) W1001 Replace fuel filter or fuel filter element. (→ Page 112) W1526 Replace sensor.000 operating hours. W1525 Replace sensor.

1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery low or faulty u Charge or replace (→ manufacturer's documentation). Engine wiring defective u Check (→ Page 109). Air in fuel system u Vent fuel system (→ Page 76). low or faulty Engine wiring defective u Check (→ Page 109). u Clean or replace filter element (→ manufacturer's documentation). possibly loose Running gear blocked (engine u Contact Service.001 Fuel filter clogged u Replace (→ Page 78). Air filter clogged u Replace air filter . faulty Engine wiring defective u Check (→ Page 109). Starter: Engine cabling or starter u Check if cable connections are properly secured. Air in fuel system u Vent fuel system (→ Page 76). Battery: Cable connections faulty u Check if cable connections are properly secured (→ manufacturer's documentation). Engine does not reach rated speed Cause Corrective action Fuel prefilter (if fitted) clogged. TIM-ID: 0000054488 . Engine governor defective u Contact Service. cannot be barred manually) Engine turns but does not fire Cause Corrective action Poor rotation by starter: Battery u Charge or replace battery (→ manufacturer's documentation). 6 Troubleshooting 6. Connectors on engine governor u Check plug connections (→ Page 111). contact Service. Engine fires unevenly Cause Corrective action Injector defective u Contact Service.(→ Page 84) Injector defective u Contact Service. Engine wiring defective u Check (→ Page 109). Engine: Overloaded u Contact Service. Engine governor defective u Contact Service. MS15033/03E 2016-02 | Troubleshooting | 37 .

Air in fuel system u Vent fuel system (→ Page 76). Engine speed not steady Cause Corrective action Injector defective u Contact Service. Exhaust turbocharger defective u Contact Service.(→ Page 84) Intercooler clogged u Contact Service. Coolant leaks at intercooler Cause Corrective action Intercooler leaky. cylinder liner defective 38 | Troubleshooting | MS15033/03E 2016-02 .001 Exhaust turbocharger. temperature too high Charge-air pressure too low Cause Corrective action Air filter clogged u Replace air filter . Engine governor defective u Contact Service. Engine room: Air-intake u Check fans and intake/exhaust lines. piston rings. cylinder u Contact Service. Blue exhaust gas Cause Corrective action Too much oil in engine u Drain engine oil (→ Page 88). major coolant u Contact Service.(→ Page 84) Injector defective u Contact Service. discharge Black exhaust gas Cause Corrective action Air filter clogged u Replace air filter . Engine: Overloaded u Contact Service. TIM-ID: 0000054488 . Speed transmitter defective u Contact Service. head. incorrect Intercooler clogged u Contact Service. Charge air temperature too high Cause Corrective action Engine coolant treatment u Check (MTU test kit).

White exhaust gas Cause Corrective action Engine is not at operating u Run engine to reach operating temperature. temperature Water in fuel u Check fuel system on fuel prefilter. TIM-ID: 0000054488 .001 MS15033/03E 2016-02 | Troubleshooting | 39 . Drain fuel prefilter (→ Page 80). Intercooler leaky u Contact Service.

speed limitation. 40 | Troubleshooting | MS15033/03E 2016-02 . Check operation of fan (plant side). Contact Service. Check cooler (plant side) for contamination. The 3. rail applications Possible engine responses in case of Yellow alarm: Warning. 5. The charge-air 3. Reduce power. Check whether alarm 23 is signaled. engine stop Possible engine responses in case of Red alarm: Engine stop. The charge-air 3. Reduce power. B5. The lube oil pressure is too low. Check cooler (plant side) for contamination. Check whether alarm 23 is signaled. coolant temperature in the 4. violated upper limit value 2. power limitation/reduction. intercooler is too high. TIM-ID: 0000047144 . coolant temperature in the 4. Contact Service. limit value 2. 9 – HI T-Coolant Intercooler Cause Corrective action The coolant temperature in the 1.1 has violated lower limit value 2. temperature is too high. Contact Service. Check whether alarms 9 and 10 are signaled. power limitation/reduction. Check whether alarms 9 and 10 are signaled. limit value 1. Contact Service. 6.has 2.2 has violated upper 2. warning 5 – HI T-Charge Air Cause Corrective action The charge-air temperature at 1. sensor B9. intercooler at sensor B26. intercooler at sensor B26. The 3.2 has violated upper 2. temperature is too high. speed limitation.2 Fault messages of Engine Control Unit ECU 9 for Series 1600. Reduce power. Contact Service.has 2. sensor B9. 5. intercooler is too high. violated upper limit value 1.004 15 – LO P-Lube Oil Cause Corrective action The lube oil pressure at sensor 1. Reduce power. Check operation of fan (plant side). Check engine oil level (→ Page 87). 10 – SS T-Coolant Intercooler Cause Corrective action The coolant temperature in the 1. 6 – SS T-Charge Air Cause Corrective action The charge-air temperature at 1. 1.

sensor B4. The exhaust gas temperature is too high. MS15033/03E 2016-02 | Troubleshooting | 41 . Check relief bore of engine coolant pump (→ Page 96). Visually inspect cooling circuit for leakage. 20 – SS T-Exhaust A Cause Corrective action The exhaust gas temperature at u Contact Service. 23 – LO Coolant Level Cause Corrective action Coolant level in high-temperature 1. Check engine coolant level (→ Page 90). 2. The lube oil pressure is too low. The exhaust gas temperature is too high. sensor B4. 2. sensor B4. The exhaust gas temperature is too high. Contact Service. circuit at switch F33 is too low. B5. Contact Service. 19 – HI T-Exhaust A Cause Corrective action The exhaust gas temperature at u Contact Service. The exhaust gas temperature is too high. 21 – HI T-Exhaust B Cause Corrective action The exhaust gas temperature at u Contact Service.21 has violated upper limit value 2.21 has violated upper limit value 1. 16 – SS P-Lube Oil Cause Corrective action The lube oil pressure at sensor 1. TIM-ID: 0000047144 . 22 – SS T-Exhaust B Cause Corrective action The exhaust gas temperature at u Contact Service. 4.22 has violated upper limit value 1.004 3. Check engine oil level (→ Page 87).22 has violated upper limit value 2.1 has violated lower limit value 2. sensor B4.

The turbocharger speed is too high.1 and B5.1 has 2. 32 – SS ETC1 Overspeed Cause Corrective action The speed of the A side LP 1. If emergency stop was tripped by engine. Contact Service. The difference in oil pressure is too high. 2. 26 – HI P-Diff-Lube Oil Cause Corrective action The difference in oil pressure 1. has violated upper limit value 2. overspeed test has been tripped. Contact Service. Cause: Fault or failure of another turbocharger. Replace engine oil filter (→ Page 89). turbocharger at sensor B44. The difference in oil pressure is too high. has violated upper limit value 1. 31 – HI ETC1 Overspeed Cause Corrective action The speed of the A side LP 1. turbocharger at sensor B44. between sensors B5. 30 – SS Engine Overspeed Cause Corrective action The engine speed has violated the 1.004 Cause: Fault or failure of another turbocharger. 42 | Troubleshooting | MS15033/03E 2016-02 . If emergency stop was tripped by engine overspeed test. violated upper limit value 1.3 2. The turbocharger speed is too high. violated upper limit value 2. Contact Service.1 and B5. An emergency engine stop has been tripped. Replace engine oil filter (→ Page 89). 25 – HI P-Diff-Lube Oil Cause Corrective action The difference in oil pressure 1. restart upper limit value or the engine engine.3 2. Reduce power. Contact Service.1 has 2. between sensors B5. contact Service. TIM-ID: 0000047144 . Reduce power.

52 – SS T-Lube Oil Cause Corrective action The lube oil temperature at sensor 1. The difference in pressure is too high. 1. has violated upper limit value 1. Contact Service. Contact Service. Contact Service. 34 – SS P-Diff-Fuel Cause Corrective action The difference in pressure 1. violated upper limit value 2. has violated upper limit value 2. The turbocharger speed is too high. TIM-ID: 0000047144 . Check operation of cooler and fan (plant side). B7.2 has 2.has violated upper limit value 2. Replace fuel filter (→ Page 78).2 has 2. MS15033/03E 2016-02 | Troubleshooting | 43 .004 high.has violated upper limit value 2. Contact Service. 33 – HI P-Diff-Fuel Cause Corrective action The difference in pressure 1. Check engine coolant level (→ Page 90).2 2. 37 – SS ETC2 Overspeed Cause Corrective action The speed of the B side LP 1. 2. Contact Service.1 and B34. turbocharger at sensor B44. Cause: Fault or failure of another turbocharger.1 and B34. Reduce power. high. The difference in pressure is too high. 36 – HI ETC2 Overspeed Cause Corrective action The speed of the B side LP 1. between sensors B34. Cause: Fault or failure of another turbocharger. between sensors B34. The lube oil temperature is too 3. B7. The turbocharger speed is too high. Reduce power.2 2. Check engine coolant level (→ Page 90). The lube oil temperature is too 3. Reduce power. Contact Service. 4. turbocharger at sensor B44. Check operation of cooler and fan (plant side). 51 – HI T-Lube Oil Cause Corrective action The lube oil temperature at sensor 1. Replace fuel filter (→ Page 78). violated upper limit value 1.

temperature is too high. Reduce power. B50. The crankcase pressure is too high.1 1. Contact Service. Stop engine. 63 – HI P-Crank Case Cause Corrective action The crankcase pressure at sensor 1. TIM-ID: 0000047144 . 66 – SS P-Fuel Cause Corrective action The fuel pressure at sensor B34. sensor B6. Replace fuel prefilter (→ Page 81). 2. 2. has violated lower limit value 2. 67 – HI T-Coolant Cause Corrective action The coolant temperature at 1. The coolant temperature is too high. 64 – SS P-Crank Case Cause Corrective action The crankcase pressure at sensor 1. sensor B6. sensor B6. Contact Service. B50. 3.has violated upper limit value 2. The fuel pressure is too low. 44 | Troubleshooting | MS15033/03E 2016-02 .has violated upper limit value 2.1 has violated upper limit value 4. has violated lower limit value 1.004 The fuel pressure is too low. 4. 65 – LO P-Fuel Cause Corrective action The fuel pressure at sensor B34. The coolant temperature is too high. Contact Service. 2. 1.1 has violated upper limit value 3. Replace fuel filter (→ Page 78). Replace fuel filter (→ Page 78). Replace fuel prefilter (→ Page 81). The crankcase pressure is too high. 60 – SS T-Coolant L4 Cause Corrective action The coolant temperature at u Contact Service. Stop engine. limit value 1.1 1. Check engine coolant level (→ Page 90). 59 – SS T-Coolant L3 Cause Corrective action The coolant temperature at u Contact Service. Contact Service. Contact Service.1 has violated upper 2. Check operation of cooler and fan (plant side). 3. The coolant 3.

Acknowledge alarm. An emergency 2. 92 – SS Starter Speed Not Reached Cause Corrective action The engine has failed to reach the 1. B48. sensor B6. temperature is too high. 89 – SS Engine Speed too Low Cause Corrective action The engine speed has violated the 1. Check engine coolant level (→ Page 90). Contact Service. The coolant 3. Check operation of cooler and fan (plant side). preset time.004 within the preset time after 3. B48. reaching starter speed. 3. 90 – SS Starter Speed Not Reached Cause Corrective action The engine has failed to reach idle u Contact Service. Observe additional messages. MS15033/03E 2016-02 | Troubleshooting | 45 . The fuel pressure is too high. Contact Service. limit value 2. Contact Service. engine stop has been tripped. 68 – SS T-Coolant Cause Corrective action The coolant temperature at 1.has violated the upper limit value. TIM-ID: 0000047144 . speed within the preset time after reaching starter disengagement speed. lower limit value. Check the starter pressure supply (plant side).1 has violated upper 2. The fuel pressure is too low. 3.has violated the lower limit value. Contact Service. Check the starter pressure supply (plant side). Observe additional messages. 83 – LO P-Fuel (Common Rail) Cause Corrective action The HP fuel pressure at sensor u Contact Service. starter disengagement speed 2. Observe additional messages. set speed threshold within the 2. 82 – HI P-Fuel (Common Rail) Cause Corrective action The HP fuel pressure at sensor u Contact Service. 91 – SS Release Speed Not Reached Cause Corrective action The engine has failed to reach 1.

value 1. 94 – LO T-Preheat Cause Corrective action The engine coolant temperature u Contact Service. 46 | Troubleshooting | MS15033/03E 2016-02 . 118 – LO ECU Power Supply Voltage Cause Corrective action The ECU supply voltage has 1. Contact Service. Contact Service. Check plug connections of Engine Control Unit (→ Page 111). Preheating is out of order. has failed to reach the preset limit value 2. violated the preset upper limit 2. violated the preset lower limit 2. too high. violated the preset upper limit 2. Check plug connections of Engine Control Unit (→ Page 111). Disconnect power supply. 3. TIM-ID: 0000047144 . Contact Service. Check plug connections of Engine Control Unit (→ Page 111). Contact Service. 3. has failed to reach the preset limit value 1. 93 – SS T-Preheat Cause Corrective action The engine coolant temperature u Contact Service. 120 – HI ECU Power Supply Voltage Cause Corrective action The ECU supply voltage has 1. violated the preset lower limit 2. ECU has violated the upper limit 2. 119 – LOLO ECU Power Supply Voltage Cause Corrective action The ECU supply voltage has 1. value 2. 3. Check state of battery charge (plant side). value 1. Preheating is out of order. Start interlock. value. Check state of battery charge (plant side). value 2. Check state of battery charge (plant side). The internal temperature is 3. Check plug connections of Engine Control Unit (→ Page 111). 121 – HIHI ECU Power Supply Voltage Cause Corrective action The ECU supply voltage has 1.004 122 – HI T-ECU Cause Corrective action The temperature sensor inside the 1. Check state of battery charge (plant side). 3. Contact Service. Check power supply (plant side).

3. 187 – AL CAN1 Error Passive Cause Corrective action CAN bus 1 to MTU automation 1. Disconnect power supply. Check connection between plant automation system and MTU system (e. Contact Service. system (e.g. coolant distribution housing is faulty or missing. disrupted or failed. Contact Service. ECU/MAU/SAM) 2. 181 – AL CAN2 Node Lost Cause Corrective action Failure of a connection or 1. Contact Service. disruption of communication with 2. 201 – SD T-Coolant TIM-ID: 0000047144 . Contact Service. Check plug connections of Engine Control Unit (→ Page 111). Check engine wiring (→ Page 109). ECU/MAU/SAM) 2. 186 – AL CAN1 Bus Off Cause Corrective action CAN bus 1 to MTU automation 1. a node on CAN bus 2. Check plug connections of Engine Control Unit (→ Page 111).g. 3. 189 – AL CAN2 Error Passive Cause Corrective action CAN bus 2 to plant automation 1. then reconnect. Check engine wiring (→ Page 109). 2.g. Disconnect power supply. disruption of communication with 2. Murphy display) automation system. Check engine wiring (→ Page 109). Contact Service. Check connection between plant automation system and MTU system (e. 180 – AL CAN1 Node Lost Cause Corrective action Failure of a connection or 1. MS15033/03E 2016-02 | Troubleshooting | 47 . Contact Service. Murphy display) automation system. disrupted or failed. Contact Service. then reconnect.1) at the 2.g. disrupted or failed. 188 – AL CAN2 Bus Off Cause Corrective action CAN bus 2 to plant automation 1. disrupted or failed.004 Cause Corrective action The signal from the coolant 1. a node on CAN bus 1. temperature sensor (B6. 2. system (e.

207 – SD T-Exhaust B Cause Corrective action The signal from the exhaust gas 1. missing. after the engine inlet is faulty or missing. temperature sensor (B9) on the A 2.1) after the 2. 211 – SD P-Lube Oil Cause Corrective action The signal from the lube oil 1. intercooler on the A side is faulty or missing. Check engine wiring (→ Page 109). 206 – SD T-Exhaust A Cause Corrective action The signal from the exhaust gas 1. 205 – SD T-Coolant Intercooler Cause Corrective action The signal from the charge-air 1. Check engine wiring (→ Page 109). coolant temperature sensor (B26) 2. Contact Service. Check engine wiring (→ Page 109). Check engine wiring (→ Page 109). pressure sensor (B50) is faulty or 2. exhaust pipe on the A side is faulty or missing. Check engine wiring (→ Page 109). TIM-ID: 0000047144 . 208 – SD P-Charge Air Cause Corrective action The signal from the charge-air 1. Contact Service.21) in the 2. 214 – SD P-CrankCase Cause Corrective action The signal from the crankcase 1. pressure sensor (B5. temperature sensor (B4. Check engine wiring (→ Page 109). Contact Service. Contact Service. Check engine wiring (→ Page 109). exhaust pipe on the B side is faulty or missing. Contact Service. Contact Service.22) in the 2. 203 – SD T-Charge Air Cause Corrective action The signal from the charge-air 1.004 filter is faulty or missing. side is faulty or missing. temperature sensor (B4. Contact Service. 48 | Troubleshooting | MS15033/03E 2016-02 . pressure sensor (B10) after the 2.

Contact Service.1) on the A side is 2. Check engine wiring (→ Page 109). temperature sensor (B7) is faulty 2.2) before the main 2. B5. 216 – SD T-Lube Oil Cause Corrective action The signal from the lube oil 1. Check engine wiring (→ Page 109).1 are faulty or missing. 215 – SD P-HD Cause Corrective action The signal from the rail pressure 1. 228 – SD P-Fuel before Filter Cause Corrective action The signal from the fuel pressure 1. MS15033/03E 2016-02 | Troubleshooting | 49 . Contact Service. fuel filter is faulty or missing. faulty or missing.004 Cause Corrective action Emergency engine stop following u Contact Service. Contact Service. 227 – SD P-Lube Oil before Filter Cause Corrective action The signal from the oil pressure 1. Check engine wiring (→ Page 109). failure of the crankshaft sensor and camshaft sensor. sensor (B5. 2.3) before the filter is 2.3 and/or 2. pressure sensors B5. sensor (B34. Check engine wiring (→ Page 109). sensor (B48. Contact Service. Check engine wiring (→ Page 109). 220 – SD Level Coolant Water Cause Corrective action The signal from the coolant level 1. 221 – SD P-Diff Lube Oil Cause Corrective action The signals from the lube oil 1. Check engine wiring (→ Page 109). or missing. Contact Service. 229 – AL Stop Camshaft Sensor Defect TIM-ID: 0000047144 . faulty or missing. Contact Service. sensor (F33) is faulty or missing.

faulty or missing. Contact Service. Check engine wiring (→ Page 109). sensor (B44. 240 – SD P-Fuel Cause Corrective action The signal from the fuel pressure 1. 50 | Troubleshooting | MS15033/03E 2016-02 . 230 – SD Crankshaft Speed Cause Corrective action The signal from the crankshaft 1.1) after the main fuel 2.004 Cause Corrective action The analog nominal speed setting 1.2) on the B side is 2. Contact Service. speed sensor (B13) is faulty or 2. faulty or missing. Contact Service. 232 – SD Charger 1 Speed Cause Corrective action The signal from the ETC speed 1. Check engine wiring (→ Page 109).1) on the A side is 2. missing. Contact Service. 2. faulty or missing. Check engine wiring (→ Page 109).1 and/or B34. 239 – SD P-Diff Fuel Cause Corrective action The signals from the pressure 1. sensor (B44. missing. Check engine wiring (→ Page 109). 233 – SD Charger 2 Speed Cause Corrective action The signal from the ETC speed 1.2 are 2. 2. Contact Service. 321 – AL Wiring Cylinder A1 Cause Corrective action Short circuit in injector wiring at 1. Contact Service. 266 – SD Speed Demand TIM-ID: 0000047144 . filter is faulty or missing. Check wiring of injector concerned (→ Page 109). Check engine wiring (→ Page 109). cylinder A1 or injector faulty. signal is missing. speed sensor (B1) is faulty or 2. sensors B34. Check engine wiring (→ Page 109). sensor (B34. Contact Service. 231 – SD Camshaft Speed Cause Corrective action The signal from the camshaft 1. Switch on plant automation system. Contact Service.

2. 2. cylinder A5 or injector faulty. 333 – AL Wiring Cylinder B3 TIM-ID: 0000047144 . Check wiring of injector concerned (→ Page 109). 332 – AL Wiring Cylinder B2 Cause Corrective action Short circuit in injector wiring at 1. 2. Check wiring of injector concerned (→ Page 109). cylinder A6 or injector faulty. Contact Service. Check wiring of injector concerned (→ Page 109). cylinder A3 or injector faulty. 2. Check wiring of injector concerned (→ Page 109). MS15033/03E 2016-02 | Troubleshooting | 51 . Contact Service. Check wiring of injector concerned (→ Page 109). cylinder B3 or injector faulty. Contact Service. Contact Service. Check wiring of injector concerned (→ Page 109). Contact Service. 326 – AL Wiring Cylinder A6 Cause Corrective action Short circuit in injector wiring at 1. Check wiring of injector concerned (→ Page 109). Check wiring of injector concerned (→ Page 109). Contact Service. 2. cylinder A4 or injector faulty. Contact Service. 323 – AL Wiring Cylinder A3 Cause Corrective action Short circuit in injector wiring at 1. 2. cylinder B1 or injector faulty. 325 – AL Wiring Cylinder A5 Cause Corrective action Short circuit in injector wiring at 1. Contact Service. 331 – AL Wiring Cylinder B1 Cause Corrective action Short circuit in injector wiring at 1.004 Cause Corrective action Short circuit in injector wiring at 1. 2. cylinder B2 or injector faulty. 322 – AL Wiring Cylinder A2 Cause Corrective action Short circuit in injector wiring at 1. cylinder A2 or injector faulty. 2. 324 – AL Wiring Cylinder A4 Cause Corrective action Short circuit in injector wiring at 1.

Check wiring of injector concerned (→ Page 109). 2. 2. cylinder B5 or injector faulty. 2. Check wiring of injector concerned (→ Page 109). Contact Service. Contact Service.004 Cause Corrective action Disruption in injector wiring at 1. Contact Service. Check wiring of injector concerned (→ Page 109). 2. 343 – AL Open Load Cylinder A3 Cause Corrective action Disruption in injector wiring at 1. Check wiring of injector concerned (→ Page 109). 335 – AL Wiring Cylinder B5 Cause Corrective action Short circuit in injector wiring at 1. 342 – AL Open Load Cylinder A2 Cause Corrective action Disruption in injector wiring at 1. 2. cylinder A2. cylinder A4. 336 – AL Wiring Cylinder B6 Cause Corrective action Short circuit in injector wiring at 1. Contact Service. Check wiring of injector concerned (→ Page 109). cylinder B4 or injector faulty. 2. 2. cylinder A5. Contact Service. 334 – AL Wiring Cylinder B4 Cause Corrective action Short circuit in injector wiring at 1. Check wiring of injector concerned (→ Page 109). Contact Service. 344 – AL Open Load Cylinder A4 Cause Corrective action Disruption in injector wiring at 1. cylinder B6 or injector faulty. 345 – AL Open Load Cylinder A5 TIM-ID: 0000047144 . 341 – AL Open Load Cylinder A1 Cause Corrective action Disruption in injector wiring at 1. 2. 52 | Troubleshooting | MS15033/03E 2016-02 . Check wiring of injector concerned (→ Page 109). Contact Service. cylinder A3. Check wiring of injector concerned (→ Page 109). cylinder A1. Contact Service.

1). 2. Check wiring of injector concerned (→ Page 109). Contact Service. 356 – AL Open Load Cylinder B6 Cause Corrective action Disruption in injector wiring at 1. 381 – AL Wiring TOP 1 TIM-ID: 0000047144 . MS15033/03E 2016-02 | Troubleshooting | 53 . Contact Service.004 Cause Corrective action Short circuit or wire break at 1. 355 – AL Open Load Cylinder B5 Cause Corrective action Disruption in injector wiring at 1. cylinder B5. cylinder A6. 352 – AL Open Load Cylinder B2 Cause Corrective action Disruption in injector wiring at 1. Check wiring of injector concerned (→ Page 109). cylinder B4. Contact Service. Check wiring of injector concerned (→ Page 109). cylinder B6. 354 – AL Open Load Cylinder B4 Cause Corrective action Disruption in injector wiring at 1. Check wiring of injector concerned (→ Page 109). Contact Service. Contact Service. cylinder B2. 2. 2. Check wiring of injector concerned (→ Page 109). Contact Service. Check wiring of injector concerned (→ Page 109). 2. Check wiring of injector concerned (→ Page 109). Contact Service. 351 – AL Open Load Cylinder B1 Cause Corrective action Disruption in injector wiring at 1. 2. 346 – AL Open Load Cylinder A6 Cause Corrective action Disruption in injector wiring at 1. Contact Service. 2. 2. Check wiring (→ Page 109). 353 – AL Open Load Cylinder B3 Cause Corrective action Disruption in injector wiring at 1. transistor output 1 plant side (TOP 2. cylinder B1. cylinder B3.

Check wiring (→ Page 109). Contact Service. Contact Service. 54 | Troubleshooting | MS15033/03E 2016-02 . the injectors has violated lower 2. Check power supply (plant side). 382 – AL Wiring TOP 2 Cause Corrective action Short circuit or wire break at 1. Contact Service. limit value 1. 3. Check wiring (→ Page 109). Check wiring (→ Page 109). 384 – AL Wiring TOP 4 Cause Corrective action Short circuit or wire break at 1. Check power supply (plant side). Check power supply (plant side). transistor output 2 plant side (TOP 2. Contact Service. 3. Check wiring (→ Page 109). 2). 3). Contact Service. 383 – AL Wiring TOP 3 Cause Corrective action Short circuit or wire break at 1. the injectors has violated lower 2. 4).004 Cause Corrective action The ECU voltage which controls 1. 413 – HIHI U-PDU TIM-ID: 0000047144 . 412 – HI U-PDU Cause Corrective action The ECU voltage which controls 1. Contact Service. 3. limit value 2. Check wiring (→ Page 109). limit value 1. transistor output 4 plant side (TOP 2. Check wiring (→ Page 109). transistor output 3 plant side (TOP 2. 410 – LO U-PDU Cause Corrective action The ECU voltage which controls 1. Contact Service. Check power supply (plant side). the injectors has violated upper 2. 3. 411 – LOLO U-PDU Cause Corrective action The ECU voltage which controls 1. limit value 2. the injectors has violated upper 2. Check wiring (→ Page 109).

Check engine wiring (→ Page 109). B side is faulty or missing. temperature sensor (B9. 440 – AL L1 P-Aux1 Cause Corrective action The pressure measuring sensor at u Contact Service. of the injector output stage.3) on the 2. 422 – SD T-Charge Air B Cause Corrective action The signal from the charge-air 1.has violated the lower limit value. Contact Service. 442 – AL L2 P-Aux1 Cause Corrective action The pressure measuring sensor at u Contact Service. the pressure measuring channel has violated lower limit value 1. The HP fuel pressure is too low. The fuel pressure is too high. 444 – SD U-PDU TIM-ID: 0000047144 . The pressure value at the pressure measuring channel is too low. 438 – LO P-Fuel 2 (Common Rail) Cause Corrective action The HP fuel pressure at sensor u Contact Service. the pressure measuring channel has violated lower limit value 2. B48.has violated the upper limit value.2 . The pressure value at the pressure measuring channel is too low. MS15033/03E 2016-02 | Troubleshooting | 55 . B48. 439 – HI P-Fuel 2 (Common Rail) Cause Corrective action The HP fuel pressure at sensor u Contact Service.2 .004 Cause Corrective action Fault in the internal supply voltage u Contact Service.

Observe additional messages. faulty sensor which has been set to initiate an engine stop. sensor (B48.004 472 – AL Stop SD Cause Corrective action This fault is signaled in case of a u Contact Service. 445 – SD P-Ambient Air Cause Corrective action The signal from the ambient u Contact Service. Contact Service.has violated upper limit value 2.has violated upper limit value 1. alarm activating power reduction 2. B10. 448 – HI P-Charge Air Cause Corrective action The charge-air pressure at sensor u Contact Service.2) on the B-side is faulty or missing. 470 – SD T-ECU Cause Corrective action The signal from the temperature u Contact Service. A main 1. B10. 454 – SS Power Reduction Active Cause Corrective action Power reduction activated. 449 – SS P-Charge Air Cause Corrective action The charge-air pressure at sensor u Contact Service. The charge-air pressure is too high. 56 | Troubleshooting | MS15033/03E 2016-02 . The charge-air pressure is too high. has occurred. sensor inside the ECU is faulty or missing TIM-ID: 0000047144 . pressure sensor inside the ECU is faulty or missing 446 – SD P-HD2 Cause Corrective action The signal from the rail pressure u Contact Service.

PCS5-CAN to signal a red summary alarm. 479 – AL Comb. Cause: Fault or failure of another turbocharger. Contact Service. The turbocharger speed is too high. Observe additional messages.3 has 2. Alarm Red (Plant) Cause Corrective action The alarm is raised if a plant 1.3 has 2. The turbocharger speed is too high. violated upper limit value 1. The turbocharger speed is too high. 478 – AL Comb. MS15033/03E 2016-02 | Troubleshooting | 57 . turbocharger at sensor B44. Check plant signal. Alarm Yel (Plant) Cause Corrective action The alarm is raised if a plant 1. PCS5-CAN to signal a yellow summary alarm. violated upper limit value 1. Contact Service. 2. turbocharger at sensor B44. Engine Protection Cause Corrective action The external engine protection 1. Reduce power.004 Cause Corrective action The speed of the B side LP 1. feature is active. Reduce power. 490 – HI ETC4 Overspeed TIM-ID: 0000047144 .4 has 2. turbocharger at sensor B44. Contact Service. Observe additional messages. 489 – SS ETC3 Overspeed Cause Corrective action The speed of the A side LP 1. 488 – HI ETC3 Overspeed Cause Corrective action The speed of the A side LP 1. Contact Service. Contact Service. 480 – AL Ext. Reduce power. violated upper limit value 2. device instructs the ECU via the 2. device instructs the ECU via the 2. Cause: Fault or failure of another turbocharger. Contact Service. Cause: Fault or failure of another turbocharger.

shorted. 58 | Troubleshooting | MS15033/03E 2016-02 . The turbocharger speed is too high. Reduce power. Do not disconnect the 2. be activated. CAN bus. Contact Service. Check engine wiring (→ Page 109). Contact Service. 536 – AL Wiring PWM_CM1 Cause Corrective action The HP fuel control block M8.4 has 2. violated upper limit value 2. interlock from the plant via the 2. If the power supply was not disconnected manually. 602 – AL CAN Engine Start Lock Cause Corrective action TIM-ID: 0000047144 . Check engine wiring (→ Page 109). Cause: Fault or failure of another turbocharger. check engine switched off while the engine was wiring (→ Page 109). flap (B side) M52. Check plant controller.004 The ECU has received a start 1.2 (B 1.1 (A 1. fails to reach standstill within a certain time following an emergency stop signal. 491 – SS ETC4 Overspeed Cause Corrective action The speed of the B side LP 1. Check engine wiring (→ Page 109). Contact Service. side) of the HP fuel pump cannot 2. Contact Service. turbocharger at sensor B44. 608 – AL Wiring PWM_CM6 Cause Corrective action Wiring to servomotor of bypass 1. 582 – AL Emergency Stop Failed Cause Corrective action The alarm is raised if the engine u Contact Service. side) of the HP fuel pump cannot 2. 549 – AL Power Cut-Off detected Cause Corrective action The ECU operating voltage was 1. be activated. Contact Service. running. power supply until the engine has reached standstill. Contact Service.2 disrupted or 2. 558 – AL Wiring PWM_CM2 Cause Corrective action The HP fuel control block M8.

615 – AL EIL Protection Cause Corrective action The engine number in the EIL 1.1) disrupted or shorted. MA53. Contact Service. Contact Service. MA53. shorted. (M53. (M53. 628 – AL Wiring PWM_CM10 Cause Corrective action Wiring to servomotor of EGR 1. Check engine wiring (→ Page 109).004 Cause Corrective action The EGR shutoff flap A side u Contact Service. Check engine wiring (→ Page 109). or B88. shutoff flap A side M53. number stored in the ECU. 626 – AL Wiring PWM_CM8 Cause Corrective action Wiring to servomotor of bypass 1. u Contact Service.1 2. Check engine wiring (→ Page 109). does not match the engine 2. NOx sensor (B88. Contact Service. shutoff flap B side M53.2) disrupted or shorted.1 disrupted or 2.2/ 2. 629 – AL Flap Egr A Defect TIM-ID: 0000047144 . Check engine wiring (→ Page 109). 609 – AL Wiring PWM_CM7 Cause Corrective action Power supply wiring of TriCAN 1.2) or the oil level sensor J1939 (B93) disrupted or shorted.1/ 2. 630 – AL Flap Egr B Defect Cause Corrective action The EGR shutoff flap B side u Contact Service. sensor (B90).1) is faulty. Contact Service. 616 – AL EIL Error Cause Corrective action The ECU cannot detect the EIL. flap (A side) M52. MS15033/03E 2016-02 | Troubleshooting | 59 .2) is faulty. 627 – AL Wiring PWM_CM9 Cause Corrective action Wiring to servomotor of EGR 1. Check engine wiring (→ Page 109). Contact Service.

pressure sensor (B91. 631 – AL Flap Bypass A Defect Cause Corrective action The bypass flap A side (M52. Contact Service. 647 – SD P-Exhaust Lambda Cause Corrective action The signal from the exhaust gas 1. 634 – SD T0-Ambient Air (HDT2800) Cause Corrective action No signal from temperature u Contact Service. combined oil temperature/level 2. sensor (B93) is faulty or missing. (B90). TIM-ID: 0000047144 . 60 | Troubleshooting | MS15033/03E 2016-02 .1) is u Contact Service. combined oil temperature/level 2. Check engine wiring (→ Page 109). 637 – SD T-Lube Oil Pan J1939 Cause Corrective action The temperature signal from the 1. Contact Service. (B90). 633 – SD P-Ambient Air (HDT2800) Cause Corrective action No signal from air pressure sensor u Contact Service. faulty. sensor (B93) is faulty or missing. 635 – SD Air Humidity (HDT2800) Cause Corrective action No signal from humidity sensor u Contact Service. Check engine wiring (→ Page 109). sensor (B90). 636 – SD Level Lube Oil J1939 Cause Corrective action The level signal from the 1. Contact Service.004 or missing.3) is faulty 2. Check engine wiring (→ Page 109).

754 – SD Bosch LSU Lambda Sensor Cause Corrective action The signal from the lambda sensor 1. Check operation of fan (plant side).3) LP turbocharger (A side) is 2. replace as necessary (→ Page 114). B90. at sensor B9. The charge-air temperature is too high. 796 – AL HI T-Charge Air B Cause Corrective action The charge-air temperature B side u Contact Service.004 at sensor B9.3 has violated upper limit value 2. Check cooler (plant side) for contamination. 2. Check engine wiring (→ Page 109). 797 – AL HIHI T-Charge Air B Cause Corrective action The charge-air temperature B side u Contact Service. B90. 2. Contact Service. (B44.and 2. TIM-ID: 0000047144 . 728 – AL L2 Delta T-NT Intercooler Cause Corrective action The difference in temperature 1.has violated upper limit value 3. Check cooler (plant side) for contamination. between sensors B26. Contact Service. 727 – AL L1 Delta T-NT Intercooler Cause Corrective action The difference in temperature 1. 2.has violated upper limit value 3. The LT coolant inlet temperature is too high in relation to the ambient air temperature. 745 – AL Emission Fault Cause Corrective action Emission fault summary alarm 1. 1. Check lambda sensor. The charge-air temperature is too high.3 has violated upper limit value 1.and 2. Contact Service. Observe additional messages. between sensors B26. faulty or missing. The LT coolant inlet temperature is too high in relation to the ambient air temperature. Check operation of fan (plant side). Contact Service. 806 – SD Charger 3 Speed Cause Corrective action The signal from the speed sensor 1. (B89) is faulty or missing. Contact Service. MS15033/03E 2016-02 | Troubleshooting | 61 .

(B44.1) is faulty or missing. BT9. Contact Service. 2. 835 – AL Gas Path Fault Cause Corrective action Emission fault summary alarm 1. Contact Service. 844 – AL HI T-Charge Air before EGR Cause Corrective action The charge-air temperature at u Contact Service. 843 – SD T-Charge Air before EGR Cause Corrective action The signal from the charge-air 1. 832 – AL EIL Different Engine Number Cause Corrective action The engine number in the EIL 1.004 sensor B9. Check engine wiring (→ Page 109). faulty or missing.4) LP turbocharger (B side) is 2. Observe additional messages.1 / 2. 834 – AL Gas Path Warning Cause Corrective action Emission fault summary alarm 1. Contact Service. Check engine wiring (→ Page 109). The charge-air temperature is too high. 62 | Troubleshooting | MS15033/03E 2016-02 . Contact Service. does not match the engine 2. Check engine wiring (→ Page 109). TIM-ID: 0000047144 . 833 – AL Emission Warning Cause Corrective action Emission fault summary alarm 1. Contact Service. number stored in the ECU.1 has violated upper limit value 1. Observe additional messages. 2. Observe additional messages. 2. 807 – SD Charger 4 Speed Cause Corrective action The signal from the speed sensor 1. temperature sensor (B9. Contact Service.

1 has violated upper limit value 2.2) is u Contact Service.3 . faulty. The charge-air temperature is too high.has violated upper limit value 1. between sensors B9. The charge-air temperature is too high. TIM-ID: 0000047144 .004 855 – AL Flap Bypass B Defect Cause Corrective action The bypass flap B side (M52.has violated upper limit value 2.3 . MS15033/03E 2016-02 | Troubleshooting | 63 . between sensors B9. The charge-air temperature is too high. sensor B9.and B9.2 . engine is at standstill if the pressure in the HP accumulator was not relieved within the preset time.2 . 845 – AL HIHI T-Charge Air before EGR Cause Corrective action The charge-air temperature at u Contact Service. Blank Shot time expired Cause Corrective action The alarm is generated when the u Contact Service. 846 – AL HI T-Charge Air Diff AB Cause Corrective action The difference in temperature u Contact Service.and B9. 847 – AL HIHI T-Charge Air Diff AB Cause Corrective action The difference in temperature u Contact Service. pressure in the HP accumulator violates the upper limit value on initiating engine start before the starter is engaged. 852 – AL Max. 851 – AL External Start and HD too high Cause Corrective action The alarm is generated if the u Contact Service.

(B88. 902 – HI T-Coolant Cylinder Head Cause Corrective action The coolant temperature at u Contact Service. 871 – AL NOx ATO1 Communication Lost Cause Corrective action The ECU cannot detect the NOx 1. sensor (B88. sensor B6.3 has violated upper limit value 1. Replace lambda sensor (→ Page 114).1) after LP 2. Acknowledge alarm. Check engine wiring (→ Page 109). Contact Service. sensor B6. case of temporary implausible 3. replace as necessary (→ Page 112). Check engine wiring (→ Page 109). Check NOx sensor. J1939 combined oil temperature 2. Contact Service.004 953 – AL Lambda value invalid Cause Corrective action Status information from the 1. The coolant temperature is too high. Contact Service.1) in the exhaust pipe after 2. 2. turbocharger A side on the bus. The coolant temperature is too high. 898 – AL Trican Communication Lost Cause Corrective action The ECU can no longer detect the 1. the LP turbocharger A side is 3. TriCAN sensor (B90) on the bus. lambda sensor (B89). 899 – AL OLT Communication Lost Cause Corrective action The ECU can no longer detect the 1. Check engine wiring (→ Page 109). Check NOx sensor. and level sensor B93 on the bus. 64 | Troubleshooting | MS15033/03E 2016-02 . faulty or missing. TIM-ID: 0000047144 . replace as necessary (→ Page 112). 857 – AL NOx ATO1 Sensor Defect Cause Corrective action The signal from the NOx sensor 1.3 has violated upper limit value 2. measured values or lambda sensor defect. generated in 2. Check engine wiring (→ Page 109). 3. Contact Service. 904 – SS T-Coolant Cylinder Head Cause Corrective action The coolant temperature at u Contact Service. Contact Service.

963 – AL GPS p5 ctrlvar max active
Cause Corrective action
Failure to reach the necessary u Contact Service.
charging pressure.

964 – AL GPS p5 ctrlvar min active
Cause Corrective action
Failure to reach the necessary u Contact Service.
charging pressure.

970 – SD P-Exhaust
Cause Corrective action
The signal from the exhaust gas 1. Check engine wiring (→ Page 109).
pressure sensor (B91.3) is faulty 2. Contact Service.
or missing.

973 – AL Check Sum IIG
Cause Corrective action
The set IIG value does not match 1. Check IIG input in DiaSys, repeat as necessary.
the preset input format. 2. Contact Service.

974 – AL CAN3 Bus Off
Cause Corrective action
First Engine-CAN (CAN 3) for 1. Check engine wiring (→ Page 109).
engine sensors/actuators 2. Contact Service.
disrupted or failed.

975 – AL CAN3 Error Passive
Cause Corrective action
First Engine-CAN (CAN 3) for 1. Check engine wiring (→ Page 109).
engine sensors/actuators faulty. 2. Contact Service.

976 – AL CAN4 Bus Off
Cause Corrective action
Second Engine-CAN (CAN 4) for 1. Check engine wiring (→ Page 109).
engine sensors/actuators 2. Contact Service.
TIM-ID: 0000047144 - 004

disrupted or failed.

977 – AL CAN4 Error Passive
Cause Corrective action
Second Engine-CAN (CAN 4) for 1. Check engine wiring (→ Page 109).
engine sensors/actuators faulty. 2. Contact Service.

MS15033/03E 2016-02 | Troubleshooting | 65

983 – AL Stop on Trigger Crashrecorder
Cause Corrective action
The alarm indicates that the Crash u Contact Service.
Recorder has been triggered and
a start interlock activated as a
result.

984 – AL NOx ATO2 Sensor Defect
Cause Corrective action
The signal from the NOx sensor 1. Check engine wiring (→ Page 109).
(B88.2) in the exhaust pipe after 2. Check NOx sensor, replace as necessary (→ Page 112).
the turbocharger B side is faulty 3. Contact Service.
or missing.

985 – AL NOx ATO2 Communication Lost
Cause Corrective action
The ECU cannot detect the NOx 1. Check engine wiring (→ Page 109).
sensor (B88.2) after LP 2. Check NOx sensor, replace as necessary (→ Page 112).
turbocharger B side on the bus. 3. Contact Service.

1015 – AL Total breakdown NOx sensors
Cause Corrective action
Both NOx sensors (B88.1 and u Contact Service.
B88.2) indicate sensor defect or
an invalid value.

1016 – AL Redundancy loss NOx sensors
Cause Corrective action
Redundancy monitoring has 1. Check whether at least one of the alarms 857, 984, 871, 985 has
detected failure of an NOx sensor. been received.
The fault may be signaled even 2. Check NOx sensor, replace as necessary (→ Page 112).
when both NOx sensors are OK, 3. Contact Service.
e.g. following engine start if one
of the sensors is already active
when the other is still warming up
and thus is not yet active, or in
case of transient operations.

1097 – AL Flap Egr A Communication Lost
TIM-ID: 0000047144 - 004

Cause Corrective action
The ECU can no longer detect the 1. Check engine wiring (→ Page 109).
EGR shutoff flap A side (M53.1/ 2. Contact Service.
MA53.1) on the bus.

66 | Troubleshooting | MS15033/03E 2016-02

1098 – AL Flap Egr A Temperature too high
Cause Corrective action
High temperature signaled by the u Contact Service.
internal electronics of the
servomotor for the EGR shutoff
flap A side (M53.1/MA53.1).

1099 – AL Flap Egr A Targetposition
Cause Corrective action
The servomotor of the EGR u Contact Service.
shutoff flap A side (M53.1/
MA53.1) has failed to reached the
target position within the preset
time.

1100 – AL Flap Egr B Communication Lost
Cause Corrective action
The ECU can no longer detect the 1. Check engine wiring (→ Page 109).
EGR shutoff flap B side (M53.2/ 2. Contact Service.
MA53.2) on the bus.

1101 – AL Flap Egr B Temperature too high
Cause Corrective action
High temperature signaled by the u Contact Service.
internal electronics of the
servomotor for the EGR shutoff
flap B side (M53.2/MA53.2).

1102 – AL Flap Egr B Targetposition
Cause Corrective action
The servomotor of the EGR u Contact Service.
shutoff flap B side (M53.2/
MA53.2) has failed to reached the
target position within the preset
time.

1103 – AL Flap BypassA Communication Lost
Cause Corrective action
TIM-ID: 0000047144 - 004

The ECU can no longer detect the 1. Check engine wiring (→ Page 109).
bypass flap A side (M52.1/ 2. Contact Service.
MA52.1) on the bus.

MS15033/03E 2016-02 | Troubleshooting | 67

Contact Service. B side (M52. between sensor B90 and the 2.2) has failed to reached the target position within the preset time.2) on the bus. internal electronics of the servomotor for the bypass flap A side (M52. MA52. 68 | Troubleshooting | MS15033/03E 2016-02 . A side (M52. internal electronics of the servomotor for the bypass flap B side (M52. bypass flap B side (M52. 1106 – AL Flap BypassB Communication Lost Cause Corrective action The ECU can no longer detect the 1. 1107 – AL Flap BypasB Temperature too high Cause Corrective action High temperature signaled by the u Contact Service. 1104 – AL Flap BypasA Temperature too high Cause Corrective action High temperature signaled by the u Contact Service.2/MA52. 1105 – AL Flap Bypass A Targetposition Cause Corrective action The servomotor of the bypass flap u Contact Service.2/ 2.1).1) has failed to reached the target position within the preset time. TIM-ID: 0000047144 . The differential air intake pressure is too high.004 ambient air pressure sensor integrated in the ECU has violated limit value 1.1/MA52. 1108 – AL Flap Bypass B Targetposition Cause Corrective action The servomotor of the bypass flap u Contact Service. 1115 – AL Difference P0 P1 Intake Air L1 Cause Corrective action The difference in pressure 1. Check engine wiring (→ Page 109).2/MA52. Check air filter (plant side) for contamination.2).1/MA52. Contact Service.

calibration run error at the EGR shutoff flap A side (M53. ambient air pressure sensor integrated in the ECU has violated limit value 2. Check air filter (plant side) for contamination. 1116 – AL Difference P0 P1 Intake Air L2 Cause Corrective action The difference in pressure 1. Cause: The range of rotation (angle) taught during the calibration run is implausible.1). MS15033/03E 2016-02 | Troubleshooting | 69 . The taught angle is not between the admissible minimum and maximum angle. The taught angle is not between the admissible minimum and maximum angle.2/ MA53. calibration run error at the bypass flap A side (M52. The TIM-ID: 0000047144 . Cause: The range of rotation (angle) taught during the calibration run is implausible.1/MA52. Contact Service. 1121 – AL Flap Egr B Calibration Drive Err Cause Corrective action The ECU has detected a u Contact Service.004 taught angle is not between the admissible minimum and maximum angle. 1120 – AL Flap Egr A Calibration Drive Err Cause Corrective action The ECU has detected a u Contact Service. Cause: The range of rotation (angle) taught during the calibration run is implausible. between sensor B90 and the 2.2).1/ MA53. The differential air intake pressure is too high.1). calibration run error at the EGR shutoff flap B side (M53. 1122 – AL Flap BypassA Calibr. Drive Err Cause Corrective action The ECU has detected a u Contact Service.

Check state of battery charge (plant side).g. The taught angle is not between the admissible minimum and maximum angle.2/ 2. Limit value 2. HT circuit) 1131 – AL Short Circuit Analog Out 2 Cause Corrective action Incorrect value on plant side at u Contact Service. output signal for fan control. shutoff flap B side (M53. calibration run error at the bypass flap B side (M52. LT circuit) 1186 – AL EGR FlpA Wear Limit2 Cause Corrective action Faulty rapid reference run for EGR 1. Check state of battery charge (plant side). Contact Service.1/ 2.2) (executed each time the ECU is started).1/ 2.1) (executed each time the ECU is started). 1123 – AL Flap BypassB Calibr. moving-coil instrument. Contact Service. 70 | Troubleshooting | MS15033/03E 2016-02 . 1187 – AL EGR FlpB Wear Limit2 Cause Corrective action Faulty rapid reference run for EGR 1. bypass flap A side (M52. analog output 1 (e. MA53. moving-coil instrument. TIM-ID: 0000047144 . Limit value 2. 1130 – AL Short Circuit Analog Out 1 Cause Corrective action Incorrect value on plant side at u Contact Service.2/MA52. MA53. output signal for fan control.2). Contact Service. Drive Err Cause Corrective action The ECU has detected a u Contact Service. Cause: The range of rotation (angle) taught during the calibration run is implausible.g. Limit value 2. MA52. analog output 2 (e.004 1188 – AL Bypass FlpA Wear Limit2 Cause Corrective action Faulty rapid reference run for 1. shutoff flap A side (M53. Check state of battery charge (plant side).1) (executed each time the ECU is started).

Contact Service.2) (executed each time the ECU is started). bypass flap B side (M52.004 MS15033/03E 2016-02 | Troubleshooting | 71 . Limit value 2. TIM-ID: 0000047144 .2/ 2. Check state of battery charge (plant side). 1189 – AL Bypass FlpB Wear Limit2 Cause Corrective action Faulty rapid reference run for 1. MA52.

A side bottom (→ Page 34). ☑ Valves are closed. Qty. 20–100 Nm F30026582 1 Box wrench. Spare parts Designation / Use Part No. Rotate crankshaft with barring device in engine direction of rotation until “OT-A1” mark and pointer are aligned. 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 TIM-ID: 0000035352 . 2. 5 mm F30002815 1 Barring device F6790714 1 Preparatory steps u Remove cylinder head cover (→ Page 75).1. variant (A). 7 Task Description 7.005 Checking TDC position of piston in cylinder A1 – Variant (A) 1. ☑ Engine coolant temperature is max.1 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. 40 °C. Install barring device. 14 mm F30028346 1 Allen key.1 Valve Drive 7. 72 | Task Description | MS15033/03E 2016-02 . Special tools. Feeler gauge Y20010128 1 Torque wrench. on flywheel housing. Material.

• Exhaust = 0. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per diagram. Install barring device. variant (B).6 +/. Check valve clearance with cold engine: • Inlet = 0.1 mm. 4. the piston is in firing TDC.05 mm. Checking TDC position of piston in cylinder A1 – Variant (B) 1.05 mm. 5. If the deviation from the reference value exceeds 0.3 +/. Use feeler gauge to determine the distance between valve bridge and rocker arm.1 mm. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as per diagram. adjust valve clearance. If the deviation from the reference value exceeds 0. Continue to turn the crankshaft until the rounded surface (arrow) points upwards and the angle between the adjustment aid and the cylinder head is 90° (Figure B). 3.3 +/. • If rocker arms on cylinder A1 are loaded. 2. • Exhaust = 0.0. on starter. 3. the piston is in overlap TDC. adjust valve clearance. 2. B side (→ Page 34). 4. Checking valve clearance ‒ Variant (A) 1.05 mm.0. Bar engine manually in direction of rotation of the engine until the straight surface (arrow) points upwards and the angle between the adjustment aid and the cylinder head is 90° (Figure A). TIM-ID: 0000035352 . Use feeler gauge to determine the distance between valve bridge and rocker arm.05 mm. Checking valve clearance ‒ Variant (B) 1. MS15033/03E 2016-02 | Valve Drive | 73 . Check valve clearance with cold engine: • Inlet = 0. A Cylinder A1 is in firing TDC B Cylinder A1 is in overlap TDC 2.0.6 +/.0. Check TDC position of piston in cylinder A1: • If rocker arms on cylinder A1 are unloaded.005 3.

Loosen locknut (1) and unscrew adjusting screw (2) by a few threads. TIM-ID: 0000035352 . Result: If not.005 74 | Valve Drive | MS15033/03E 2016-02 . Adjusting valve clearance 1. Check if the feeler gauge just passes through between valve bridge and rocker arm (3). holding adjusting screw (2) firm with Allen screw. 2. Readjust adjusting screw (2) so that the feel- er gauge just passes through the gap. Remove barring device (→ Page 34). 4. Name Size Type Lubricant Value/Standard Nut M10 x 1 Tightening torque 43 Nm +4 Nm 5. Install cylinder head cover (→ Page 75). Final steps 1. adjust valve clearance. 2. 3. Tighten locknut (1) with torque wrench to specified torque. Insert feeler gauge between valve bridge and rocker arm (3).

Clean mating faces.1.1 to 18 tion 1: MS15033/03E 2016-02 | Valve Drive | 75 . Name Size Type Lubricant Value/Standard TIM-ID: 0000035536 . 5. 1. 7.2 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Removing and installing cylin- der head cover Note: Cover the engine beneath the cylinder head with rags to soak up escaping residual oil. 4. Position cylinder head cover and screws at positions 1 to 4 and tighten to specified initial tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw with twin col. Check condition of profile gasket and replace if required. 2. 3.002 Screw with twin col. Tighten screws at positions 1 to 18 to specified torque using a torque wrench.M8 Tightening torque 20 Nm ±2 Nm lar Consecutive tightening sequence starting at posi. Remove screws (2). Remove cylinder head cover (1).M8 Preload torque 10 Nm lar 6.

Loosen threaded vent plugs (3) and screw out by approx. 7. Risk of fire and explosion! • Avoid open flames. Material. Close threaded vent plug (2) and tighten by hand. Venting fuel prefilter 1. Spare parts Designation / Use Part No. • Do not smoke. Note: Catch emerging fuel with a suitable rag. 3 to 4 turns. Operate the pump with the handle (1) until bubble-free fuel emerges from the vent plug (2). 4.005 76 | Fuel System | MS15033/03E 2016-02 .2 Fuel System 7. protective gloves. Special tools. 7. Torque wrench. 5. and safety glasses / facial protection. Close threaded vent plug (2) and tighten by hand. TIM-ID: 0000028012 . Operate the pump with the handle (1) until bubble-free fuel emerges from the vent plug (2). 6. Unlock fuel priming pump. Note: Catch emerging fuel with a suitable rag.2. ☑ Engine cooled down to ambient temperature. 2. • Wear protective clothing. electrical sparks and ignition sources.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Qty. 3. 4–20 Nm F30044239 1 Ratchet adapter F30027340 1 WARNING Fuels are combustible and explosive. screw out han- dle (1). 3 to 4 turns. Loosen threaded vent plug (2) and screw out by approx.

2. Provide a suitable container in which to col- lect the fuel. 4. Venting fuel filter 1. Unlock fuel priming pump.3 Nm TIM-ID: 0000028012 . Screw in threaded vent plug (arrowed) and tighten to specified torque using a torque wrench. unscrew han- dle (arrowed).005 MS15033/03E 2016-02 | Fuel System | 77 . Open threaded vent plug (arrowed). Name Size Type Lubricant Value/Standard Threaded vent plug 10 Tightening torque 6. Note: Do not remove threaded vent plug.5 Nm ±1. 3.

Remove fuel filter element. 7. TIM-ID: 0000035537 . electrical sparks and ignition sources. if damaged. Replacing fuel filter 1. Replace sealing ring. 2. Screw in new fuel filter element in filter hous- ing (2) and tighten by hand. Remove drain screw (3). Install drain plug (3) and tighten with torque wrench to the specified tightening torque. • Wear protective clothing. Name Size Type Lubricant Value/Standard Threaded cover 32 A/F Tightening torque (Engine oil) 40 Nm ±5 Nm 11. ☑ Engine cooled down to ambient temperature.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. until fuel has drained from filter housing (2). Check condition of the sealing ring on the threaded cover (1). Name Size Type Lubricant Value/Standard Drain plug 10 Tightening torque 6.5 Nm ±1. 32 mm F30006120 1 Engine oil Fuel filter element (→ Spare Parts Catalog) 2 WARNING Fuels are combustible and explosive. Screw threaded cover (1) onto filter housing (2) and use torque wrench to tighten to the specified torque. 7. Remove threaded cover (1). 3 to 4 turns. 3. Wait 10 minutes. Special tools.3. 4. and safety glasses / facial protection. Torque wrench. Qty. 9.005 10. 8. • Do not smoke. Risk of fire and explosion! • Avoid open flames. Spare parts Designation / Use Part No. 4–20 Nm F30044239 1 Torque wrench. 20–100 Nm F30026582 1 Ratchet adapter F30027340 1 Socket. 6.3 Nm 78 | Fuel Filter | MS15033/03E 2016-02 . Material. 5. Coat sealing ring with engine oil.3 Fuel Filter 7. Loosen screw cap (1) on fuel filter and un- screw it approx. protective gloves.

12. Vent fuel system (→ Page 76). TIM-ID: 0000035537 .005 MS15033/03E 2016-02 | Fuel Filter | 79 .

and safety glasses / facial protection. Provide a suitable container to collect the wa- ter. Risk of fire and explosion! • Avoid open flames.003 80 | Fuel Filter | MS15033/03E 2016-02 . Allow water to drain off. • Do not smoke. electrical sparks and ignition sources.3. Open drain screw (1). 4. draining conden- sate 1. 7. TIM-ID: 0000031021 . protective gloves. • Wear protective clothing. WARNING Fuels are combustible and explosive. 2. Screw in and close drain screw (2).2 Fuel prefilter – Condensate draining Preconditions ☑ Engine is stopped and starting disabled. Fuel prefilter. 3.

7. Special tools. Insert new filter element (3) in filter cover (1). Close fuel supply. TIM-ID: 0000045441 . • Do not smoke. Qty. Coat new O-ring (2) with fuel. 5. Remove filter cover (1) with filter element (3) from filter housing (4). Tighten filter cover (1) with torque wrench to the specified tightening torque.3 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. MS15033/03E 2016-02 | Fuel Filter | 81 . 8. Risk of fire and explosion! • Avoid open flames. 3. 7. and safety glasses / facial protection.005 Name Size Type Lubricant Value/Standard Filter cover A/F46 Tightening torque 40 Nm Final steps 1. 8–40 Nm F30043446 1 Ratchet adapter F30027340 1 Diesel fuel Filter element (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Screw filter cover (1) with filter element (3) into filter housing (4).3. • Wear protective clothing. 2. Install new O-ring (2) on filter cover (1). Replacing fuel prefilter 1. 9. Preparatory step u Provide a suitable container in which to collect the fuel. Material. 4. Vent fuel system (→ Page 76). 2. electrical sparks and ignition sources. Remove filter element (3) from filter cov- er (1). Torque wrench. protective gloves. Open fuel inlet. Spare parts Designation / Use Part No. 6. Unscrew filter cover (1).

6.1 Air filter element – Removal and installation (optional) Preconditions ☑ Engine is stopped and starting disabled. 7. re- place if necessary. 8. 5.4. Qty. Remove collar nut (6).004 82 | Air Filter | MS15033/03E 2016-02 . Clean housing (3) and dust bowl (8). Clean all mating and sealing surfaces. Sealing (→ Spare Parts Catalog) Air filter element – Removal and installation 1.4 Air Filter 7. Secure dust bowl (9) with latches (8). Fit partition (7) and dust bowl (9) according to marking. 4. 7. Special tools. Material. 2. Spare parts Designation / Use Part No. 3. Release latches (9). 9. Screw off air filter element (4). Remove dust bowl (8) and partition (7). Check seal (5) for damage and cleanness. TIM-ID: 0000005455 .

3. Fit new filter element if old one is heavily contaminated or damaged (→ Page 84).4. risk of rupturing internal organs! • Never direct air jet at people. Fit new filter element if old one is damaged (→ Page 84). Material. re- place if necessary. Check seal for damage and cleanness. Note: Debris particles must not enter the intake system.2 Air filter element and (optional) dust bowl ‒ Cleaning Preconditions ☑ Engine is stopped and starting disabled. 2. Blow out filter element with compressed air (max. 1. 3 bar) from inside until all dust has been removed. TIM-ID: 0000005423 . 5. 2. Visual inspection 1. 6. Open air filter and remove filter element (→ Page 82). Qty. Spare parts Designation / Use Part No.006 MS15033/03E 2016-02 | Air Filter | 83 . Use inspection lamp to check cleaned filter element for damage. Clean dust bowl (if fitted). Special tools. Air filter element – Cleaning Note: Clean paper filter element dry only. Clean all mating and sealing surfaces. 7. 4. • Always wear safety goggles/face mask and ear defenders. Risk of injury to eyes and damage to hearing. Sealing (→ Spare Parts Catalog) WARNING Compressed air gun ejects a jet of pressurized air.

Reset signal ring of service indicator (→ Page 85). 7. Remove air filter and install new one (→ Page 82). Material. Spare parts Designation / Use Part No. TIM-ID: 0000055450 . Air filter (→ Spare Parts Catalog) Replacing air filter 1. 2.4. Qty. Special tools.3 Air filter – Replacement (option) Preconditions ☑ Engine is stopped and starting disabled.001 84 | Air Filter | MS15033/03E 2016-02 .

2.004 MS15033/03E 2016-02 | Air Intake | 85 . press reset button (1). After installation of new filter. Checking signal ring position 1.1 Service indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled.5. 7. Result: Signal ring returns to initial position.5 Air Intake 7. TIM-ID: 0000000985 . Replace air filter if the signal ring (2) is com- pletely visible in the red area of the observa- tion window (3) (→ Page 84).

1 Regeneration procedure NOTICE Accumulation of hydrocarbons in the SCR catalyst in extended low-load or idle operation. • The exhaust temperature upstream of the SCR catalyst must not exceed 250 °C in this mode.001 86 | Exhaust Gas Aftertreatment | MS15033/03E 2016-02 . run the engine for minimum 1 h under load.6.6 Exhaust Gas Aftertreatment 7. TIM-ID: 0000063474 . Risk of overheating of the SCR catalyst! • After more than 20 h of low-load or idle operation. 7.

If necessary. top up to "max." (2) mark(→ Page 88). Oil level must be between "min. Checking oil level prior to en- gine start 1. MS15033/03E 2016-02 | Lube Oil System. Insert oil dipstick (1) in guide tube up to the stop. Oil level must be between "min. Insert oil dipstick (1) in guide tube up to the stop. 7. 5. Checking oil level after the engine is stopped TIM-ID: 0000035570 ." mark (→ Page 88). 10 seconds and check oil level. Lube Oil Circuit 7. remove oil dipstick (1) from the guide tube and wipe it. 5 minutes after stopping the engine." (1) marks. top up to the "max. Lube Oil Circuit | 87 . 3." marks. withdraw after approx.1 Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled. 4.002 1. 3." (2) and "max. Withdraw oil dipstick (arrow) from guide tube and wipe it.7. 5. 2. withdraw after approx. 10 sec- onds and check oil level. 4. If necessary. Insert oil dipstick (arrow) into guide tube up to the stop." and "max.7 Lube Oil System. 2. Insert oil dipstick (1) into guide tube up to the stop.

Engine oil WARNING Hot oil.5 Tightening torque (Engine oil) 100 Nm 4. 2. ☑ Engine is at operating temperature.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. 88 | Lube Oil System. Close cap (1) on cylinder head cover. Qty. and goggles / safety mask. 3. Insert drain plug (2) and use torque wrench to tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Drain plug M26x1. gloves. ☑ MTU Fluids and Lubricants Specifications (A001063/. 2. Provide a suitable container to collect the oil. Special tools. TIM-ID: 0000035571 . • Do not inhale oil vapor. Check engine oil level (→ Page 87). Fill with oil. Oil can contain combustion residues which are harmful to health.7. 7.002 Filling with new oil 1. Replace engine oil filter (→ Page 89). Remove drain plug (2) and drain oil. 4.) are available. Open cap (1) on cylinder head cover. Lube Oil Circuit | MS15033/03E 2016-02 . Spare parts Designation / Use Part No. • Avoid contact with skin. 3. oil quantity (→ Page 23). Draining oil via drain plug on oil pan 1.. Material. Risk of injury and poisoning! • Wear protective clothing.

Screw on threaded cover (1) with oil filter element (3) and tighten to the specified torque with a torque TIM-ID: 0000035560 . Replace sealing ring (2) if damaged.Replacement 1. Material. 7. 2. Name Size Type Lubricant Value/Standard Threaded cover 32 A/F Tightening torque (Engine oil) 35 Nm ±3. Replace other engine oil filters in the same way. Take off threaded cover (1) with oil filter ele- ment (3). Engine oil filter .1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. 6. Oil can contain combustion residues which are harmful to health. 7.004 wrench. Risk of injury and poisoning! • Wear protective clothing. 8–40 Nm F30043446 1 Ratchet adapter F30027340 1 Socket.8 Oil Filtration / Cooling 7. • Avoid contact with skin. Spare parts Designation / Use Part No. Check oil level (→ Page 87) MS15033/03E 2016-02 | Oil Filtration / Cooling | 89 . 11. 3. 4. Insert new oil filter element (3) in cover (1) and press in until it locks in place. Special tools. 9. • Do not inhale oil vapor. gloves.8. Wait 10 minutes until the oil has drained from the filter housings. Torque wrench. Check condition of sealing ring (2) on cover. 5. 3 to 4 revolutions. Pull oil filter element (3) to detach it from threaded cover (1). 32 mm F30006120 1 Engine oil Oil filter element (→ Spare Parts Catalog) WARNING Hot oil. Coat sealing ring (2) with oil.5 Nm 10. Unscrew the oil filter covers (1) approx. Qty. and goggles / safety mask. 8.

6. Checking engine coolant level by means of level sensor 1. Check coolant level (coolant must be visible at the lower edge of the cast-in eye or at the marking plate). 2. Position breather valve on filler neck and close. 2.9.) are available. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. gloves. 4. High-Temperature Circuit 7.005 90 | Coolant Circuit. 3.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. and goggles / safety mask. Continue to turn breather valve counterclock- wise and remove. Top up with treated coolant as necessary (→ Page 94). TIM-ID: 0000000911 . ☑ MTU Fluids and Lubricants Specifications (A001063/.. 5. Top up with treated coolant as necessary (→ Page 94). • Wear protective clothing. Check breather valve (visual inspection) and clean if necessary. Checking engine coolant level at filler neck 1. Switch on engine control system and check readings on the display. General. High-Temperature Circuit | MS15033/03E 2016-02 . General. 7. WARNING Coolant is hot and under pressure.9 Coolant Circuit. Risk of injury and scalding! • Let the engine cool down.

7. Drain engine coolant (→ Page 92). TIM-ID: 0000000036 . Coolant Engine coolant change 1.031 MS15033/03E 2016-02 | Coolant Circuit. Spare parts Designation / Use Part No.9. General. Qty. Fill with engine coolant (→ Page 94). High-Temperature Circuit | 91 . Material.2 Engine coolant – Change Special tools. 2.

9. • Wear protective clothing. TIM-ID: 0000035572 . if installed. Switch off preheater. Spare parts Designation / Use Part No. 2. High-Temperature Circuit | MS15033/03E 2016-02 . Open drain plug and drain off coolant at en- gine coolant pump (1). Continue to turn breather valve counterclock- wise and remove. Provide a suitable container to catch the coolant. Risk of injury and scalding! • Let the engine cool down.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. 3. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. gloves. Draw off separated corrosion inhibitor oil in expansion tank through the filler neck. 7. 2. Special tools. Engine coolant – Draining 1.002 92 | Coolant Circuit. General. Qty. Material. and goggles / safety mask. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape. 4. Preparatory steps 1.

TIM-ID: 0000035572 . Open drain plugs and drain coolant at crank- case.002 MS15033/03E 2016-02 | Coolant Circuit. 5. General.2). left side (1. Install drain plug with new sealing ring.2). 6. Open drain plugs and drain coolant at crank- case. High-Temperature Circuit | 93 . 8. Position breather valve on filler neck and close. 7. right side (1.

Turn breather valve (1) of coolant expansion tank counterclockwise until the first stop and allow pressure to escape. WARNING High level of engine noise when the engine is running. Material. Fill coolant through filler neck on expansion tank or through filling line until coolant level reaches lower edge of cast-in eye or marking plate. General. Check proper condition of breather valve (1).007 Coolant – Filling 1. • Wear protective clothing. Possible formation of cracks in the engine! • Fill / top up coolant only into cold engine. Preparatory steps 1. Spare parts Designation / Use Part No. 2.) are available. Risk of damage to hearing! • Wear ear protectors.9. Coolant WARNING Coolant is hot and under pressure. ☑ MTU Fluids and Lubricants Specifications (A001063/. 2. Continue to turn valve cover (1) counter- clockwise and remove. High-Temperature Circuit | MS15033/03E 2016-02 .4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. TIM-ID: 0000000909 .. Special tools. 3. Risk of injury and scalding! • Let the engine cool down. Qty. and goggles / safety mask. NOTICE Cold coolant in hot engine can cause thermal stress. Fit breather valve (1) and close it. 7. 94 | Coolant Circuit. clean sealing faces if required. gloves.

top up with coolant if required.007 MS15033/03E 2016-02 | Coolant Circuit. Final steps 1. Check coolant level (→ Page 90). TIM-ID: 0000000909 . General. 2. High-Temperature Circuit | 95 . Start the engine and operate it at idle speed for some minutes.

5 Engine coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of damage to hearing! • Wear ear protectors. Keep away from the engine's danger zone. General.9. Engine coolant pump – Relief bore check 1. Risk of crushing. danger of parts of the body being caught or pulled in! • Only run the engine at low power. con- tact Service.1 ml per hour respectively 100 ml per 1. 3.002 96 | Coolant Circuit. WARNING High level of engine noise when the engine is running. • Permissible coolant discharge quantity: Up to 0. TIM-ID: 0000032404 . 7. High-Temperature Circuit | MS15033/03E 2016-02 . Stop engine (→ Page 31) and disable engine start. Check relief bore (1) for coolant discharge.000 operating hours. 2. If discharge exceeds the specified limits.

1 Charge-air coolant level – Check Preconditions ☑ Engine is stopped and starting disabled.) are available. ☑ MTU Fluids and Lubricants Specifications (A001063/. Check satisfactory condition of breather valve. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Fit breather valve and close it. 2. 2. Top up coolant if necessary (→ Page 100). 6. Top up coolant if necessary (→ Page 100). WARNING Coolant is hot and under pressure. Continue to turn breather valve counterclock- wise and remove. 7. gloves.10 Low-Temperature Circuit 7. Check coolant level (coolant must be visible at marker plate).003 MS15033/03E 2016-02 | Low-Temperature Circuit | 97 . Checking charge-air coolant lev- el at filler neck 1. Risk of injury and scalding! • Let the engine cool down. 3.10. • Wear protective clothing. and goggles / safety mask. Checking charge-air coolant level by means of level sensor 1.. clean sealing faces if required. TIM-ID: 0000031873 . 4. 5. Switch on engine control system and check display (coolant level is automatically monitored by engine con- trol system).

011 98 | Low-Temperature Circuit | MS15033/03E 2016-02 . Material. Drain charge-air coolant (→ Page 99). Fill with charge-air coolant (→ Page 100). Qty.2 Charge-air coolant – Change Special tools. Spare parts Designation / Use Part No. Coolant Charge-air coolant – Change 1. TIM-ID: 0000000041 . 2. 7.10.

Material. Place breather valve on filler neck and close. 5. Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. and goggles / safety mask. 4. Spare parts Designation / Use Part No. • Wear protective clothing. Charge-air coolant – Draining 1. 6. Provide an appropriate container to drain the coolant into. Open drain plugs and drain coolant on the in- tercooler. Qty. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck. Continue to turn breather valve counterclock- wise and remove.10. Open drain screw and drain off coolant at the charge-air coolant pump (1). 3. TIM-ID: 0000035573 .001 MS15033/03E 2016-02 | Low-Temperature Circuit | 99 . Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. gloves. 7. right (1) and left side (2). Screw in drain plugs with new sealing rings. 2. Special tools. 8. 7. Risk of injury and scalding! • Let the engine cool down.3 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled.

100 | Low-Temperature Circuit | MS15033/03E 2016-02 . Fit breather valve (1) and close it. Material.10. • Wear protective clothing. Preparatory steps 1. 7. Coolant Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Spare parts Designation / Use Part No. 3. WARNING High level of engine noise when the engine is running. Check proper condition of breather valve (1). 4. Risk of injury and scalding! • Let the engine cool down. Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level reaches marker plate. Risk of damage to hearing! • Wear ear protectors. gloves. clean sealing faces if required. Continue to turn breather valve (1) counter- clockwise and remove. NOTICE Cold coolant in hot engine can cause thermal stress.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. 2.) are available. 2. Qty. Install plug screws of filling points with new sealing rings. Possible formation of cracks in the engine! • Fill / top up coolant only into cold engine. and goggles / safety mask. ☑ MTU Fluids and Lubricants Specifications (A001063/. 3. Turn breather valve (1) on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.006 Coolant – Filling 1. TIM-ID: 0000031875 . Special tools. Remove plug screw from filling point on cool- ant line to intercooler..

Start the engine and operate it at idle speed for some minutes. 2.006 MS15033/03E 2016-02 | Low-Temperature Circuit | 101 . TIM-ID: 0000031875 . Final steps 1. Check coolant level (→ Page 97).

7.10.5 Charge-air coolant pump – Relief bore check
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.

Charge-air coolant pump – Re-
lief bore check
1. Check relief bore (1) for coolant discharge.
• Permissible coolant discharge: Up to
0.1 ml per hour respectively 100 ml per
1,000 operating hours.
Result: If discharge exceeds the specified limits, con-
tact Service.
2. If relief bore (1) is clogged:
• Stop engine (→ Page 31) and disable en-
gine start.
• Clean relief bore (1) with wire.

TIM-ID: 0000035574 - 002

102 | Low-Temperature Circuit | MS15033/03E 2016-02

7.11 Belt Drive
7.11.1 Coolant pump – Drive belt replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Assembly jig F6794712 1
Poly-vee belt (→ Spare Parts Catalog)

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• 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.

Preparatory step
1. Install barring gear (→ Page 34).
2. Cut poly-vee belt (2) on charge-air coolant pump and engine coolant pump with a suitable cutting tool.

Replacing engine coolant pump
drive belt (HT circuit)
1. Fit new poly-vee belt (2) on back four grooves
of belt pulley (1) to crankshaft.
2. Fit poly-vee belt (2) on back four grooves of
belt pulley (4) to crankshaft and preload with
assembly jig (3).
3. Bar engine with barring gear until poly-vee
belt (2) lies completely on belt pulley (4).
4. Remove assembly jig (3).
TIM-ID: 0000045474 - 001

MS15033/03E 2016-02 | Belt Drive | 103

Replacing charge-air coolant
pump drive belt (LT circuit)
1. Fit new poly-vee belt (2) on front three
grooves of belt pulley (1) to crankshaft.
2. Fit poly-vee belt (2) on front three grooves of
belt pulley (3) to crankshaft and preload with
assembly jig (4).
3. Bar engine with barring gear until poly-vee
belt (2) lies completely on belt pulley (3).
4. Remove assembly jig (4).

Final step
u Install barring gear (→ Page 34).

TIM-ID: 0000045474 - 001

104 | Belt Drive | MS15033/03E 2016-02

7. Preparatory step u Remove battery-charging generator drive belt (→ Page 107). Material. Risk of hands being crushed! • Lock belt tensioner in position. Spare parts Designation / Use Part No. Coat screws (2) with engine oil.1 Battery-charging generator – Belt tensioner and diverter pulley replacement Preconditions ☑ Engine is stopped and starting disabled. 2. 3. Install bolts (2). 5. Tighten screws (2). Remove belt tensioner (3). • Only use specified tools and devices. Qty. Special tools. TIM-ID: 0000045462 . 20–100 Nm F30026582 1 Ratchet adapter F30027340 1 Engine oil Belt tensioner (→ Spare Parts Catalog) Diverter pulley (→ Spare Parts Catalog) WARNING Belt tensioner spring is pretensioned. Install new belt tensioner (3). Torque wrench. Note: Leave pin (1) in new belt tensioner. Replacing belt tensioner 1.12 Battery-Charging Generator 7.12.005 MS15033/03E 2016-02 | Battery-Charging Generator | 105 . 4.

2. TIM-ID: 0000045462 . Install new diverter pulley (1) with screw (2). 4. Replacing diverter pulley 1. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 60 Nm ±10 Nm Final steps Note: Remove pin before relieving belt tensioner. Coat thread of screw (2) with engine oil. Remove screw (2). u Install battery-charging generator drive belt (→ Page 107). 5.005 106 | Battery-Charging Generator | MS15033/03E 2016-02 . Remove diverter pulley (1). Tighten screw (2) to specified torque using a torque wrench. 3.

Insert 8 mm steel pin (e. Remove 8 mm steel pin. Remove 8 mm steel pin. Turn belt tensioner clockwise against the spring force almost up to the stop to remove the 8 mm steel pin. Installing battery-charging gen- erator drive belt 1. 4. Make sure that drive belt (3) is correctly seat- ed in the grooves. 7. Release belt tensioner and remove square wrench with extension. 5. 2. Risk of hands being crushed! • Lock belt tensioner in position. Release belt tensioner and remove square wrench with extension. MS15033/03E 2016-02 | Battery-Charging Generator | 107 .g. 7. 6. 3. 4. 5.12. Insert 8 mm steel pin (e. Removing battery-charging gen- erator drive belt 1.g.005 7. no force must be applied. Turn belt tensioner clockwise against the spring force almost up to the stop. punch) (1) to lock belt tensioner. punch) (1) to lock belt tensioner. Fit new drive belt (3). TIM-ID: 0000045461 . 2. Note: When placing the drive belt in the grooves. Turn belt tensioner clockwise against the spring force almost up to the stop. 6. Turn belt tensioner clockwise against the spring force almost up to the stop to remove the 8 mm steel pin. 3. Remove drive belt (3). 8. • Only use specified tools and devices. Fit square wrench with extension into square hole (2) on belt tensioner. WARNING Belt tensioner spring is pretensioned. Fit square wrench with extension into square hole (2) on belt tensioner.2 Battery-charging generator – Drive belt removal and installation Preconditions ☑ Engine is stopped and starting disabled.

Mount dial gage (1) on engine-side coupling flange. 5. 6. 8. 3. Press connecting flange in opposite direction. 2. Carry out this measuring procedure twice with the measuring points arranged 90 de- grees from each other. Driving End and Free End (Coupling) 7. Bearing bushing wear is equal to the half of the measured value. Set dial-gage anvil onto outer coupling part.1 Coupling – Radial clearance check Preconditions ☑ Engine is stopped and starting disabled. 7. Set dial gage (1) to zero. Push coupling inner part over the drive shaft connecting flange upwards towards the dial gage. Contact Service if the measured value exceeds 1. 7.003 108 | Drive Systems. Read off at dial gage (1).6 mm wear).13 Drive Systems. Use a suitable tool to move the con- necting flange (mounting lever). Driving End and Free End (Coupling) | MS15033/03E 2016-02 . Checking radial clearance 1. TIM-ID: 0000045493 .2 mm (0.13. 4. ☑ Guard is removed.

Note: Close connectors that are not plugged in with the protective cap supplied. Special tools. 7. 2. Check securing screws of cable clamps on engine and tighten loose screw connections. contact Service. Spare parts Designation / Use Part No.024 MS15033/03E 2016-02 | Wiring (General) for Engine/Gearbox/Unit | 109 . Solvent (isopropyl alcohol) X00058037 1 Engine cabling – Check 1. 6. Ensure that cables are securely seated in clamps and cannot move freely. Qty. 8. Replace faulty cable clamps. Replace faulty cable clips. plug connectors and contacts. Ensure that all connecting plugs of the sensors are correctly engaged.14 Wiring (General) for Engine/Gearbox/Unit 7. Check if all cable clips are closed and intact. 5. 7. Material. 3. TIM-ID: 0000000029 . Visually inspect the following electrical components for damage: • Connector housings • Contacts • Plug connectors • Cables and terminals • Plug-in contacts Result: If cable conductors are damaged. tighten loose clamps.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled.14. Use isopropyl alcohol to clean dirty connector housings. 4. Check cable clamps for secure fit. 9.

Check legibility of cable labels. connector socket housings and all contacts with isopropyl alcohol. Release latches of connectors and withdraw connectors. Use isopropyl alcohol to remove coarse dirt from housing surface.1 Engine governor and connector – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Clean connector housings. Use isopropyl alcohol to remove dirt from the connector and cable surfaces. Solvent (isopropyl alcohol) X00058037 1 NOTICE Insertion of unsuitable test probe. 3. test prod. Spare parts Designation / Use Part No. e.15. Special tools. 3. sockets and all contacts are dry: Fit connectors and latch them. 2.15 Accessories for (Electronic) Engine Governor / Control System 7. Engine governor and connector – Cleaning 1. The contacts in the plug connection can be bent! • Carry out check of plug connection only with test connectors.g. Material. TIM-ID: 0000000047 . Qty.014 110 | Accessories for (Electronic) Engine Governor / Control System | MS15033/03E 2016-02 . 1. Heavily contaminated connectors on engine governor – Cleaning Note: Close connectors that are not plugged in with the protective cap supplied. Clean or replace illegible labels. 7. 2. When connectors.

Checking plug-in connections on engine governor 1. Make sure that cable clamps are not defective. Check firm seating of all connectors on the engine governor. TIM-ID: 0000032518 .2 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled.15. 7. 2.003 MS15033/03E 2016-02 | Accessories for (Electronic) Engine Governor / Control System | 111 . Ensure that the clips (1) are engaged. Check firm seating of all screws (2) on engine governor cable clamps.

Unscrew control unit (1) at the eyelets. 2. Risk of burns! • Allow the engine to cool down to below 50 °C before beginning work.3 NOx sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. • Wear suitable protective equipment/thermal gloves. Risk of damage to components! • Switch off ignition before replacing components. Risk of damage to components! • Avoid shocks and impacts.15. 4–20 Nm F30044239 1 Torque wrench. 7. Torque wrench. Removing NOx sensor Note: Observe arrangement and position of sensor (→ Page 18). 3. Disconnect and remove male connector (2) from control unit (1). NOTICE Ceramic cell breakage due to shock or impact. • Avoid unprotected contact with hot surfaces. Material. 10–60 Nm F30452769 1 Ratchet adapter F30027340 1 Assembly compound (Molykote P 37) 50564 1 NOx sensor (→ Spare Parts Catalog) 1 WARNING Hot components/surfaces. TIM-ID: 0000025205 . Special tools. Qty. NOTICE High voltage. Remove sensor (3). • Exercise extreme care when handling sensors. 1.016 112 | Accessories for (Electronic) Engine Governor / Control System | MS15033/03E 2016-02 . Spare parts Designation / Use Part No.

5. 4. Remove protective cap on thread of sensor (3) only just before installation. Name Size Type Lubricant Value/Standard Screw M6 Tightening torque max. 1. Fit male connector (2) and latch it. TIM-ID: 0000025205 . Installing NOx sensor Note: Note the following: • If the sensor (3) was subjected to shock or impact load.016 MS15033/03E 2016-02 | Accessories for (Electronic) Engine Governor / Control System | 113 . Install control unit (1) at the eyelets and tighten screws to the specified tightening torque. it is considered to be defective and may not be used. • Always replace NOx sensor (3) together with control unit (1). 3. 12 Nm 2. Note: Do not wipe off the thread lubricant applied by the manufacturer. Coat sensor (3) thread with specified assembly compound as required. Screw in sensor (3) by hand. Name Size Type Lubricant Value/Standard Nut M20 Tightening torque (Assembly compound 40 Nm +4 Nm (Molykote P 37)) 6. Tighten nut (3) to specified torque using a torque wrench.

NOTICE Ceramic cell breakage due to shock or impact. NOTICE High voltage. Observe the following general information: • Layout and position of sensor (→ Page 18). • Avoid unprotected contact with hot surfaces. • Wear suitable protective equipment/thermal gloves. Remove sensor (2). 7.4 Lambda sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. Spare parts Designation / Use Part No. ☑ Power supply to electronic engine management system is switched off. 10–60 Nm F30452769 1 Ratchet adapter F30027340 1 Assembly compound (Molykote P 37) 50564 1 Lambda sensor (→ Spare Parts Catalog) 1 WARNING Hot components/surfaces. TIM-ID: 0000025194 .016 114 | Accessories for (Electronic) Engine Governor / Control System | MS15033/03E 2016-02 . Risk of damage to components! • Switch off ignition before replacing components. Risk of burns! • Allow the engine to cool down to below 50 °C before beginning work. Material. • Exercise extreme care when handling sensors. Removing Lambda sensor 1.15. 3. Special tools. 2. Risk of damage to components! • Avoid shocks and impacts. Unplug and remove male connector (1). Torque wrench. Qty.

Installing Lambda sensor Note: When the sensor was subjected to shock or impact load.). 1.5 Tightening torque (Assembly compound 40 Nm +4 Nm (Molykote P 37)) 5. contact Service. Remove protective cap on thread only just before installation. Name Size Type Lubricant Value/Standard Nut M18 x 1. TIM-ID: 0000025194 . 2. Tighten nut (2) to specified torque using a torque wrench. it is deemed to be defective and may not be used. 3. Fit male connector (1) and latch it. 4. Note: Do not wipe off the thread lubricant applied by the manufacturer.. Coat sensor thread with specified assembly compound as required. 6. If no DiaSys® is available. Reset Lambda sensor calibration with DiaSys® (→ Dialog system DiaSys® E531920/. Screw in sensor by hand.016 MS15033/03E 2016-02 | Accessories for (Electronic) Engine Governor / Control System | 115 .

5% urea concentration AGR Abgasrückführung Exhaust gas recirculation AL Alarm ANSI American National Standards Institute Association of American standardization organiza- tions ATL Abgasturbolader Exhaust turbocharger BDM Backup Data Module Data backup module BR Baureihe Series BV Betriebsstoffvorschrift Fluids and Lubricants Specifications / Preservation and Represervation Specifications. C&I Commercial and Industrial CAN Controller Area Network Data bus system.. German national standards institute. Brand name of the German Association of Vehicle Manufacturers (VDA) Urea solution with 32. V. MTU publication no.5% urea concentration Designation used in Northern America DIFF Difference DILA Diagnostic lamp DIN Deutsches Institut für Normung e. At the same time identifier of German standards (DIN = “Deut- sche Industrie-Norm”) TIM-ID: 0000009959 .1 Abbreviations Abbre.Meaning Explanation viation AC Alternating Current AdBlue . bus standard CaPoS Capacitor Power System Capacitor-based starting system CDC Calibration Drift Compensation Drift compensation must be reset in the engine gov- ernor using DiaSys® to ensure optimum emissions and consumption characteristics CE Comunidad Europea European Community CRC Cyclic Redundancy Control Check sum procedure to detect data transmission faults DBR Drehzahlbegrenzungskurve Speed limitation curve DC Direct Current DEF Diesel Exhaust Fluid Urea solution with 32.012 DL Default Lost Alarm: Default CAN bus failure DN Nominal diameter (pipe) DOC Diesel Oxidation Catalyst DPF Diesel Particulate Filter I/O Input/Output ECU Engine Control Unit Engine governor EIL Engine Identification Label Electronic engine nameplate EMC Electromagnetic Compatibility 116 | Appendix A | MS15033/03E 2016-02 . A00. 8 Appendix A 8.

International umbrella organization for all national tion standardization institutes ITS Integrated Test System KGS Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204 KS Kupplungsseite Engine driving end in accordance with DIN ISO 1204 LED Light Emitting Diode LO Low Alarm: Measured value lower than 1st minimum limit LOLO Low Low Alarm: Measured value lower than 2nd minimum lim- it MTU Motoren.Meaning Explanation viation EPA Environmental Protection Agency US Environmental Protection Agency EPDM Ethylene Propylene Diene Monomer rubber ESD Electrostatic Discharge Protection against static discharge ESI Emergency Stop Input Emergency stop input channel of ECU9 ETK Ersatzteilkatalog Spare Parts Catalog EU European Union EWG Europäische Wirtschaftsgemeinschaft European Economic Community FO Frequency Output FSW Function Software GND Ground HD Hochdruck High pressure HI High Alarm: Measured value exceeds 1st maximum limit HIHI High High Alarm: Measured value exceeds 2nd maximum limit HT High Temperature ID Identification number IEC International Electrotechnical Commission Standards and conformity assessment body for all fields of electrical engineering IGI Ignition Input Ignition input channel of ECU9 IIG Initiale Injektorgleichstellung The injector code must be entered in the engine gov- ernor using DiaSys® to ensure optimum emissions and consumption characteristics ISO International Organization for Standardiza. Abbre. standardization organization SAM Service and Automation Module SD Sensor Defect Alarm: Sensor failure MS15033/03E 2016-02 | Appendix A | 117 . control and plant-related sys- TIM-ID: 0000009959 .S.012 tem integration of peripheral components PDU Process Data Unit POM Power Output Module Module to control starter and battery-charging gen- erator PU Projektierungsumgebung Project configuration environment P-xyz Pressure-xyz Pressure measuring point xyz SAE Society of Automotive Engineers U.und Turbinenunion MV Magnetventil Solenoid valve OEM Original Equipment Manufacturer OT Oberer Totpunkt Top Dead Center PAU Power Automation Unit Module for monitoring.

Meaning Explanation viation SS Safety System Safety system alarm TBO Time Between Overhaul TEN Technical Evolution Network Technical sales documents. technical data T-xyz Temperature-xyz Temperature measuring point xyz U Symbol for electric voltage UIC Union Internationale des Chemins de Fer International railway association Ultra. Abbre.012 118 | Appendix A | MS15033/03E 2016-02 . UltraCaps modules Capacitors for starting system Caps UT Unterer Totpunkt Bottom Dead Center WZK Werkzeugkatalog Tool Catalog TIM-ID: 0000009959 . engine data.

simple and correct identification of spare parts for your drive system or vehicle fleet. go to the MTU Internet site: http://www.mtu-online. Your contact at Headquarters: E-mail: spare.parts@mtu-online.com 24h Hotline With our 24h hotline and high flexibility. agencies and service workshops.: +49 7541 9077778 TIM-ID: 0000000873 .com Tel. 8.com Tel. For locally available support. With this aim in mind.: +49 7541 9077777 Fax.: +49 7541 9077777 Fax. representatives and custom- er service centers ensure fast and direct support on site and ensure the high availability of our products. preventive maintenance and corrective operations in case of a malfunction. Your contact person in our Customer Assistance Center: E-mail: info@mtu-online. sales offices.: +49 7541 9077778 Asia/Pacific: +65 6100 2688 North and Latin America: +1 248 560 8000 Spare Parts Service Fast.016 MS15033/03E 2016-02 | Appendix A | 119 . The right spare part at the right time at the right place. we're your contact around the clock: during each operating phase. a central warehouse at headquarters and on-site stores at our subsidiary companies. Local Support Experienced and qualified specialists place their knowledge and expertise at your disposal. for information on changes in conditions of use and for supplying spare parts. we can call on a globally networked spares logistics system.2 MTU Contact/Service Partners The worldwide network of the sales organization with subsidiaries.

5 mm Part No. 9 Appendix B 9.8 Engine – Barring manually (→ Page 34) Allen key.1 Valve clearance – Check and adjustment (→ Page 72) Assembly jig Part No.004 120 | Appendix B | MS15033/03E 2016-02 .: 1 Used in: 7.11.1 Special Tools Adapter Part No.1 Coolant pump – Drive belt replacement (→ Page 103) DCL-ID: 0000029795 .: 1 Used in: 4.: F6794712 Qty.: F30002815 Qty.: F30011619 Qty.1.: 1 Used in: 7.

: F6797426 Qty.: 1 Used in: 7.1.1.: 1 Used in: 4.004 MS15033/03E 2016-02 | Special Tools | 121 .8 Engine – Barring manually (→ Page 34) Box wrench.: 1 Used in: 4.: 1 Used in: 7.: F6790714 Qty. Barring device Part No.: Y20010128 Qty.1 Valve clearance – Check and adjustment (→ Page 72) DCL-ID: 0000029795 .: 1 Used in: 7.1 Valve clearance – Check and adjustment (→ Page 72) Feeler gauge Part No.1 Valve clearance – Check and adjustment (→ Page 72) Barring device Part No.: F30028346 Qty.8 Engine – Barring manually (→ Page 34) Qty.1. 14 mm Part No.

: F30452769 DCL-ID: 0000029795 .3.1 Engine oil filter – Replacement (→ Page 89) Torque wrench. 10–60 Nm Part No.15.7 Plant – Cleaning (→ Page 33) Ratchet adapter Part No.12.: 1 Used in: 7.: 1 Used in: 7.: - Qty.: 1 Used in: 7.4 Lambda sensor – Replacement (→ Page 114) Socket.4 Lambda sensor – Replacement (→ Page 114) 122 | Special Tools | MS15033/03E 2016-02 .15.1 Fuel filter – Replacement (→ Page 78) Qty.1 Engine oil filter – Replacement (→ Page 89) Qty.: F30006120 Qty.3 Fuel prefilter – Filter element replacement (→ Page 81) Qty.: 1 Used in: 7.8.3 NOx sensor – Replacement (→ Page 112) Qty. High-pressure cleaning unit Part No.3.3.004 Qty.: F30027340 Qty.15.: 1 Used in: 7.8.1 Fuel filter – Replacement (→ Page 78) Qty.1 Battery-charging generator – Belt tensioner and diverter pulley replacement (→ Page 105) Qty.: 1 Used in: 7.2.8 Engine – Barring manually (→ Page 34) Qty.: 1 Used in: 7.15.1 Fuel system – Venting (→ Page 76) Qty.3 NOx sensor – Replacement (→ Page 112) Qty.: 1 Used in: 7.: 1 Used in: 7.: 1 Used in: 4.: 1 Used in: 4.: 1 Used in: 7.: 1 Used in: 7. 32 mm Part No.

: 1 Used in: 7.12.: 1 Used in: 7.: 1 Used in: 7.3 Fuel prefilter – Filter element replacement (→ Page 81) Qty.004 MS15033/03E 2016-02 | Special Tools | 123 .3.1 Valve clearance – Check and adjustment (→ Page 72) Qty.3 NOx sensor – Replacement (→ Page 112) Torque wrench. Torque wrench.: 1 Used in: 7.2.15.: F30044239 Qty.1 Fuel filter – Replacement (→ Page 78) Qty.1 Battery-charging generator – Belt tensioner and diverter pulley replacement (→ Page 105) Torque wrench.1 Fuel filter – Replacement (→ Page 78) Qty. 8–40 Nm Part No.: 1 Used in: 7.: 1 Used in: 7.: 1 Used in: 7. 20–100 Nm Part No.3.1 Fuel system – Venting (→ Page 76) Qty.1 Engine oil filter – Replacement (→ Page 89) DCL-ID: 0000029795 . 4–20 Nm Part No.: 1 Used in: 7.3.: F30026582 Qty.1.: F30043446 Qty.8.

9.004 – Change  91.2 Index A D Abbreviations 116 Diverter pulley  Actuators  – Replacement   – Overview  18 – On battery-charging generator  105 After stopping the engine 32 Drive belt  Air filter  – Installation   – Replacement  84 – on battery-charging generator  107 – Service indicator check  85 – Charge-air coolant pump   Air filter element  – Replacement  103 – Cleaning  83 – Engine coolant pump   – Removal and installation  82 – Replacement  103 – Removal   B – from battery-charging generator  107 Battery-charging generator  Dust bowl  – Belt tensioner   – Cleaning  83 – Replacement  105 – Diverter pulley   E – Replacement  105 ECU 9  – Drive belt   – Fault messages  40 – Installation  107 Engine  – Removal  107 – Barring manually  34 Belt tensioner  – Overview  17 – Replacement   – Start  29 – On battery-charging generator  105 – Stop  31 Engine cabling  C – Check  109 Cabling  Engine coolant  – Check   – Change  91 – On engine  109 – Check   Charge-air coolant  – Level at filler neck  90 – Change  98 – Level with level sensor  90 – Draining  99 – Draining  92 – Filling  100 – Filling  94 Charge-air coolant level  Engine coolant level  – Check  97 – Check  90 Charge-air coolant pump  Engine coolant pump  – Drive belt   – Drive belt   – Replacement  103 – Replacement  103 – Relief bore check  102 – Relief bore check  96 Connector  Engine driving end  – Cleaning  110 – Definition  16 Contact persons 119 Engine free end  Coolant  – Definition  16 DCL-ID: 0000029795 . 98 Engine governor  Coolant level  – Cleaning  110 – Check  90 – Plug-in connections   Coupling  – Check  111 – Radial clearance check  108 Engine oil  Cylinder  – Change  88 – Designation  16 Engine oil filter  Cylinder head cover  – Replacement  89 – Installation  75 Engine oil level  – Removal  75 – Check after stopping the engine  87 – Check prior to engine start  87 124 | Index | MS15033/03E 2016-02 .

Engine sides  Safety regulations  – Designation  16 – Auxiliary materials  13 – Environmental protection  13 F – Fire prevention  13 Fault messages  – Fluids and lubricants  13 – ECU 9  40 – Important provisions  5 Filter  – Maintenance work  10 – Fuel   – Operation  8 – Replacement  78 – Organizational requirements  6 Fuel filter  – Personnel requirements  6 – Replacement  78 – Repair work  10 Fuel prefilter  – Startup  8 – Filter element replacement  81 Safety requirements  Fuel prefilter   – Safety notices. standards 15 MS15033/03E 2016-02 | Index | 125 .004 – 12V1600R50  24 R Regeneration  – Procedure  86 Relief bore  – Engine coolant pump – Check  96 S Safety notices. standards  15 – Condensate draining  80 Sensors  Fuel system  – Overview  18 – Venting  76 – Replacement   – Lambda  114 H – NOx  112 Hotline 119 Service indicator  – Check  85 L Service partners 119 Lambda sensor  Spare parts service 119 – Replacement  114 Startup  – After extended out-of-service periods (>3 months)  28 M – After scheduled out-of-service-period  27 Main engine dimensions 23 Maintenance schedule  T – Maintenance task reference table [QL1]  36 Technical data  MTU contact persons 119 – 12V1600R50  24 transport 7 N Troubleshooting 37 NOx sensor  – Replacement  112 V Valve clearance  O – Adjustment  72 Operational checks 30 – Check  72 Overview  – Actuators  18 – Sensors  18 P Plant  – Cleaning  33 Plug-in connections  – Check   – On engine governor  111 Product data  DCL-ID: 0000029795 .