16v4000r43 PDF

Operating Instructions
Diesel engine
16 V 4000 Rx3 x
MS15042/00E
Downloaded from www.Manualslib.com manuals search engine

Engine model kW/cyl. Application group
16V4000R43 137.5 kW/cyl. 2A, continuous operation, unrestricted
16V 4000 R43L 150 kW/cyl. 2A, continuous operation, unrestricted
16V4000R43R 125 kW/cyl. 2A, continuous operation, unrestricted
Table 1: Applicability
© 2014 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior
written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
tion, microfilming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen
GmbH reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents
1 Safety 7 Task Description
1.1 Important requirements for all products 5 7.1 Engine 75
1.2 Personnel and organizational requirements 6 7.1.1 Engine – Barring manually 75
1.3 Transport 7 7.1.2 Cranking engine with starting system 77
1.4 Crankshaft transport locking device 8 7.1.3 Engine – Performing test run 78
1.5 Safety requirements for startup and 7.2 Cylinder Liner 79
operation 11 7.2.1 Cylinder liner – Endoscopic examination 79
1.6 Safety requirements for maintenance and 7.2.2 Instructions and comments on endoscopic and
repair work 12 visual examination of cylinder liners 81
1.7 Fire prevention and environmental 7.3 Crankcase Breather 83
protection, fluids and lubricants, auxiliary 7.3.1 Crankcase breather – Oil separator element
materials 15 replacement 83
1.8 Standards for safety notices in the text 17
7.4 Valve Drive 85
7.4.1 Valve gear – Lubrication 85
2 General Information 7.4.2 Valve clearance – Check and adjustment 86
7.4.3 Cylinder head cover – Removal and
2.1 Engine side and cylinder designations 18
installation 90
2.2 Engine layout 19
2.3 Sensors, actuators and injectors – Overview 21 7.5 Injection Pump / HP Pump 91
7.5.1 HP pump – Relief bore check 91
7.5.2 HP pump – Filling with engine oil 92
3 Technical Data
7.6 Injection Valve / Injector 93
3.1 16V 4000 R43 engine data 24 7.6.1 Injector – Replacement 93
3.2 16 V 4000 R43L engine data 28 7.6.2 Injector – Removal and installation 94
3.3 16 V 4000 R43R engine data 31
3.4 Firing order 34 7.7 Fuel System 99
7.7.1 Fuel system – Venting 99
3.5 Main engine dimensions 35
7.8 Fuel Filter 100
4 Operation 7.8.1 Fuel filter – Replacement 100
7.8.2 Fuel prefilter – Draining 101
4.1 Putting the engine into operation after 7.8.3 Fuel prefilter – Filter element replacement 102
extended out-of-service periods (>3 months) 36 7.8.4 Intermediate fuel filter – Replacement 103
4.2 Putting the engine into operation after 7.9 Exhaust Turbocharger 104
scheduled out-of-service-period 37 7.9.1 Exhaust turbocharger – Turbine housing
4.3 Starting the engine in manual mode 38 check 104
4.4 Stopping the engine in manual mode 39 7.9.2 Compressor wheel – Cleaning 107
4.5 Preparing the engine for extended out-of-
7.10 Charge-Air Cooling 111
service period 40
7.10.1 Intercooler – Checking condensate drain for
4.6 Plant – Cleaning 41 coolant leakage and obstruction 111
5 Maintenance 7.11 Air Filter 112

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7.11.1 Air filter element and (optional) dust bowl ‒

5.1 Maintenance task reference table [QL1] 42 Cleaning 112
7.11.2 Air filter ‒ Replacement 113
7.11.3 Air filter element – Removal and installation
6 Troubleshooting
(optional) 114
6.1 Troubleshooting 44 7.12 Starting Equipment 115
6.2 Fault messages on PAU display 47 7.12.1 Starter – Condition check 115
6.3 Fault messages of engine governor ADEC
(ECU 7) for Series 4000, rail applications 48 7.13 Air Intake 116
7.13.1 Service indicator – Signal ring position check 116
MS15042/00E 2014-10 | Table of Contents | 3

7.17.4 Charge-air coolant – Filling 141
7.14 Lube Oil System, Lube Oil Circuit 117 7.17.5 Charge-air coolant pump – Relief bore check 144
7.14.1 Engine oil – Level check 117
7.14.2 Engine oil – Change 118 7.18 Engine Mounting / Support 145
7.14.3 Engine oil – Sample extraction and analysis 120 7.18.1 Engine mounts – Resilient element check 145
7.15 Oil Filtration / Cooling 121 7.19 Drive, Power Generation and Safety
7.15.1 Engine oil filter – Replacement 121 Systems 147
7.15.2 Checking oil indicator filter 122 7.19.1 Generator – Greasing antifriction bearing 147
7.15.3 Centrifugal oil filter – Cleaning and filter- 7.19.2 Generator – Cleaning intake air grille 148
sleeve replacement 124
7.20 Wiring (General) for Engine/Gearbox/Unit 149
7.16 Coolant Circuit, General, High-Temperature 7.20.1 Еngine cabling ‒ Check 149
Circuit 126
7.16.1 Engine coolant – Level check 126
7.21 Accessories for (Electronic) Engine
7.16.2 Engine coolant – Change 127 Governor / Control System 150
7.16.3 Engine coolant – Draining 128 7.21.1 CDC parameters – Reset with DiaSys® 150
7.16.4 Replenishing engine coolant 129 7.21.2 Engine governor and connectors – Cleaning 151
7.16.5 Engine coolant pump – Relief bore check 132 7.21.3 Engine governor plug connections – Check 152
7.16.6 Engine coolant – Sample extraction and
analysis 133
8 Appendix A
7.16.7 Preheating unit – Overview 134
7.16.8 Preheater unit – Removal 136 8.1 Abbreviations 153
7.16.9 Preheater unit – Installation 137 8.2 MTU contact persons/service partners 155
7.17 Low-Temperature Circuit 138
7.17.1 Charge-air coolant – Level check 138 9 Appendix B
7.17.2 Charge-air coolant – Change 139
7.17.3 Charge-air coolant – Draining 140 9.1 Special Tools 156
9.2 Index 162
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4 | Table of Contents | MS15042/00E 2014-10

1 Safety
1.1 Important requirements for all products
Nameplate
The product is identified by a nameplate, model designation or serial number which must match the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Improper use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Noncompliance with the safety instructions and warning notices
Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine management/parameters)
• In compliance with all safety regulations and in accordance with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re-
sulting from improper, non-intended use.
Changes or modifications
Unauthorized changes to the product represent a contravention of its intended use and compromise
TIM-ID: 0000040530 - 005
safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
MS15042/00E 2014-10 | Safety | 5

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

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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6 | Safety | MS15042/00E 2014-10

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

Place the engine/genset on a firm, flat surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis.
MS15042/00E 2014-10 | Safety | 7

1.4 Crankshaft transport locking device
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30452769 1
Engine oil
Transport locking device

Note: The transport locking device on both sides protects the crankshaft bearings from impact and vibration
damage during engine transport.
For installation and removal of the transport locking device, follow the in-
structions below:
1. The transport locking device must remain installed on both engine sides as long as possible during en-
gine installation in order to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both engine sides
according to the instructions.
3. If the engine is to be moved together with the generator, the transport locking device for the generator
must also be installed.
4. Always use the screws supplied with or installed in the transport locking device to secure it on the en-
gine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the genera-
tor is already installed on the engine, ensure that the transport locking device of the generator is also
removed.
Removing guard plates and en-

gine supports (if applicable) on
driving end (KS)
1. Remove screws (4) om both sides and take
off with washers (3), guard plates (1) and
engine supports (2).
2. Store the removed parts of the transport
locking device carefully for any reuse.
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8 | Safety | MS15042/00E 2014-10

Fitting the transport locking de-
vice on the driving end (KS)
Note: Screw plate (6) onto the upper part of the openings only.
1. Fasten the plates (6) with screws (4) and washers (5) at the lateral openings on both sides of the fly-
wheel housing and tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
2. Fit locknut (2) on screws (1) up to the end of the thread.
3. The long side of retainer (3) must point downwards. Insert retainer (3) through the openings of plate (6).
Note: Retainer (3) must tension only the flywheel, not the ring gear.
4. Insert screw (1) in bores of retainer (3) until retainer (3) is locked in position.
Note: Screw (1) must be tightened alternately on both sides of the flywheel housing.
5. Tighten screw (1) to specified tightening torque .
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
6. Fit locknut (2) of screw (1) on plate (6) and tighten.
Removing the transport locking

device from the driving end (KS)
1. Release the locknuts (2) on both sides of
the flywheel housing, remove screw (1) and
take off retainer (3).
2. Remove screws (4) and take off with wash-
ers (5) and plates (6).
3. Store the removed parts required for re-in-
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stallation carefully together with this docu-

mentation.
MS15042/00E 2014-10 | Safety | 9

Installing guard plates and en-
gine supports (if applicable) on
driving end (KS)
Note: Always use the screws supplied with or re-
moved from the guard plates and engine
supports to secure them on the engine.
1. Install engine supports (2) on both sides
with guard plates (1) washers (3), and
screws (4).
2. Tighten screws (4).
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10 | Safety | MS15042/00E 2014-10

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

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

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

Some components are live (high voltage) when electrical equipment is in operation.
Observe the safety instructions for these appliances.
MS15042/00E 2014-10 | Safety | 11

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

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

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Never route fuel or oil lines in the vicinity of hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).
Always use suitable ladders and work platforms when working above head-height. Ensure that compo-
nents or assemblies are placed on stable surfaces.
12 | Safety | MS15042/00E 2014-10

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

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

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

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Observe the safety requirements of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte (battery acid) to come into contact with skin or clothing.
Wear goggles and protective gloves.
Do not place tools on the battery.
Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.
MS15042/00E 2014-10 | Safety | 13

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

Always wear special laser-protection goggles when working with laser equipment (danger due to in-
tensely focused radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 nm to
700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to pre-
vent any risk to the eyes.
Measuring component deviations

Workpieces, components and measuring instruments are within specified tolerances at a reference
temperature of 20°C. TIM-ID: 0000040535 - 006
14 | Safety | MS15042/00E 2014-10

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

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

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum-
ables and other chemical substances, follow the safety regulations that apply to the product. Take spe-
cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
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coming into contact with ignition sources and do not smoke.
Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.
MS15042/00E 2014-10 | Safety | 15

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

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

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• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• If spilled onto clothing, remove the affected clothing immediately.
• After contact with skin, rinse affected parts of the body with plenty of water.
• Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi-
ble.
16 | Safety | MS15042/00E 2014-10

1.8 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Safety notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.
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MS15042/00E 2014-10 | Safety | 17

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

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on
the left-hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The
cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 013
18 | General Information | MS15042/00E 2014-10

2.2 Engine layout
16 V 4000 R43 L/R
1 Oil heat exchanger 8 Intercooler 15 Generator

2 Crankcase breather 9 Starting equipment 16 Vibration damper (free
3 Power Output Module 10 Engine mount end)
(POM) 11 Oil filler neck 17 Auxiliary PTO (battery-
4 Centrifugal oil filter 12 Cylinder head charging generator)
5 Exhaust system 13 Fuel filter 18 Coolant pump (HT)
6 Exhaust turbocharger 14 HP fuel pump 19 Coolant filter
7 Air intake 20 Coolant pump (LT)
21 Engine management
TIM-ID: 0000057262 - 001
MS15042/00E 2014-10 | General Information | 19

1 Oil heat exchanger 8 Engine mount 15 Vibration damper (free
2 Crankcase breather 9 Additional fuel filter end)
3 Air intake 10 Oil filler neck 16 Auxiliary PTO
4 Exhaust turbocharger 11 Cylinder head 17 Coolant pump (HT)
5 Exhaust system 12 Fuel filter 18 Coolant pump (LT)
6 Intercooler 13 HP fuel pump 19 Automatic oil filter
7 Charge-air manifold 14 Generator
Engine model designation

Key to the engine model designation 16 V 4000 R43 L/R
16 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
R Application: Rail
4 Application segment (2, 4, 6, 8)
3 Design index
R/L Power-reduced / power-enhanced
TIM-ID: 0000057262 - 001

2.3 Sensors, actuators and injectors – Overview
Sensors, actuators
1 Engine governor 6 Sensor B34 (fuel pressure 11 Sensor B1 (camshaft

2 Sensor B3 (intake air tem- after filter) speed)
perature) 7 Sensor F46 (leak-off fuel) 12 Sensor B48 (fuel pressure
3 Sensor B6 (coolant tem- 8 Sensor B5.1 (engine oil after HP pump)
perature) pressure after filter) 13 Sensor B7.1 (engine oil
4 Sensor B44.1 (turbocharg- 9 Sensor B5.3 (engine oil temperature)
er A speed) pressure before filter) 14 Sensor B33 (fuel tempera-
5 Sensor B4.21 (exhaust 10 Sensor B7.2 (engine oil ture)
temperature A side) temperature)
TIM-ID: 0000012931 - 005

1 Sensor B50 (crankcase 4 Sensor B26 (charge-air 7 Sensor B10 (engine speed)
pressure) coolant temperature)
2 Sensor B4.22 (exhaust 5 Sensor B13 (charge-air
temperature B side) pressure)
3 Sensor B44.2 (turbocharg- 6 Sensor B9 (charge-air tem-
er B speed) perature)
TIM-ID: 0000012931 - 005

Injectors
A1 Injector Y39.1 A7 Injector Y39.7 B5 Injector Y39.15

A2 Injector Y39.2 A8 Injector Y39.8 B6 Injector Y39.16
A3 Injector Y39.3 B1 Injector Y39.11 B7 Injector Y39.17
A4 Injector Y39.4 B2 Injector Y39.12 B8 Injector Y39.18
A5 Injector Y39.5 B3 Injector Y39.13
A6 Injector Y39.6 B4 Injector Y39.14
The injectors are numbered in ascending order and located below the cylinder head covers. Injector re-
placement and necessary activities (→ Page 93).
TIM-ID: 0000012931 - 005

3 Technical Data
3.1 16V 4000 R43 engine data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
Engine model 16V4000

R43
Application group 2A
Intake air temperature °C 25
Charge-air coolant temperature °C 45
Barometric pressure mbar 1000
Site altitude above sea level m 100
Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 16
Rated engine speed A rpm 1800
UIC rated power (fuel stop power ISO 3046) A kW 2200
General conditions (for max. power)

Intake depression (new filter) A mbar 25
Intake depression, max. L mbar 35
Exhaust overpressure A mbar 30
Exhaust overpressure, max. L mbar 85
Fuel temperature at engine inlet connection R °C 25
Fuel temperature at engine inlet connection, max. (w/o power reduction) L °C 55
TIM-ID: 0000036888 - 002
Consumption
Specific fuel consumption (be) - 100% BL (+5%; EN 590; 42.8MJ/kg) R g/kWh 206
24 | Technical Data | MS15042/00E 2014-10

Model-related data (basic design)
Cylinder arrangement: V angle Degrees 90
(°)
Bore mm 170
Stroke mm 210
Cylinder displacement Liters 4.77
Total displacement Liters 76.3
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2
Combustion air / exhaust gas

Charge-air pressure before cylinder R bar abs 3.9
Exhaust temperature after turbocharger R °C -
Coolant system (HT circuit)

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

Coolant temperature (at engine connection: outlet to cooling equipment) R °C 52.5
Coolant temperature before intercooler (with up to 40 % antifreeze) A °C -
Coolant temperature difference after/before intercooler, min. L °C 8
Coolant temperature difference after/before intercooler, max. L °C 12
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Charge-air temperature after intercooler, max. L °C 81

Lube oil system

Lube oil operating temperature before engine, from R °C 60
Lube oil operating temperature before engine, to R °C 95
MS15042/00E 2014-10 | Technical Data | 25

Lube oil operating pressure before engine (measurement block) R bar 5.7
Lube oil operating pressure before engine, warning R bar -
Lube oil operating pressure before engine, shutdown L bar -
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.7
Fuel system
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3
Fuel pressure at engine inlet connection, min. (when engine is running) L bar -0.3
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 1.5
General operating data

Coolant preheating: preheating temperature (min.) R °C -
Inclinations - standard oil system (Reference: waterline)

Longitudinal inclination, continuous max., driving end down (Option: max. op- L Degrees 3
erating inclinations) (°)
Longitudinal inclination, temporary max., driving end down (Option: max. oper- L Degrees -
ating inclinations) (°)
Longitudinal inclination, temporary max., driving end up (Option: max. operat- L Degrees -
ing inclinations) (°)
Transverse inclination, continuous max. (Option: max. operating inclinations) L Degrees 6
(°)
Capacities
Engine coolant, engine side (without cooling equipment) R Liters 235
Charge-air coolant, engine side R Liters 70
Engine oil capacity, initial filling (standard oil system) (Option: max. operating R Liters 330
inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 180
operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 255
TIM-ID: 0000036888 - 002
Weights / main dimensions

Engine dry weight (with standard accessories installed, w/o coupling) R kg 7930

Acoustics
Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis- R dB(A) 117
tance, ISO 6798, +3dB(A) tolerance)
Engine surface noise without intake noise - BL (free-field sound pressure level R dB(A) 106
Lp, 1m distance, ISO 6798, +2dB(A) tolerance)
TIM-ID: 0000036888 - 002

3.2 16 V 4000 R43L engine data
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value up to which the engine can be operated without change (e.g. of power setting)
N Undefined value
- Not applicable
X Applicable

R43L
Charge-air coolant , temperature above air temperature K 20
Site altitude above sea level for full power at 30°C air temperature m 1200
Site altitude above sea level for full power at 40°C air temperature m 400
Power-related data (power ratings are net brake power as per ISO 3046)
Nominal engine speed A rpm 1800
UIC rated speed (fuel stop power as per ISO 3046) A kW 2400
Boundary conditions (for maximum power)

Exhaust gas overpressure A mbar 30
Exhaust gas overpressure, max. L mbar 85
Fuel temperature at engine inlet connection, max. (without reduction in power) L °C 55
Consumption
TIM-ID: 0000010611 - 002
Specific fuel consumption (be) - 100% BL (+5%; EN 590; 42.8MJ/kg) G g/kWh 207
Lube oil consumption after 100 h run time (B = hourly fuel consumption) R % of B 0.3
Model-related data (basic design)

Cylinder configuration: V angle Angle (°) 90
Bore mm 170

Stroke mm 210
Inlet valves per cylinder 2
Exhaust valves per cylinder 2
Air/exhaust gas
Exhaust temperature after exhaust turbocharger R °C –
Coolant system (high-temperature circuit)

Coolant temperature (at engine connection: outlet to cooling system) A °C –
Coolant temperature after engine, warning R °C –
Coolant temperature after engine, shutdown L °C –
Coolant antifreeze concentration, max. L % 50
Coolant pump: Inlet pressure, max. L bar 2.5
Thermostat: starts to open R °C 79
Thermostat: fully open R °C 92
Coolant system (low-temperature circuit)

Coolant temperature (at engine connection: outlet to cooling system) R °C 53
Coolant temperature before intercooler (with up to 40% antifreeze) A °C –
Coolant temperature difference before/after intercooler, min. L °C 8
Coolant temperature difference before/after intercooler, max. L °C 12
Coolant antifreeze concentration, max. L % 50
Thermostat: starts to open R °C 38
Thermostat: fully open R °C 51
Lube oil system

TIM-ID: 0000010611 - 002
Lube oil operating pressure before engine (measuring block) R bar 5.7
Lube oil operating pressure before engine, warning R bar –
Lube oil pressure before engine, shutdown L bar –
Lube oil operating pressure (low idle) (measuring point: before engine) R bar 2.7

Fuel system
Fuel pressure at engine inlet connection, min. (during engine start) L bar -0.1
Fuel pressure at engine inlet connection, min. (during engine operation) L bar -0.3
Fuel pressure at engine inlet connection, max. (during engine start) L bar 1.5
General operating data

Coolant preheating: Preheating temperature (min.) R °C 24
Inclinations, standard oil system (reference: absolute horizontal)

Max. continuous longitudinal inclination, driving end down (option: max. oper- L Angle (°) 3
ating inclinations)
Max. temporary longitudinal inclination, driving end down (option: max. operat- L Angle (°) –
ing inclinations)
Max. temporary longitudinal inclination, driving end up (option: max. operating L Angle (°) –
inclinations)
Max. continuous transverse inclination (option: max. operating inclinations) L Angle (°) 6
Capacities
Engine coolant capacity, engine side (without cooling equipment) R Liters 235
Engine oil capacity, initial filling (standard oil system) (option: max. operating R Liters 330
inclinations)
Oil pan capacity, dipstick mark min. (standard oil system) (option: max. oper- L Liters 180
ating inclinations)
Oil pan capacity, dipstick mark max. (standard oil system) (option: max. oper- L Liters 255
ating inclinations)
Weights/main dimensions
Engine dry weight (with standard accessories installed, without clutch) R kg 7930
Acoustics
TIM-ID: 0000010611 - 002
Engine surface noise, without intake noise - BL (free-field sound-pressure level R dB(A) 106
Lp, 1m distance, ISO 6798)

3.3 16 V 4000 R43R engine data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

R43R
Intake air temperature °C 25
Charge-air coolant temperature °C 45
Site altitude above sea level m 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Rated engine speed A rpm 1800
UIC rated power (fuel stop power ISO 3046) A kW 2000
GENERAL CONDITIONS (for max. power)

Exhaust overpressure A mbar 30
Exhaust overpressure, max. L mbar 85
Fuel temperature at engine inlet connection, max. (w/o power reduction) L °C 55
CONSUMPTION
TIM-ID: 0000035381 - 001
Specific fuel consumption (be) - 100% BL (+5%; EN 590; 42.8MJ/kg) R g/kWh 207
MODEL-RELATED DATA (basic design)

Cylinder arrangement: V angle Degrees 90
(°)
Bore mm 170

Stroke mm 210
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2
COMBUSTION AIR / EXHAUST GAS

Exhaust temperature after turbocharger R °C -
COOLANT SYSTEM (HT circuit)

Coolant temperature (at engine connection: outlet to cooling equipment) A °C -
Coolant temperature after engine, warning R °C -
Coolant temperature after engine, shutdown L °C -
Coolant pump: inlet pressure, max. L bar 2.5
COOLANT SYSTEM (LT circuit)

Coolant temperature (at engine connection: outlet to cooling equipment) R °C 52
Coolant temperature before intercooler (with up to 40 % antifreeze) A °C -
Coolant temperature difference after/before intercooler, min. L °C 7
Coolant temperature difference after/before intercooler, max. L °C 11
LUBE OIL SYSTEM

TIM-ID: 0000035381 - 001
Lube oil operating pressure before engine (measurement block) R bar 5.7
Lube oil operating pressure before engine, warning R bar -
Lube oil operating pressure before engine, shutdown L bar -
Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.7

FUEL SYSTEM
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3
Fuel pressure at engine inlet connection, min. (when engine is running) L bar -0.3
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 1.5
GENERAL OPERATING DATA

Coolant preheating: preheating temperature (min.) R °C -
INCLINATIONS - STANDARD OIL SYSTEM (Reference: waterline)

Longitudinal inclination, continuous max. driving end down (Option: max. oper- L Degrees 3
Longitudinal inclination, temporary max. driving end down (Option: max. oper- L Degrees -
Longitudinal inclination, temporary max., driving end up (Option: max. operat- L Degrees -
ing inclinations) (°)
Transverse inclination, continuous max. (option: max. operating inclinations) L Degrees 6
(°)
CAPACITIES
Engine coolant capacity, engine side (without cooling equipment) R Liters 235
Engine oil capacity, initial filling (standard oil system) (Option: max. operating R Liters 330
inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. L Liters 180
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. L Liters 255
WEIGHTS / MAIN DIMENSIONS

Engine dry weight (with standard accessories installed, w/o coupling) R kg 7930
ACOUSTICS
TIM-ID: 0000035381 - 001
Engine surface noise w/o intake noise - BL (free-field sound pressure level Lp, R dB(A) 105
1m distance, ISO 6798, +2dB(A) tolerance)

3.4 Firing order
Firing order
Number of cylinders Firing order
8V A1-B4-A4-A2-B3-A3-B2-B1
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
TIM-ID: 0000002796 - 004

3.5 Main engine dimensions
Main engine dimensions
Item Dimension
Length (A) 8 V approx. 2129 mm
Width (B) 8 V approx. 1399 mm
Width (B) 12, 16, 20 V approx. 1562 mm
Height (C) 8 V approx. 1988 mm
Height (C) 12, 16, 20 V approx. 2013 mm
TIM-ID: 0000010039 - 004

4 Operation
4.1 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
☑Engine is stopped and starting disabled.
☑MTU Preservation and Represervation Specifications (A001070/..) are available.
Putting the engine into operation after extended out-of-service periods (>3
months)
Item Action
Engine Depreservation (→ MTU Preservation and Represervation Specifications
A001070/..).
Valve drive Lubricate valve gear (→ Page 85).
Lube oil system Check engine oil level (→ Page 117).
Bar engine with starting equipment (→ Page 77).
Fuel system Vent (→ Page 99).
Coolant circuit Out-of-service period more than 1 year: Change engine coolant (→ Page 127)
Change charge-air coolant (→ Page 139).
Coolant circuit Check engine coolant level (→ Page 126).
Check charge-air coolant level (→ Page 138).
Coolant circuit Preheat engine coolant with coolant preheater (if applicable).
Engine control system Check plug connections (→ Page 152).
Engine Control System Switch on.
HP fuel pump Only for engines without oil priming pump:
Fill HP fuel pump with fresh engine oil (→ Page 92).
TIM-ID: 0000010084 - 005
36 | Operation | MS15042/00E 2014-10

4.2 Putting the engine into operation after scheduled out-of-
service-period
Preconditions
Startup
Item Action
Lube oil system Check engine oil level (→ Page 117).
Coolant circuit Check engine coolant level (→ Page 126);
Check charge-air coolant level (→ Page 138).
Coolant circuit Heat coolant with coolant preheater (if available; see manufacturer's docu-
mentation).
Engine control system Put into operation (see manufacturer's documentation).
TIM-ID: 0000002683 - 006
MS15042/00E 2014-10 | Operation | 37

4.3 Starting the engine in manual mode
Preconditions
☑Engine is not under load.
☑External start interlock is not activated.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the en-
gine's danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Action
Operating mode switch (if Switch to manual mode.
applicable)
Coolant preheater If engine coolant temperature is ≤ 25 °C: Switch on preheater.
Starting the engine

Item Action
Switchgear cabinet, opera- 1. Make sure that engine coolant temperature is > 25 °C.
tor station etc. (depending 2. Press start button.
on manufacturer). • Automatic starting procedure is performed;
• Engine speed instrument indicates increasing speed;
• After the starting sequence is completed, engine is running at idle
speed.
TIM-ID: 0000035115 - 004
38 | Operation | MS15042/00E 2014-10

4.4 Stopping the engine in manual mode
Preconditions
☑Engine not under load.
☑Engine in manual mode.
NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical
stresses.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and
constant levels are indicated.
Preparations
Item Action
Engine Run engine at idling speed under zero load.
Stopping the engine

Item Action
Switchgear cabinet, control Press stop button.
panel etc. (depending on • Automatic stopping sequence is executed.
manufacturer) • If the coolant temperature is too high, the engine runs on automatical-
ly for up to 3 minutes.
TIM-ID: 0000036818 - 002
MS15042/00E 2014-10 | Operation | 39

4.5 Preparing the engine for extended out-of-service period
Preconditions
☑MTU Preservation and Represervation Specifications (A001070/..) are available.
After stopping the engine

Item Action
Coolant circuit Drain engine coolant (→ Page 128). Drain charge-air coolant (→ Page 140).
There is a danger of freezing if:
• engine is to remain out of service for an extended period and engine
coolant has no antifreeze additive;
• the coolant is not maintained at a suitable temperature;
• antifreeze concentration is 40% and outside temperature is below
-40 °C.
Engine control system Switch off.
Air intake and exhaust sys- Out-of-service-period > 1 week:
tem • Seal engine's air and exhaust sides.
Out-of-service-period > 1 month:
• Preserve engine (→ MTU Preservation and Represervation Specifica-
tions A001070/..).
TIM-ID: 0000002322 - 005
40 | Operation | MS15042/00E 2014-10

4.6 Plant – Cleaning
Preconditions
☑Operating voltage is not applied.

Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
WARNING
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
• Never direct water jet at people.
• Wear protective clothing, protective gloves and safety goggles/face mask.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors
or ECUs.
Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).
2. Prior to putting the cleaning unit into operation, read the operating instructions of the water/steam jet
unit carefully and observe the safety precautions.
3. For external cleaning of the plant with water or steam-jet cleaners:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 029
• The temperature of the cleaning medium must not exceed 80°C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Note: Never aim compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.
MS15042/00E 2014-10 | Operation | 41

5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Maintenance tasks
W0500 Check engine oil level. (→ Page 117)
W0501 Visually inspect engine for leaks and general condition. -
W0502 Check intercooler drain(s). (→ Page 111)
W0503 Check service indicator of air filter. (→ Page 116)
W0504 Check relief bores of HP fuel pump. (→ Page 91)
W0505 Check relief bores of water pump(s). (→ Page 132) (→ Page 144)
W0506 Check engine for abnormal running noises, exhaust color and (→ Page 44)
vibrations.
W0507 Drain water and contaminants from fuel prefilter. (→ Page 101)
W0508 Check reading on differential pressure gage of fuel prefilter. -
W1001 Replace fuel filter or fuel filter element. (→ Page 100)
W1005 Replace air filter. (→ Page 113)
W1006 Replace fuel injectors. (→ Page 93)
W1008 Replace engine oil filter when changing engine oil, or when the (→ Page 121)
interval (years) is reached, at the latest.
W1009 Check layer thickness of the oil residue, clean out and replace (→ Page 124)
filter sleeve; accomplish together with every engine oil change,
at the latest.
W1011 Perform endoscopic examination. (→ Page 79)
W1027 Clean air filter, empty dust bowl. (→ Page 112)
W1047 Check and clean oil indicator filter. (→ Page 122)
W1055 Replace oil separator. (→ Page 83)
W1076 Clean compressor wheel. (→ Page 107)
W1164 Replace filter element and sealing ring of fuel prefilter depend- (→ Page 102)
ing on degree of contamination, when the limit (years) is
reached, at the latest.
TIM-ID: 0000057213 - 001
W1207 Check valve clearance, adjust if necessary. ATTENTION! First (→ Page 86)
adjustment after 1,000 operating hours.
W1463 Check general condition of engine mounting (visual inspection). (→ Page 145)
W1481 Replace intermediate fuel filter or filter element of intermediate (→ Page 103)
fuel filter.
42 | Maintenance | MS15042/00E 2014-10

Task Maintenance tasks
W1577 Check turbine housing externally for cracks, perform endoscop- (→ Page 104)
ic examination to check it internally for cracks, replace if neces-
sary.
W1713 Injector: Reset drift compensation parameters (CDC). (→ Page 150)
Table 2: Maintenance task reference table [QL1]

TIM-ID: 0000057213 - 001
MS15042/00E 2014-10 | Maintenance | 43

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

Component Probable Cause Measure
Battery Low or faulty Charge or replace (see manufacturer's
documentation).
Cable connections faulty Check if cable connections are properly
secured (see manufacturer's documen-
tation).
Starter Engine cabling or starter faulty Check if cable connections are properly
secured, contact Service.
Engine cabling Faulty Check (→ Page 149).
Engine/generator Assemblies or connectors possibly loose Perform visual inspection (see manufac-
control system turer's documentation).
Engine governor Plug-in connections possibly loose Check plug-in connections (→ Page 152).
Engine Running gear blocked (engine cannot be Contact Service.
barred manually)
Engine turns but does not fire

Starter Poor rotation by starter Battery low or Charge or replace battery (see manufac-
faulty turer's documentation).
Fuel system Air in fuel system Vent fuel system (→ Page 99)
Engine governor Faulty Contact Service.
Engine fires unevenly

Fuel injection equip- Injector faulty Replace (→ Page 93).
ment
TIM-ID: 0000010515 - 002
Engine does not reach rated speed

Fuel supply Fuel prefilter clogged Replace.
Fuel filter clogged Replace (→ Page 100).
Air supply Air filter clogged Check signal ring position of service in-
dicator (if fitted) .
ment
44 | Troubleshooting | MS15042/00E 2014-10

Engine Overloaded Contact Service.
Engine speed not steady

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

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

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

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

ment
Engine Overloaded Contact Service.
TIM-ID: 0000010515 - 002
Blue exhaust gas

Engine oil Too much oil in engine Drain engine oil (→ Page 118).
Oil separator of crankcase breather con- Replace.
taminated
Exhaust turbocharger, Faulty Contact Service.
cylinder head, piston
rings, cylinder liner
MS15042/00E 2014-10 | Troubleshooting | 45

White exhaust gas
Engine Not at operating temperature Run engine to reach operating tempera-
ture.
Fuel system Water in fuel Check fuel system at fuel prefilter
Drain fuel prefilter
Intercooler Leaking Contact Service.
TIM-ID: 0000010515 - 002

6.2 Fault messages on PAU display
The fault code numbers are generated by the engine governor and, depending on the relevant control
system, transmitted to the display.
The display is a two-line B/W-LCD for 16 ASCII characters per line and equipped with background illu-
mination.
1 Display 3 Control key (move up in 5 Control key "ESC"

2 Control key "ENTER" the menu)
4 Control key (move down in
the menu)
Contact Service should troubleshooting as prescribed in the table below prove unsuccessful
(→ Page 48).
• If a yellow alarm occurs (minor fault), operation can be continued. However, performance might be
limited.
• If a red alarm occurs (serious fault), continued operation may be impossible. Engine power is reduced
automatically or the engine is shut down automatically.
Explanation of fault message table:
TIM-ID: 0000016551 - 005
Fault message:
Brief description of the reported fault.
Cause:
More detailed description of the cause of the fault message.
Remedial action:
Measures for the vehicle operator. If several measures are specified for a single fault message, car-
ry them out in the listed order until the fault is eliminated.
A fault cause can result in several fault messages.

Not all fault codes are applicable depending on engine configuration and number of cylinders.
6.3 Fault messages of engine governor ADEC (ECU 7) for Series
4000, rail applications
3 – HI T-Fuel
Yellow alarm; warning
Cause Corrective action
Fuel temperature too high. u Reduce power.
4 – SS T-Fuel L2
Red alarm; power reduction ≥ 20%; forced idle
Fuel temperature too high. 1. Acknowledge alarm.
2. Request towing locomotive if required.
5 – HI T-Charge Air
Charge-air temperature too high. 1. Reduce power.
2. If fault code number 9 is signaled at the same time, then it has
priority.
6 – SS T-Charge Air L2
Yellow alarm; power limitation < 20%;
Charge-air temperature too high. 1. Reduce power.
priority.
9 – HI T-Coolant Intercooler
Coolant temperature in 1. Reduce power.
intercooler too high. 2. Check engine lines for leaks. Check coolant cooler for leaks,
contamination and operation.
TIM-ID: 0000016866 - 006
10 – SS T-Coolant Intercooler L2
Coolant temperature in 1. Reduce power.
intercooler too high. 2. Check engine lines for leaks. Check coolant cooler for leaks,
contamination and operation.
3. Contact Service.

15 – LO P-Lube Oil
Lube oil pressure too low. u Check oil level, top up as necessary (→ Page 117).
16 – SS P-Lube Oil L2
Red alarm; engine stop
Lube oil pressure too low. 1. Check oil level, top up as necessary (→ Page 117).
2. Acknowledge alarm.
3. Restart engine (→ Page 38).
19 – HI T-Exhaust A
Exhaust gas temperature (A- 1. Reduce power.
side) too high. 2. Check air filter.
20 – SS T-Exhaust A
Red alarm; power reduction ≥ 20%
Exhaust gas temperature (A- 1. Reduce power.
21 – HI T-Exhaust B
Exhaust gas temperature (B- 1. Reduce power.
22 – SS T-Exhaust B
TIM-ID: 0000016866 - 006

Exhaust gas temperature (B- 1. Reduce power.

25 – HI P-Diff. Lube Oil
Differential pressure at oil filter u Replace oil filter (→ Page 121).
too high.
26 – HI P-Diff. Lube Oil

Differential pressure at oil filter 1. Replace oil filter (→ Page 121).
too high. 2. Request towing locomotive if required.
27 – HI Leak Fuel Level

Leak fuel level too high. u Contact Service.
30 – SS Engine Overspeed L2
Engine speed too high. 1. Acknowledge alarm.
31 – HI ETC1 Overspeed L1
Yellow alarm; power limitation > 20%
ETC1 (A-side) speed too high. 1. Reduce power.
2. Check air filter.
32 – SS ETC1 Overspeed L2
ETC1 (A-side) speed too high. 1. Reduce power.
TIM-ID: 0000016866 - 006
36 – HI ETC2 Overspeed L1
Yellow alarm; power limitation > 20%
ETC2 (B-side) speed too high. 1. Reduce power.

37 – SS ETC2 Overspeed L2
ETC2 (B-side) speed too high. 1. Reduce power.
51 – HI T-Lube Oil
Lube oil temperature too high. 1. Reduce power.
priority.
52 – SS T-Lube Oil L2
Lube oil temperature too high. 1. Reduce power.
priority.
59 – SS T-Coolant L3
Red alarm; forced idle
Coolant temperature too high. 1. Activate fan emergency operating mode if required.
2. Allow engine to cool down.
3. Check engine coolant cooler, clean if dirty.
Coolant temperature too high. 1. Allow engine to cool down.
TIM-ID: 0000016866 - 006

5. Activate fan emergency operating mode if required.

63 – HI P-Crankcase
Crankcase pressure too high. 1. Reduce power.
2. Replace oil separator element.
64 – SS P-Crankcase L2
Crankcase pressure too high. 1. Request towing locomotive if required.
2. Contact Service.
65 – LO P-Fuel
Fuel pressure before HP pump 1. Check fuel lines for leakage.
too low. 2. Drain fuel prefilter (→ Page 101).
3. Replace filter element of fuel prefilter (→ Page 102).
4. Replace fuel filter and, if required, intermediate fuel filter
(→ Page 100).
66 – SS P-Fuel L2
No alarm, fault is registered.
Fuel pressure before HP pump 1. Check fuel lines for leakage.
too low. Possibly only reduced 2. Drain fuel prefilter (→ Page 101).
power is available. 3. Replace filter element of fuel prefilter (→ Page 102).
4. Replace fuel filter and, if required, intermediate fuel filter
(→ Page 100).
67 – HI T-Coolant L1
Coolant temperature too high. 1. Reduce power.
TIM-ID: 0000016866 - 006

Coolant temperature too high. 1. Activate fan emergency operating mode if required.
2. Allow engine to cool down.

81 – AL Rail Leakage
Pressure gradient in rail is too u Contact Service.
low during starting or too high
during stopping; HP system
leaky; air in system.
82 – HI P-Fuel (Common Rail) L1

Rail pressure > set value; MCR u Contact Service.
reduction; start of injection
readjusted (retarded); suction
restrictor of HP fuel block
jamming or HP fuel control block
cabling faulty.
83 – LO P-Fuel (Common Rail) L1

Rail pressure < set value; MCR 1. Request towing locomotive if required.
reduction; suction restrictor of 2. Contact Service.
HP fuel control block faulty or
leakage in HP fuel system.
89 – AL Engine Speed too Low

Engine speed too low. 1. Acknowledge alarm.
3. Observe additional messages.
90 – SS No Idling Speed
TIM-ID: 0000016866 - 006
Idle speed not reached 1. Check battery.

2. Check wiring and power supply.
3. Initiate new starting attempt.

91 – SS No Runup Speed
Runup speed not reached. 1. Check battery.
2. Check starter.
3. Initiate new starting attempt.
92 – SS No Starter Speed
Starter speed not reached; 1. Initiate new starting attempt.
termination of starting 2. Check voltage at starter power supply.
sequence; starter does not turn 3. Request towing locomotive if required.
or turns slowly.
93 – SS T-Preheat
No alarm, fault is registered.
Preheating temperature too low; 1. Extend preheating period.
coolant temperature too low for 2. Check preheating unit.
engine start. Significantly
increased engine wear. Engine
start might be inhibited by the
locomotive control system.
Engine may be started in
emergency situations only.
94 – LO T-Preheat
Preheating temperature too low; 1. Extend preheating period.
coolant temperature too low for 2. Check preheating unit.
engine start. Excessive engine
wear. Engine start might be
inhibited by the locomotive
control system. Engine may be
started in emergency situations
only.
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102 – AL Consumption Meter Faulty

Consumption meter faulty. u Contact Service.

104 – AL Operating Hrs. Meter Defective
Hour meter faulty. u Contact Service.
118 – LO ECU Supply Voltage

Supply voltage too low. u Check ECU supply voltage.
119 – LOLO ECU Power Supply Voltage L2

Supply voltage too low. 1. Check ECU supply voltage.
120 – HI ECU Supply Voltage

Supply voltage too high. u Check ECU supply voltage.
121 – HIHI ECU Power Supply Voltage L2

Supply voltage too high. 1. Check ECU supply voltage.
122 – HI T-ECU
Electronic unit temperature too 1. Reduce power.
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high. 2. Note further alarms, e.g. NT- Intercooler.
176 – AL LifeData Not Avail

No (matching) LifeData backup u Contact Service.
system available.

177 – AL LifeData Restore Incomplete
This fault message is generated u Contact Service.
if a CRC is faulty during a data
upload (to the engine governor)
(indicated for each indiv.
module).
180 – AL CAN1 Node Lost

Connection to a node on CAN 1. Check the devices connected to the CAN bus.
bus 1 failed. 2. Check wiring (2x121Ω terminating resistors in place?).
3. Contact Service.
181 – AL CAN2 Node Lost

Connection to a node on CAN 1. Check the devices connected to the CAN bus.
bus 2 failed. 2. Check wiring (2x121Ω terminating resistors in place?).
3. Contact Service.
182 – AL CAN Wrong Parameters

Incorrect parameter values u Contact Service.
entered in data record.
183 – AL CAN No PU-Data

The selected CAN mode 1. Check the devices connected to the CAN bus.
initializes communication by 2. Contact Service.
means of the PU data module.
However, the required PU data
module is not available or not
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valid.

184 – AL CAN PU-Data Flash Error
A programming error occurred u Contact service for electronic equipment.
when attempting to copy a
received PU data module into
the Flash module.
186 – AL CAN1 Bus Off

CAN controller 1 is in "Bus-Off" 1. Check CAN bus for short circuit, rectify short circuit as
status. necessary.
2. Check shielding, improve shielding as necessary.
187 – AL CAN1 Error Passive

CAN controller 1 has signaled a 1. Check CAN bus for short circuit, rectify short circuit as
warning. necessary.
188 – AL CAN2 Bus Off

CAN controller 2 is in "Bus-Off" 1. Check CAN bus for short circuit, rectify short circuit as
status. Automatic changeover to necessary.
CAN 1; short circuit; massive 2. Check shielding, improve shielding as necessary.
interference or baud rate
incompatibility.
189 – AL CAN2 Error Passive

CAN controller 2 has signaled a 1. Check CAN bus for short circuit, rectify short circuit as
warning. necessary.
TIM-ID: 0000016866 - 006
201 – SD T-Coolant
Coolant temperature sensor u Check sensor B6 and wiring, replace as necessary
faulty; short circuit or wire (→ Page 149).
break.

202 – SD T-Fuel
Fuel temperature sensor faulty; u Check sensor B33 and wiring, replace as necessary
short circuit or wire break. (→ Page 149).
203 – SD T-Charge Air

Charge-air temperature sensor u Check sensor B9 and wiring, replace as necessary
break.
204 – SD Lube Oil Level (Option)

Optional yellow alarm; warning
Lube oil level sensor faulty; u Check sensor B24 and wiring, replace as necessary
205 – SD T-Coolant Intercooler

Intercooler coolant temperature u Check sensor B26 and wiring, replace as necessary
sensor faulty; short circuit or (→ Page 149).
wire break.
206 – SD T-Exhaust A
Exhaust temperature sensor on u Check sensor B4.21 and wiring, replace as necessary
A-side faulty; short circuit or (→ Page 149).
wire break.
207 – SD T-Exhaust B
TIM-ID: 0000016866 - 006

Exhaust temperature sensor on u Check sensor B4.22 and wiring, replace as necessary
B-side faulty; short circuit or (→ Page 149).
wire break.

208 – SD P-Charge Air
Charge-air pressure sensor u Check sensor B10 and wiring, replace as necessary
break.
211 – SD P-Lube Oil

Lube oil pressure sensor faulty; u Check sensor B5.1/5.3 and wiring, replace as necessary
214 – SD P-Crankcase
Crankcase pressure sensor u Check sensor B50 and wiring, replace as necessary
break.
215 – SD P-HP Fuel

Rail pressure sensor faulty; high- u Check sensor B48 and wiring, replace as necessary
pressure regulator emergency (→ Page 149).
mode; short circuit or wire
break.
216 – SD T-Lube Oil

Lube oil temperature sensor u Check sensor B7.1 and wiring, replace as necessary
break.
219 – SD T-Intake Air

TIM-ID: 0000016866 - 006

Intake air temperature sensor u Check sensor B3 and wiring, replace as necessary
break.

222 – SD Leak Fuel Level
Leak fuel level sensor faulty; u Check sensor F46 and wiring, replace as necessary
227 – SD P-Oil bef. Filter

Sensor for lube oil pressure u Check sensor B5.3 and wiring, replace as necessary
before filter faulty; short circuit (→ Page 149).
or wire break.
229 – AL Stop Camshaft Sensor Defect

Engine stop due to camshaft 1. Check sensor and wiring to connectors B1 and B13, replace as
sensor fault and a previous necessary (→ Page 149).
crankshaft sensor fault in the 2. Acknowledge alarm.
same operating cycle. 3. Restart engine (→ Page 38).
230 – SD Crankshaft Speed

Crankshaft sensor faulty; short u Check sensor B13 and wiring, replace as necessary
circuit or wire break. (→ Page 149).
231 – SD Camshaft Speed

Camshaft sensor faulty; short u Check sensor B1 and wiring, replace as necessary
circuit or wire break. (→ Page 149).
232 – SD ETC Speed 1

TIM-ID: 0000016866 - 006

Speed sensor of primary u Check sensor B44.1 and wiring, replace as necessary
turbocharger faulty; short circuit (→ Page 149).
or wire break.

233 – SD ETC Speed 2
Speed sensor of primary u Check sensor B44.2 and wiring, replace as necessary
turbocharger faulty; short circuit (→ Page 149).
or wire break.
240 – SD P-Fuel
Fuel pressure sensor after fuel u Check sensor B34 and wiring, replace as necessary
main filter defective; short (→ Page 149).
circuit or wire break.
245 – SD ECU Supply Voltage

Internal Engine Control Unit u Replace engine governor.
fault; electronics faulty.
266 – SD Speed Setting

Analog nominal speed setting 1. Check wiring (→ Page 149).
faulty; short circuit or wire 2. Check speed setting.
break. 3. Contact Service.
270 – SD Frequency Input

Frequency input faulty; short 1. Check wiring (→ Page 149).
circuit or wire break. 2. Check setpoint speed transmitter.
3. Contact Service.
321 – AL Wiring Cylinder A1

TIM-ID: 0000016866 - 006

Short circuit in cylinder injector u Check solenoid valve.
wiring. Result: Misfiring.






TIM-ID: 0000016866 - 006



331 – AL Wiring Cylinder B1




TIM-ID: 0000016866 - 006






341 – AL Open Load Cylinder A1

Open circuit in cylinder injector u Check solenoid valve.
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TIM-ID: 0000016866 - 006


351 – AL Open Load Cylinder B1





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361 – AL Power Stage Low

Internal electronic fault, 1. Observe any other messages.
electronics possibly faulty. 2. Check solenoid valve wiring (→ Page 149).
362 – AL Power Stage High

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Internal electronic fault, 1. Observe any other messages.
electronics possibly faulty. 2. Check solenoid valve wiring (→ Page 149).

363 – AL Stop Power Stage
Internal electronic fault, 1. Check wiring (→ Page 149).
electronics possibly faulty. 2. Acknowledge alarm.
3. Restart engine .
365 – AL Stop SV-Wiring Ground

Injector wiring fault. 1. Check wiring (→ Page 149).
3. Restart engine .
381 – AL Wiring TOP 1

Short circuit or wire break on u Check wiring to plant (→ Page 149).
transistor output 1 plant-side 1
(TOP 1).

transistor output 2 plant-side
(TOP 2).

(TOP 3).
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(TOP 4).

408 – AL Open Load Emerg. Stop Input ESI
Line disruption on the input for 1. Check wiring (→ Page 149).
emergency stop; wiring 2. Check target device input.
defective or no resistance
through the switch.
410 – LO U-PDU L1
Injector voltage too low. 1. Check wiring (→ Page 149).
2. Check supply.
411 – LOLO U-PDU L2

Injector voltage too low. 1. Check wiring (→ Page 149).
2. Check supply.
4. Restart engine .
412 – HI U-PDU L2 L1
Injector voltage too high. 1. Check wiring (→ Page 149).
2. Check supply.
413 – HIHI U-PDU L2

Injector voltage too high. 1. Check wiring (→ Page 149).
2. Check supply.
4. Restart engine .
TIM-ID: 0000016866 - 006
444 – SD U-PDU
Injector power stage sensor u Replace engine governor.
defect; internal fault in engine
governor.

454 – SS Power Reduction Active
CAN message
Alarm is only available as a 1. Observe any other messages.
separate CAN message, power 2. Determine and rectify cause of power reduction.
reduction is active.
470 – SD T-ECU
Temperature sensor for engine u Check sensor and wiring, replace as necessary (→ Page 149).
governor faulty; short circuit or
wire break.
471 – SD HP Fuel Control Block

Control of HP fuel control block u Check sensor and wiring, replace as necessary (→ Page 149).
faulty; short circuit or wire
break.
474 – AL Wiring FO
Line break or short circuit at FO u Check wiring (→ Page 149).
channel.
476 – AL Crash Rec. Init. Error

Initialization error of crash u Check settings with DiaSys.
recorder.
478 – AL Comb. Alarm Yel (Plant)

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Combined alarm initiated by u Observe any other messages.
plant.

479 – AL Comb. Alarm Red (Plant)
Red alarm
Combined alarm initiated by u Observe any other messages.
plant.
500 – AL Wiring POM Starter 1

A wiring fault in connection of u Check connection between POM and starter.
starter 1 of Central Power
Management (CPM) has been
detected. This may be due to a
missing consumer, wire break or
a short circuit.
501 – AL Wiring POM Starter 2

A wiring fault in connection of u Check connection between POM and starter.
starter 2 of Central Power
Management (CPM) has been
detected. This may be due to a
missing consumer, wire break or
a short circuit.
502 – AL Open Load POM Battery-charging Generator

A line interruption was detected u Check connection between POM and battery-charging
at the battery-charging generator.
connection for the POM.
503 – AL No Battery Charge

Battery is not charged by u Check battery-charging generator and wiring (→ Page 149).
TIM-ID: 0000016866 - 006
battery-charging generator.
504 – AL CAN POM Node Lost

POM missing on CAN bus. u Check connection and POM.

506 – AL Starter Voltage too low
The battery voltage is too low for u Check starter battery and wiring (→ Page 149).
the starting process.
507 – AL POM Error

A general POM fault occurred. u Replace POM.
508 – AL Wrong POM-ID

POM sends a different ID u Check POM wiring harness.
number than expected.
515 – AL Starter Not Engaged

Starter on POM could not be 1. Repeat start.
engaged. If the number of 2. Check POM, starter and wiring (→ Page 149).
admissible automatic starting
attempts is executed, the
starting sequence is terminated.
519 – Oil Level Calibration Fault (Option)

Error writing calibration value u Check sensor and wiring, replace as necessary (→ Page 149).
into flash or SD of level sensor.
549 – AL Voltage Interruption Detected

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The operating voltage of the u Instruct the operator only to disconnect the power supply when
engine governor was switched of the engine has stopped.
with the engine running. This
may lead to overpressure in the
HP fuel system, which might
cause damage to the engine.

551 – SS Engine Overspeed Camshaft
Camshaft overspeed. 1. Request towing locomotive.
2. Contact Service.
577 – SD T-Lube Oil in Oil Pan (Option)

Oil pan temperature sensor u Check sensor B7.2 and wiring, replace as necessary
break.
582 – AL Emergency Stop Failed

Flashing yellow or red alarm
Emergency stop command from 1. Request towing locomotive.
locomotive control system was 2. Contact Service.
not executed.
584 – AL CAN Start Clearance failed

Yellow alarm; Warning; CAN u Contact Service.
object Start clearance was not
received within the expected
time period.
585 – AL Engine Start suppressed

Engine starting attempt 1. Observe additional messages.
suppressed due to start 2. Contact Service.
interlock.
593 – AL T-Lube Oil Pan Low (Option)

TIM-ID: 0000016866 - 006

T-Lube Oil Pan has violated the 1. Extend preheating period.
limit value (too cold); 2. Request towing locomotive if required.
significantly increased engine 3. Move locomotive into heated hall if necessary.
wear. Engine start might be
inhibited by the locomotive
control system.

596 – AL Develop PR Set
Standard production data record u Contact Service.
available. The data record stored
is for testing.
600 – SD T-Exhaust A+B

Exhaust temperature sensor on u Check sensor and wiring (B4.21 and B.22), replace as
A and B sides defective; short necessary.
601 – SD ETC1+ETC2
Exhaust temperature sensor on u Check sensor and wiring (B44.1 and B44.2), replace as
A and B sides defective; short necessary.
602 – AL CAN Engine Start Lock

Start interlock initiated by plant. 1. Check plant configuration.
606 – AL Double Nodes Lost CAN 1+2

No communication between 1. Check wiring and power supply of plant.
ADEC and PAU. 2. Acknowledge alarm.
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7 Task Description
7.1 Engine
7.1.1 Engine – Barring manually
Preconditions

Barring device F6555766 1
Ratchet with extension F30006212 1
DANGER
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
Engine – Barring manually

1. Release screws (1) and remove end cov-
er (2) from flywheel housing.
TIM-ID: 0000000917 - 012
MS15042/00E 2014-10 | Task Description | 75

2. Engage barring device (2) in ring gear of fly-
wheel and install it on flywheel housing.
3. Fit ratchet (1) onto barring device (2).
Note: No resistance other than compression re-
sistance must be encountered.
4. Rotate crankshaft in engine direction of ro-
tation.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
5. For removal, follow the reverse sequence
of work steps.
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76 | Task Description | MS15042/00E 2014-10

7.1.2 Cranking engine with starting system
DANGER
gine's danger zone.
Cranking engine with starting system

Note: Engine cranking only starts after a 4 second delay.
1. Only crank engine under zero load: Press and hold TURN key on the PAU.
2. Crank engine until oil pressure is displayed.
3. To stop engine: release the TURN key.
4. Engine starting is automatucally interrupted after the maximum permitted time period has elapsed. Re-
peat engine starting sequence after approx. 20 seconds if required.
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7.1.3 Engine – Performing test run
DANGER
gine's danger zone.
WARNING
Engine – Performing test run

1. Start engine (→ Page 38).
2. Perform test run at least until engine coolant reaches steady-state temperature and at 1/3 power at
least.
3. Carry out operational checks (engine operation) on the running engine (→ Maintenance schedule).
4. Stop engine (→ Page 39).
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7.2 Cylinder Liner
7.2.1 Cylinder liner – Endoscopic examination
Preconditions
☑Engine is stopped and starting disabled

Barring device F6555766 1
Ratchet with extension F30006212 1
Endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 90).
2. Remove injector (→ Page 94).
Positioning crankshaft at BDC

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

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

1. Compile endoscopic report using the table.
2. Use technical terms to describe the liner surface (→ Page 81).
3. Depending on findings:
• Do not take any action or
• carry out a further endoscopic examination as part of maintenance work or
• contact Service; cylinder liner must be replaced.
Final steps
1. Install injector (→ Page 94).
2. Install cylinder head cover (→ Page 90).
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7.2.2 Instructions and comments on endoscopic and visual examination of cylinder
liners
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex-
amination report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
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clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.

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

Ratchet adapter F30027340 1
Engine oil
Filter element (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Replacing oil separator element

1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from oil separa-
tor housing (4).
3. Insert new filter element (1) in oil separator
housing (4), make sure that it is positioned
correctly.
4. Install cover (2) with new O-ring.
TIM-ID: 0000048613 - 002

5. Use torque wrench to tighten the screws (2) of cover (1) to the specified torque.
Screw Tightening torque (Engine oil) 10 Nm −2 Nm
6. Replace further oil filter elements in the same way.
7. Check oil separator for leaks.
TIM-ID: 0000048613 - 002

7.4 Valve Drive
7.4.1 Valve gear – Lubrication
Preconditions

Engine oil
Valve gear – Lubrication

1. Remove cylinder head covers (→ Page 90).
2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjust-
ing screws with oil.
4. Install cylinder head covers (→ Page 90).
TIM-ID: 0000000921 - 010

7.4.2 Valve clearance – Check and adjustment
Preconditions
☑Engine coolant temperature is max. 40 °C.
☑Valves are closed.

Feeler gauge Y20098771 1
Socket wrench, 24 mm F30039526 1
Engine oil
Preparatory steps
2. Install barring device (→ Page 75).
Note: The OT mark (if fitted) on the flywheel must
not be used for reference.
3. Rotate crankshaft with barring device in en-
gine direction of rotation until "OT / A1"
mark and pointer are aligned.
TIM-ID: 0000000922 - 013

Diagram for 8V engines – Two
crankshaft positions


TIM-ID: 0000000922 - 013

Checking valve clearance at two crankshaft positions

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

1. Release locknut (1).
2. Insert feeler gauge (3) between valve
bridge and rocker arm.
3. Using Allen key, set adjusting screw (2) so
that the specified valve clearance is provid-
ed.
4. Feeler gauge (3) must just pass through
gap.
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5. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw
(2) to prevent it from turning.
Locknut M16 x 1.5 Tightening torque (Engine oil) 90 Nm +9 Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Final steps
1. Remove barring device (→ Page 75).
TIM-ID: 0000000922 - 013

7.4.3 Cylinder head cover – Removal and installation
Preconditions

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

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

1. Clean mounting surface.
2. Check O-ring (6) for damage, replace as necessary.
3. Coat O-ring (6) with assembly compound.
4. Position O-ring (6) in groove of cylinder head cover (1).
5. Fit cylinder head cover (1) on cylinder head (7).
6. Install cylinder head cover (1) with screws (3, 4) and washers (2, 5).
TIM-ID: 0000012309 - 013

7.5 Injection Pump / HP Pump
7.5.1 HP pump – Relief bore check
DANGER
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
HP pump – Relief bore check

1. Visually inspect relief bore (1) for fuel dis-
charge.
2. For jacketed HP lines, leakage is indicated
by the yellow combined alarm.
3. If fuel discharge is found or indicated, con-
tact Service.
TIM-ID: 0000012375 - 007

7.5.2 HP pump – Filling with engine oil
Preconditions

Engine oil
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Oils/oil vapors are combustible/explosive.
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.
NOTICE
HP fuel pump not filled with engine oil.
Damage to components, major material damage!
• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.
Filling HP pump
1. Remove plug screw (1).
2. Use pump oiler to fill HP pump with engine
oil until engine oil emerges.
3. Install plug screw (1).
TIM-ID: 0000001640 - 012

7.6 Injection Valve / Injector
7.6.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Injector – Replacement
u Remove injector and install new one (→ Page 94).
TIM-ID: 0000042329 - 002

7.6.2 Injector – Removal and installation
Preconditions

Installation/removal tool F6789889 1
Milling cutter F30452739 1
Torque wrench, 0.5-5 Nm 0015384230 1
Assembly paste (Optimoly Paste White T) 40477 1
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Engine oil
WARNING
• Do not smoke.
Preparatory steps
1. Shut off fuel supply to engine.
Removing injector
1. Disconnect connectors on injector.
TIM-ID: 0000000925 - 014

2. Remove HP fuel line (4).
Note: While the adapter is removed, the injector
is drained.
3. Remove adapter (3).
4. Remove screw (2) and take off hold-down
clamp (1).
5. Install installation/removal tool on cylinder

head.
6. Remove injector with installation/removal
tool.
7. Remove installation/removal tool.
8. Remove sealing ring (4) from injector or

use a self-made hook to take it out of the
cylinder head.
9. Remove O-rings (3), O-ring (2) and damper
ring (1) from injector.
10. Clean all mating and sealing surfaces.
11. Cover all connections and bores, or seal
with suitable plugs.
TIM-ID: 0000000925 - 014

Installing injector
1. Remove plug before installing the injec-
tor. (Do not remove the plug from the HP
line before installing the adapter).
2. Coat injector with assembly paste at the
seat of the nozzle retaining nut.
3. Fit new sealing ring (included in the scope
of delivery of the injector) with assembly
compound on injector, observe installation
position of sealing ring.
4. Fit new O-rings (3) (included in the scope

of delivery of the injector), O-ring (2) and
damping ring (1) onto the injector and coat
with assembly compound.
5. Remove oil carbon from sealing face on cyl-
inder head and protective sleeve with mill-
ing cutter.
6. Insert injector into cylinder head, ensuring
that the HP line adapter is correctly
aligned.
7. Press in injector with installation/removal

tool.
8. Remove installation/removal tool.
TIM-ID: 0000000925 - 014

9. Coat bolt mating face (2) and thread with
engine oil.
10. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the speci-
fied initial tightening torque.
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
Note: Ensure special cleanness.
11. Coat thread and sealing cone of adapter (3) with engine oil.
12. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
Adapter Preload torque (Engine oil) 5 Nm to 10 Nm
13. Tighten screw (2) with torque wrench to the specified tightening torque.
Screw M12 Tightening torque (Engine oil) 100 Nm + 10 Nm
14. Tighten adapter (3) with torque wrench to the specified tightening torque.
Adapter Tightening torque (Engine oil) 100 Nm + 10 Nm
Note: Ensure special cleanness.
15. Coat thread and sealing cone of HP line (5) with engine oil.
16. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening
sequence:
1 Adapter (4)
TIM-ID: 0000000925 - 014
2 Rail (6)
Union nut / thrust Tightening torque (Engine oil) 40 Nm + 5 Nm
screw

17. Loosen double-walled HP line (5) and follow the same sequence to tighten to the specified torque.
Tightening sequence:
1 Adapter (4)
2 Rail (6)
Union nut / thrust Tightening torque (Engine oil) 40 Nm + 5 Nm
screw
18. Fit connectors on injector.
Note: Failure to reset drift compensation (CDC)
will void the emissions certification.
19. Reset drift compensation (CDC) with Dia-
Sys® (→ E531920/...). If DiaSys® is not
available, contact Service.
Final steps
2. Open fuel supply to engine.
TIM-ID: 0000000925 - 014

7.7 Fuel System
7.7.1 Fuel system – Venting
Preconditions

Fuel
WARNING
• Do not smoke.
Venting LP fuel system

1. Open vent plug (1).
2. Unlock fuel priming pump (2), screw out
handle by turning it counterclockwise.
3. Operate the pump with the handle (2) until
bubble-free fuel emerges from the vent
plug (1).
4. Close vent plug (1).
5. Screw in handle by turning it clockwise.
6. Verify that fuel priming pump (2) is locked:
handle must be tightened.
TIM-ID: 0000000926 - 004

7.8 Fuel Filter
7.8.1 Fuel filter – Replacement
Preconditions

Filter wrench F30379104 1
Engine oil
Easy-change filter (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Fuel filter – Replacement

1. Remove easy-change filter using filter
wrench.
2. Clean sealing face on filter head.
3. Apply a thin coat of oil to the seal on the
easy-change filter (arrowed).
4. Screw on the easy-change filter by hand
until the seal is in contact and tighten
hand-tight.
5. Replace the other easy-change filters in the
same way.
6. Vent fuel system (→ Page 99).
TIM-ID: 0000000927 - 008

7.8.2 Fuel prefilter – Draining
Preconditions

Diesel fuel
Sealing (→ Spare Parts Catalog) 1
WARNING
• Do not smoke.
Fuel prefilter – Draining

1. Open vent plug (1) of the filter.
2. Unlock drain cock (2) by pressing toggle
and open it.
3. Drain water and contaminants from the fil-
ter until pure fuel emerges.
4. Close drain cock (2).
5. Remove screws (4) securing the cover (1)

and take off cover.
6. Fill filter housing with clean fuel.
7. Insert new seal (3) in cover (1).
8. Fit cover (1) with seal (3) and tighten
screws (4).
9. When fuel emerges from system, close
vent plug (2).
TIM-ID: 0000004928 - 006

7.8.3 Fuel prefilter – Filter element replacement
Preconditions

Diesel fuel
Filter element (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Replacing filter element

1. Close shut-off valve in fuel supply line.
2. Open vent plug (1) of the filter.
3. Unlock drain cock (2) by pressing toggle
and open it.
4. Drain water and dirt from filter.
5. Close drain cock (2).
6. Remove screws (6) securing the cover (1)

and take off cover.
7. Remove spring (2) and filter element (3).
8. Insert new filter element (3) and spring
housing (2).
9. Fill filter housing with clean fuel.
10. Insert new seal (5) in cover (1).
11. Fit cover (1) with seal (5) and tighten
TIM-ID: 0000004943 - 006
screws (6).
12. Close vent plug (4) when fuel emerges.

7.8.4 Intermediate fuel filter – Replacement
Preconditions

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

placement
1. Remove easy-change filter (2) with filter
wrench.
2. Clean sealing surface on filter head (1).
3. Coat seal on easy-change filter (2) slightly
with engine oil (arrow).
4. Screw on easy-change filter (2) by hand un-
til the seal makes contact with the filter
head and tighten manually.
5. Replace further easy-change filters in the
same way.
6. Vent fuel system (→ Page 99)
TIM-ID: 0000044159 - 002

7.9 Exhaust Turbocharger
7.9.1 Exhaust turbocharger – Turbine housing check
Endoscope Y20097353 1
Engine oil
Assembly compound (Ultra-Therm MTU) 50547
2-component adhesive 50712
Turbine housing (→ Spare Parts Catalog) 2
Seal (→ Spare Parts Catalog) 2
Removing containment cover

Note: Procedure is described for one side only.
Instructions apply mirror-inverted for the
other side.
1. Remove screws (4,6) and take off together
with heat shield (2), washers (3,7) and
spacer (5).
2. Remove screws (8) and take off together
with protective cover (1) and washers (9).
3. Remove insulation mat from bellows (12).
4. Release clamp (11) to allow turbine hous-
ing (10) to be pulled off bellows (12).
Removing turbine housing

Note: Mark position of clamp (1) and
clamps (3,6) or take photos.
1. Release clamps (3,6) and take off together
with bellows (4) and sealing ring (5).
2. Release clamp (1) and remove turbine
housing (2).
TIM-ID: 0000013059 - 006

Checking turbine housing
1. Use endoscope to check turbine housing
inside for cracks.
Note: Cracks are only admissible in the volute in
circumferential direction.
2. If crack exceeds max. permissible crack
length: (12V: x= 30 mm) or cracks in trans-
versal direction: Replace turbine housing.
Note: Cracks are only admissible in the volute in
circumferential direction.
3. If crack exceeds max. permissible crack
length: (16V / 20V: x= 10 mm) or cracks in
transversal direction: Replace turbine hous-
ing.
Installing turbine housing

1. Position turbine housing (2) with clamp (1).
2. Align turbine housing (2) with bearing hous-
ing and clamp (1) in accordance with the
marking.
3. Tighten clamp (1) to the specified tightening torque.

Clamp (1) Tightening torque (Assembly compound 24 Nm +3 Nm
(Ultra-Therm MTU))
Note: Secure bellows on engine side first, then on locomotive side.
4. Coat screw threads and clamping area of clamps (3,6) with assembly compound prior to installation.
5. Align bellows (4) and clamps (3,6) according to the markings or the photos.
TIM-ID: 0000013059 - 006
Note: Check sealing ring (5) for damage, replace if necessary.

6. Install bellows (4) with sealing ring (5) and clamps (3,6).
Note: Bellows must not turn relative to turbine housing during tightening.
Clamp (3) Tightening torque (Assembly compound 27 Nm
(Ultra-Therm MTU))

Clamp (6) Tightening torque (Assembly compound 20 Nm
(Ultra-Therm MTU))
Installing containment cover

1. Fit new seal in bellows (12), glue with 2-
component adhesive.
2. Coat screw threads and clamping area of
clamp (11) with assembly compound prior
to installation.
Note: Turbine housing must not damage seal dur-
ing installation.
3. Position turbine housing (10) on bel-
lows (12).
4. Install turbine housing (10) with clamp (11)
on bellows (12).
5. Tighten clamp (11) with torque wrench to the specified tightening torque.
Clamp Tightening torque (Assembly compound 15 Nm +2 Nm
(Ultra-Therm MTU))
6. Install insulation mat on bellows (12).
7. Install protective cover (1) with washers (9) and screws (8) and tighten with torque wrench to the speci-
fied tightening torque.
Screw M12 Tightening torque (Assembly compound 60 Nm +6 Nm
(Ultra-Therm MTU))
8. Install heat shield (2) with spacer (5), washers (3,7) and screws (4,6).
TIM-ID: 0000013059 - 006

7.9.2 Compressor wheel – Cleaning
Preconditions

Cleaner 40377 1
Engine oil
Sealing rings 700429160001 2
Sealing rings 700429300000 2
Gasket X52499100020 2
WARNING
Chemical substances.
Risk of irritation or burning of eyes, skin and airways!
• Observe information provided in the relevant safety data sheet.
• Wear protective gear as specified in the relevant safety data sheet.
NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Use appropriate cleaning tool.
NOTICE
Contamination of components.
Damage to component!
• Check components for special cleanliness.
Preparatory steps
1. Remove air filter (→ Page 114).
2. Remove bellows.
3. Seal all openings with suitable covers.
TIM-ID: 0000048620 - 002

4. Remove screws (1) from charge-air pipe to
compressor housing.
5. Loosen clamps on air intake (1).

6. Remove air intake.
7. Loosen clamp (2).

8. Remove intake housing (1).
TIM-ID: 0000048620 - 002

9. Loosen clamp (2).
10. Remove compressor housing (1).
Compressor wheel – Cleaning

Note: Do not use wire brush, scraper or similar
tools for cleaning.
1. Clean compressor housing with a smooth
paint brush or brush.
2. Clean compressor wheel (1) and bearing
housing (2).
3. Thoroughly remove cleaner from all compo-
nents.
4. Install new sealing ring between bearing
housing/compressor housing.
Final steps
1. Install compressor housing (1).
TIM-ID: 0000048620 - 002

2. Position clamp (2) and tighten to specified torque using a torque wrench.
Clamp Tightening torque max. 27 Nm
3. Install intake housing (1) with new sealing
ring.
4. Position clamp (2) and tighten to specified torque using a torque wrench.
Clamp Tightening torque 15 Nm + 2 Nm
5. Install air intake.
Note: Install new gasket.
6. Install charge-air pipe to compressor housing.
7. Tighten screws.
8. Install bellows.
9. Install air filter (→ Page 114).
TIM-ID: 0000048620 - 002

7.10 Charge-Air Cooling
7.10.1 Intercooler – Checking condensate drain for coolant leakage and obstruction
DANGER
WARNING
WARNING
Intercooler – Checking conden-

sate drain for coolant leakage
and obstructions
1. With the engine running check if air es-
capes from the condensate drain bore(s)
on the right and left of the engine (driving
end).If no air escapes:
• Clean condensate drain bore(s)
• Blow out with compressed air
2. If a large amount of coolant is continuously
discharged, the intercooler is leaking. Con-
tact Service.
Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 94).
2. Bar engine manually (→ Page 75).
3. Bar engine with starting system to blow out combustion chambers (→ Page 77).
TIM-ID: 0000000929 - 007
4. Install injectors (→ Page 94).

7.11 Air Filter
7.11.1 Air filter element and (optional) dust bowl ‒ Cleaning
Preconditions

Sealing (→ Spare Parts Catalog)
WARNING
Air filter element – Cleaning

Note: Clean paper filter element dry only.
1. Open air filter and remove filter element
(→ Page 114).
2. Check seal for damage and cleanness, re-
place if necessary.
Note: Debris particles must not enter the intake
system.
4. Clean dust bowl (if fitted).
5. Blow out filter element with compressed air
(max. 3 bar) from inside until all dust has
been removed.
6. Fit new filter element if old one is heavily
contaminated or damaged (→ Page 113).
Visual inspection
1. Use inspection lamp to check cleaned filter
element for damage.
2. Fit new filter element if old one is damaged
(→ Page 113).
TIM-ID: 0000005423 - 006

7.11.2 Air filter ‒ Replacement
Air filter (→ Spare Parts Catalog)
Air filter ‒ Replacement

1. Remove air filter and install new one (→ Page 114).
2. Reset signal ring of service indicator (→ Page 116).
TIM-ID: 0000000903 - 005

7.11.3 Air filter element – Removal and installation (optional)
Preconditions

Sealing (→ Spare Parts Catalog)
Air filter element – Removal and

installation
1. Release latches (9).
2. Remove dust bowl (8) and partition (7).
3. Remove collar nut (6).
4. Screw off air filter element (4).
5. Clean housing (3) and dust bowl (8).
6. Check seal (5) for damage and cleanness,
replace if necessary.
8. Fit partition (7) and dust bowl (9) according
to marking.
9. Secure dust bowl (9) with latches (8).
TIM-ID: 0000005455 - 004

7.12 Starting Equipment
7.12.1 Starter – Condition check
Preconditions
Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 149).
TIM-ID: 0000000905 - 017

7.13 Air Intake
7.13.1 Service indicator – Signal ring position check
Preconditions
Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 113).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves
back to initial position.
TIM-ID: 0000005484 - 009

7.14 Lube Oil System, Lube Oil Circuit
7.14.1 Engine oil – Level check
Preconditions
Oil level check prior to engine

start
1. Withdraw dipstick from guide tube and
wipe it.
2. Insert dipstick into guide tube to stop,
withdraw after approx. 10 seconds and
check oil level.
Note: After extended standstill, the oil level may
be up to 2 cm above mark (1). This may be
caused e.g. by oil from oil filters and heat
exchanger flowing back into the oil pan.
3. The oil level must reach mark (1) or exceed
mark (1) by up to 2 cm.
4. Top up with oil to mark (1) as necessary
(→ Page 118).
5. Insert dipstick into guide tube up to the
stop.
Oil level check after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube to stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between marks (1) and (2).
4. Top up with oil to mark (1) as necessary (→ Page 118).
5. Insert dipstick into guide tube up to the stop.
TIM-ID: 0000000931 - 012

7.14.2 Engine oil – Change
Preconditions
☑Engine is at operating temperature.
☑MTU Fluids and Lubricants Specifications (A001061/..) are available.

Ratchet F30027341 1
Engine oil
Sealing ring (→ Spare Parts Catalog)
WARNING
Hot oil.
Version without semirotary hand pump: Draining oil at drain plug(s) on oil pan
1. Provide a suitable container in which to collect the engine oil.
2. Remove drain plug(s) and drain engine oil.
3. Install drain plug(s) with new sealing ring.
Version with semirotary hand pump: Extracting the engine oil

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

1. Check layer thickness of the oil residue, clean out and replace filter sleeve (→ Page 124).
2. Replace engine oil filter (→ Page 121).
TIM-ID: 0000000930 - 011

Draining residual oil from equip-
ment carrier (only with unsched-
uled engine oil change)
1. Provide a suitable container in which to col-
lect the engine oil.
2. Remove drain plug (1) and drain engine oil
from engine oil heat exchanger and from
engine oil filter.
3. Remove drain plugs (2) and (3) and drain
engine oil.
4. Install drain plug(s) with new sealing ring.
5. Tighten drain (2) and (3) with torque wrench to specified tightening torque.
Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm
Filling with new engine oil

1. Open cover (1) on filler neck.
2. Pour engine oil through the filler neck up to
the "max." mark on the oil dipstick.
3. Close cover (1) on filler neck.
4. Check engine oil level (→ Page 117).
5. Bar engine with startingsystem
(→ Page 77).
TIM-ID: 0000000930 - 011

7.14.3 Engine oil – Sample extraction and analysis
Preconditions

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

and analysis
1. With the engine running at operating tem-
perature, open screw on centrifugal oil fil-
ter mount by 1 to 2 turns.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Re-tighten screw.
5. Using the equipment and chemicals in the
MTU test kit, examine oil for:
• Dispersion capability (spot test);
• Water content;
• Dilution by fuel.
TIM-ID: 0000000932 - 005

7.15 Oil Filtration / Cooling
7.15.1 Engine oil filter – Replacement
Preconditions

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

1. Unscrew engine oil filter with filter wrench.
2. Clean sealing face on connecting piece.
3. Check sealing ring of new engine oil filter
and apply a thin layer of engine oil.
4. Screw on and tighten engine oil filter by
hand.
5. Replace other engine oil filters in the same
way.
6. Bar engine with startingsystem
(→ Page 77).
7. Check engine oil level (→ Page 117).
TIM-ID: 0000000933 - 009

7.15.2 Checking oil indicator filter
Preconditions

Cleaner (Snow-White 11-0) 40460 1
Cleaner (Hakupur 312) 30390 1
Engine oil
Strainer (→ Spare Parts Catalog)
Square-section ring (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Use appropriate cleaning tool.
Removing strainer
1. Clean oil indicator filter before dismantling
it.
2. Remove screws (1).
3. Take off cover (2) and O-ring (3).
4. Remove strainer (5) from the filter housing
and allow oil to drip into container.
TIM-ID: 0000036227 - 005

Cleaning strainer
1. Shake coarse contamination out of strainer (5).
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
Note: Do not damage the fabric of the strainer.
3. Use a soft brush to remove stubborn deposits from strainer if required.
4. Blow out strainer (5) with compressed air from inside.
Checking strainer
Item Findings Action
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Notify Service
Strainer Damaged Fit new part
Square-section ring Damaged Fit new part
O-ring Damaged Fit new part
Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Insert strainer into housing.
3. Fill housing with new engine oil.
4. Coat O-ring (3) with engine oil and fit in filter housing.
5. Fit cover (2) and secure with screws (1) and washers.
TIM-ID: 0000036227 - 005

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

Cold cleaner (Hakutex 60) X00056750 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
TIM-ID: 0000000934 - 014

Centrifugal oil filter – Cleaning
and filter-sleeve replacement
1. Remove clamp (14).
2. Release Tommy nut (2) and take off cov-
er (1).
3. Carefully lift rotor (11), allow oil to drain
and remove from housing.
4. Holding the rotor (11) firmly, release rotor
cover nut (3).
5. Take off rotor cover (4).
6. Remove filter sleeve (6).
7. Measure thickness of oil residues on filter
sleeve (6).
Result: If the oil residues exceed the maximum lay-
er thickness of 45 mm, shorten the mainte-
nance interval.
8. Disassemble rotor tube (7), conical disk (8)
and rotor base (10).
9. Wash rotor cover (4), rotor tube (7), conical
disk (8) and rotor base (10) with cold
cleaner.
10. Blow out with compressed air.
11. Check sealing ring (9), fit new one if neces-
sary.
12. Assemble rotor tube (7), conical disk (8)
and rotor base (10) with sealing ring (9).
13. Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the
outer wall.
14. Check sealing ring (5), fit new one if neces-
sary.
15. Mount rotor cover (4) with sealing ring (5).
16. Tighten rotor cover nut (3) with torque wrench to the specified torque.
Nut Tightening torque 35 Nm to 45 Nm
17. Place rotor (11) in housing (12) and check for ease of movement.
18. Check sealing ring (13), fit new one if necessary.
19. Fit sealing ring (13) on housing (12).
20. Fit cover (1).
21. Tighten Tommy nut (2) by hand.
22. Install clamp (14) and tighten with torque wrench to the specified torque.
TIM-ID: 0000000934 - 014
Clamp Tightening torque 8 Nm to 10 Nm

23. Tighten cover nut (2) with torque wrench to the specified torque.
Screw Tightening torque 5 Nm to 7 Nm

7.16 Coolant Circuit, General, High-Temperature Circuit
7.16.1 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
Checking engine coolant level at filler neck:

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

remote cooler:
Note: Engine coolant must be visible at marker
plate.
1. Check engine coolant level.
2. Top up engine coolant as necessary
(→ Page 129).
3. Check and clean cap.
4. Place cap on filler neck and close.
Checking engine coolant level via level sensor:

Note: Engine coolant level is automatically monitored by the engine control system.
1. Switch on engine control system and check readings on the display.
2. Top up engine coolant as necessary (→ Page 129).
TIM-ID: 0000000937 - 013

7.16.2 Engine coolant – Change
Coolant
Engine coolant change

1. Drain engine coolant (→ Page 128).
2. Fill with engine coolant (→ Page 129).
TIM-ID: 0000000036 - 031

7.16.3 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide a suitable receptacle to catch the coolant.
2. Switch off preheating unit.
Engine coolant – Draining

1. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow
pressure to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off separated corrosion inhibitor oil in expansion tank through the filler neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• at HT coolant pump elbow
• on crankcase, left and right sides.
• at preheating unit
5. Close all open drain points.
6. Position breather valve on filler neck and
close.
TIM-ID: 0000000936 - 005

7.16.4 Replenishing engine coolant
Preconditions
☑Engine shut down and secured against being restarted.

Coolant
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn the valve cover (1) on the coolant ex-
pansion tank counterclockwise to the stop
and allow pressure to escape.
2. Continue to turn valve cover (1) counter-
clockwise and remove.
TIM-ID: 0000006724 - 007

Replenishing coolant using a
pump
1. Connect a suitable pump with a hose to the
drain valve (arrowed).
2. Open bleed valve on distributor block (ar-

rowed).
3. Open drain valve and pump coolant into en-
gine at 0.5 bar minimum.
4. When coolant emerges from the bleed
valve, close the bleed valve.
5. Fill expansion tank up to the overflow.
6. Close drain valve.
7. Check pressure cap is in perfect condition
and clean sealing faces if necessary.
8. Position breather valve on filler neck and
close.
10. After running the engine for 10 seconds un-
der zero load, shut it down (→ Page 39).
11. Turn pressure cap of coolant expansion
tank counterclockwise until the first stop
and allow pressure to escape.
12. Continue to turn cap counterclockwise and
remove.
13. Check coolant level (→ Page 126) and top
up coolant as required:
a) Add coolant to expansion tank until the
coolant level at the overflow remains
constant.
b) Position breather valve on filler neck
and close.
14. Repeat the steps from "Start engine"
(→ Step 9) until coolant no longer needs to
TIM-ID: 0000006724 - 007
be topped up.
15. Disconnect pump and hose.

Alternatively: top up coolant
through filler neck
1. Open bleed valve on distributor block (ar-
rowed).
2. Add coolant to expansion tank until the
coolant level at the overflow remains con-
stant.
3. When coolant emerges from the bleed
valve, close the bleed valve.
4. Check pressure cap is in perfect condition
and clean sealing faces if necessary.
5. Position pressure cap on the filler neck and
close to the first stop.
7. After running the engine for 10 seconds un-
der zero load, shut it down (→ Page 39).
8. Turn pressure cap counterclockwise and
remove.
up coolant as required:
a) Add coolant to expansion tank until the
coolant level at the overflow remains
constant.
b) Position breather valve on filler neck
and close.
be topped up.
Final steps
1. Start the engine and run it under zero load for several minutes.
2. Check coolant level (→ Page 126) and top up coolant as required.
TIM-ID: 0000006724 - 007

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

bore check
1. Check relief bore for oil and coolant dis-
charge.
2. Stop engine (→ Page 39) and disable en-
gine start, observe general safety instruc-
tions for maintenance and repair.
3. Clean the relief bore with a wire if it is
dirty.
• Permissible coolant discharge: up to 10
drops per hour.
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits:
Contact Service.
TIM-ID: 0000000961 - 013

7.16.6 Engine coolant – Sample extraction and analysis
Preconditions

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

tion and analysis
1. With the engine running, open drain
valve (1).
2. Flush sample-extraction point by draining
approx. 1 liter coolant.
3. Drain approx. 1 liter coolant into a clean
container.
4. Close drain valve (1).
5. Using the equipment and chemicals in the
MTU test kit, examine coolant for:
• Antifreeze concentration
• Corrosion inhibitor concentration
• pH value
6. For engine coolant changing intervals
(→ MTU Fluids and Lubricants Specifica-
tions (A001061/..)).
TIM-ID: 0000000938 - 009

7.16.7 Preheating unit – Overview
Preheating unit
1 Preheating unit
TIM-ID: 0000014751 - 005

Coolant line holders
1 Preheating unit 3 Washer 5 Washer

2 Screw 4 Clamp 6 Nut
TIM-ID: 0000014751 - 005

7.16.8 Preheater unit – Removal
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!
WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.
WARNING
WARNING
• Do not smoke.
Preheater unit – Removal

1. Switch off preheater unit and disconnect from power supply.
2. Close shut-off valves.
3. Detach exhaust interface and unplug connector.
4. Disconnect ground strap.
Note: Collect emerging fuel or coolant in suitable containers.
5. Remove lines.
6. Attach preheater unit to lifting gear and take up slack in cable.
7. Remove preheater unit.
8. Lift off preheater unit using lifting gear and set down.
9. Seal all openings with suitable covers.
TIM-ID: 0000014754 - 007

7.16.9 Preheater unit – Installation
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!
WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.
WARNING
• Do not smoke.
Preheater unit – Installation

1. Remove covers.
Note: Pay attention to flow direction indicated by arrows on pump and non-return valve.
2. Lift up preheater unit using lifting gear and move to installation position.
3. Install preheating unit.
4. Remove lifting gear.
5. Reconnect ground strap.
6. Attach exhaust interface and plug in connector.
7. Install all lines.
8. Connect preheater unit to power supply.
9. Open shut-off valves.
10. Vent coolant and fuel systems.
11. Switch on preheater unit.
12. Check preheater unit for leaks during operation.
TIM-ID: 0000014757 - 007

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

1. Turn cap on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.
2. Continue to turn cap counterclockwise and remove.
Note: Charge-air coolant must be visible at mark-
er plate.
3. Check charge-air coolant level.
4. Top up charge-air coolant as necessary
(→ Page 141).
5. Check that cap is in serviceable condition.
6. Clean sealing surfaces as necessary.
7. Fit cap and close tight.
Checking charge-air coolant level by means of level sensor:

Note: Coolant level is automatically monitored by engine control system.
1. Switch on engine control system and check readings on the display.
2. Top up charge-air coolant as necessary (→ Page 141).
TIM-ID: 0000000042 - 008

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

1. Drain charge-air coolant (→ Page 140).
2. Fill with charge-air coolant (→ Page 141).
TIM-ID: 0000000041 - 011

7.17.3 Charge-air coolant – Draining
Preconditions

WARNING
Charge-air coolant – Draining

1. Provide a suitable container to catch the
coolant.
2. Turn valve cover on coolant expansion tank
counterclockwise up to the first stop and
allow pressure to escape.
3. Continue to turn valve cover counterclock-
wise and remove.
4. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
5. Open drain valves and/or drain plugs and
drain engine coolant at the following
points:
• at the LT coolant pump (arrows)
• at the HT coolant pump (arrows)
6. Remove plug (1) for HT circuit draining.

7. Remove plug (2) for LT circuit draining.
8. Drain off residual coolant.
9. Install plugs (1, 2) with new sealing rings.
10. Close all drain valves and screw in drain
plugs with new sealing rings.
11. Place valve cover onto filler neck and
close.
TIM-ID: 0000014864 - 003

7.17.4 Charge-air coolant – Filling
Preconditions

Coolant
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
2. Continue to turn breather valve counter-
TIM-ID: 0000000940 - 007

Filling with coolant using a
pump
1. Connect a suitable pump with a hose to the
drain valve (arrowed).
2. Loosen the vent line union at the distribu-

tor piece (arrowed).
3. Open drain valve and pump coolant into en-
gine at 0.5 bar minimum.
4. Tighten the union (arrowed) if coolant leaks
out at the loose union.
5. Fill expansion tank up to overflow edge.
6. Close drain valve.
7. Check serviceable condition of breather
valve and clean sealing faces as necessary.
8. Place breather valve on filler neck and
close.
10. After 10 seconds of running the engine
without load, stop the engine (→ Page 39).
12. Continue to turn breather valve counter-
up coolant as necessary:
a) Fill coolant into expansion tank until
coolant level at top edge of filler neck
remains constant.
b) Place breather valve on filler neck and
close.
TIM-ID: 0000000940 - 007
be topped up.
15. Remove pump and hose.

Alternatively: Filling with cool-
ant through filler neck
1. Loosen the vent line union at the distribu-
tor piece (arrowed).
2. Top up coolant in expansion tank via filler
neck until coolant level at top edge of filler
neck remains constant.
3. Tighten the union (arrowed) if coolant leaks
out at the loose union.
4. Check serviceable condition of breather
valve on coolant expansion tank, clean
sealing faces as necessary.
5. Fit breather valve and close it.
7. After 10 seconds of running the engine
without load, stop the engine (→ Page 39).
9. Turn breather valve counterclockwise and
remove.
up with coolant through the filler neck as
necessary:
a) Top up coolant in expansion tank via
filler neck until coolant level at top
edge of filler neck remains constant.
b) Fit breather valve and close it.
be topped up.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 138) and top up coolant as necessary.
TIM-ID: 0000000940 - 007

7.17.5 Charge-air coolant pump – Relief bore check
DANGER
WARNING
Charge-air coolant pump – Relief

bore check
1. Check relief bore for oil and coolant dis-
charge.
2. Stop engine (→ Page 39) and disable en-
gine start, observe general safety instruc-
tions for maintenance and repair.
3. Clean the relief bore with a wire if it is
dirty.
• Permissible coolant discharge: up to 10
drops per hour.
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits:
Contact Service.
TIM-ID: 0000000964 - 007

7.18 Engine Mounting / Support
7.18.1 Engine mounts – Resilient element check
Preconditions
☑Engine filled with coolant and engine oil.

Feeler gauge Y20010128 1
Vernier caliper Y20001743 1
Combination box and open-end wrench F30379609 1
Engine oil
NOTICE
Contamination of engine mounts made of natural rubber with fuel or oil.
Engine mounts swell. Risk of shorter service life or destruction of the mounts!
• Cover engine mounts when working with fuel or oil.
• Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them.
Engine mounts – Resilient ele-

ments check
1. Rub rubber surface with a dry cloth, de-
grease if required.
2. Check resilient elements for crack forma-
tion and deformation by visual inspection.
3. Have cracked elements replaced, contact
Service.
TIM-ID: 0000015376 - 008
Measuring adjustment dimension

1. Measure dimension (A) with Vernier caliper.
Note: On new blocked mounts, the adjustment dimension is approx. 28 mm.
2. If the measured value of dimension A = 20 mm is reached, the resilient element must be replaced, con-
tact Service.

Engine mounts – Buffer clear-
ance check
1. Check dimension (A) with feeler gauge on
measuring groove (arrow).
2. If dimension (A) is not 4 mm ±0.3 mm, ad-
just buffer clearance.
Engine mounts – Buffer clear-

ance adjustment
1. Take off protective cap (1).
2. Remove nut (3).
3. Adjust buffer clearance by turning the cen-
tral buffer (2).
Note: Engine oil must not get in contact with the
rubber elements of the resilient mount.
4. Coat mating face of nut (3) and thread of
central buffer (2) with a little engine oil.
5. Tighten nut (3) to the specified tightening torque. When doing so, lock the central buffer (2) to prevent
it turning.
Nut M27 x 2 Tightening torque (Engine oil) 580 Nm +50 Nm
6. Fit protective cap (1).
TIM-ID: 0000015376 - 008

7.19 Drive, Power Generation and Safety Systems
7.19.1 Generator – Greasing antifriction bearing
Preconditions
☑Engine is running.

Grease gun (→ Tools Catalog)
ISOFLEX TOPAS NB 52, manufacturer: Klüber 60g
DANGER
WARNING
Greasing antifriction bearing

1. Clean grease nipple (arrow).
2. Attach grease gun with suitable connecting
head, DIN71412 Form A, on grease nipple.
Note: Repeat greasing when the unit is running.
The temperature of the antifriction bearing
increases temporarily after greasing.
3. Use appropriate grease and press in the
correct amount of grease.
TIM-ID: 0000015691 - 003

7.19.2 Generator – Cleaning intake air grille
Preconditions

Vacuum cleaner (→ Tools Catalog)
Cleaning intake air grille

1. Clean intake air grille on generator dry.
2. Use vacuum cleaner to remove dust from
intake air grille.
TIM-ID: 0000007698 - 002

7.20 Wiring (General) for Engine/Gearbox/Unit
7.20.1 Еngine cabling ‒ Check
Preconditions

Solvent (isopropyl alcohol) X00058037 1
Еngine cabling ‒ Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check that cable clamps are firm, tighten loose cable clamps.
6. Replace faulty cable clamps.
7. Visually inspect the following electrical line components for damage:
• Connector housing
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
8. Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
9. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 022

7.21 Accessories for (Electronic) Engine Governor / Control System
7.21.1 CDC parameters – Reset with DiaSys®
Preconditions
Resetting CDC parameters (DiaSys® is available)

Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer ap-
plicable.
u Reset the CDC parameters with DiaSys® (→ Manufacturer's documentation).
Resetting CDC parameters (DiaSys® is not available)

Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer ap-
plicable.
u Contact Service.
TIM-ID: 0000029731 - 002

7.21.2 Engine governor and connectors – Cleaning
Preconditions

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

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

Note: Seal unused connectors with the supplied protective cap.
1. Release the latch and pull off connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and latch them.
TIM-ID: 0000000047 - 011

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

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

8 Appendix A
8.1 Abbreviations
Abbre- Meaning Explanation
viation
AC Alternating Current
AdBlue - Brand name of the German Association of Vehicle
Manufacturers (VDA)
Urea solution with 32.5% urea concentration
EGR Exhaust gas recirculation
AL Alarm
ANSI American National Standards Institute
BDM Backup Data Module
BR Series
BV Fluids and lubricants specification/preser- MTU publication no. A00..
vation specification
CAN Controller Area Network Data bus system, bus standard
CaPoS Capacitor Power System Capacitor-based starting system
CDC Calibration Drift Compensation Drift compensation must be reset in the engine con-
trol system using DiaSys® to ensure optimum emis-
sions and consumption characteristics.
CRC Cyclic Redundancy Control Check sum procedure to detect data transmission
faults
DC Direct Current
DEF Diesel Exhaust Fluid Urea solution with 32.5% urea concentration
Designation used in North America
DIFF Difference
DIN Deutsches Institut für Normung e. V. Also identifier of German standards (DIN = “Deut-
sche Industrie-Norm”)
DL Default Lost Alarm: Default CAN bus failure
DOC Diesel Oxidation Catalyst
DPF Diesel Particulate Filter
ECU Engine Control Unit Engine control system
ETC Exhaust turbocharger
ETK Spare parts catalog
FO Frequency Output
TIM-ID: 0000009959 - 010
GND Ground
HP High pressure
HI High Alarm: Measured value higher than 1st maximum
limit
HIHI High High Alarm: Measured value higher than 2nd maximum
limit
HT High Temperature
ID Identification number
MS15042/00E 2014-10 | Appendix A | 153

Abbre- Meaning Explanation
viation
IIG Initial injector equalization The injector code must be entered in the engine con-
trol system using DiaSys® to ensure optimum emis-
sions and consumption characteristics.
ISO International Organization for Standardiza- International umbrella organization for all national
tion standardization institutes
ITS Integrated Test System
KGS Kraftgegenseite Free end in accordance with DIN ISO 1204
KS Kraftseite 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 Maschinen- und Turbinenunion
MV Magnetventil Solenoid valve
OEM Original Equipment Manufacturer
OT Oberer Totpunkt Top dead center (TDC)
PAU Power Automation Unit Module for monitoring, control and plant-related sys-
tem integration of peripheral components
PDU Process Data Unit
POM Power Output Module Module to control starter and battery-charging gen-
erator
PU Projektumgebung Project environment
P-xyz Pressure-xyz Pressure measuring point xyz indicates measuring
point designation
SAE Society of Automotive Engineers U.S. standardization organization
SAM Service and Automation Module
SD Sensor Defect Alarm: Faulty sensor
SS Safety System Safety system alarm
TBO Time Before Overhaul
TEN Technical Evolution Network Technical sales documents, engine data, technical
data
T-xyz Temperature-xyz Temperature measuring point xyz, indicates measur-
ing point designation
U Symbol for electric voltage
UIC Union Internationale des Chemins de Fer International railway association
Ultra- UltraCaps modules Capacitors for starting system
TIM-ID: 0000009959 - 010
Caps
UT Unterer Totpunkt Bottom dead center (BDC)
WZK Tool Catalog
154 | Appendix A | MS15042/00E 2014-10

8.2 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015
MS15042/00E 2014-10 | Appendix A | 155

9 Appendix B
9.1 Special Tools
Barring device
Part No.: F6555766
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 75)
Qty.: 1
Used in: 7.2.1 Cylinder liner – Endoscopic examination
(→ Page 79)
Combination box and open-end wrench

Part No.: F30379609
Qty.: 1
Used in: 7.18.1 Engine mounts – Resilient element check
(→ Page 145)
Endoscope
Part No.: Y20097353
Qty.: 1
(→ Page 79)
Qty.: 1
Used in: 7.9.1 Exhaust turbocharger – Turbine housing check
(→ Page 104)
DCL-ID: 0000035416 - 001
156 | Appendix B | MS15042/00E 2014-10

Feeler gauge
Part No.: Y20098771
Qty.: 1
Used in: 7.4.2 Valve clearance – Check and adjustment
(→ Page 86)
Feeler gauge
Part No.: Y20010128
Qty.: 1
(→ Page 145)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.8.1 Fuel filter – Replacement (→ Page 100)
Qty.: 1
Used in: 7.8.4 Intermediate fuel filter – Replacement
(→ Page 103)
Qty.:
Used in: 7.15.1 Engine oil filter – Replacement (→ Page 121)
Grease gun
Part No.:
Qty.:
Used in: 7.19.1 Generator – Greasing antifriction bearing
(→ Page 147)
DCL-ID: 0000035416 - 001
MS15042/00E 2014-10 | Appendix B | 157

Installation/removal tool
Part No.: F6789889
Qty.: 1
Used in: 7.6.2 Injector – Removal and installation (→ Page 94)
Milling cutter
Part No.: F30452739
Qty.: 1
MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 7.14.3 Engine oil – Sample extraction and analysis
(→ Page 120)
Qty.: 1
Used in: 7.16.6 Engine coolant – Sample extraction and analysis
(→ Page 133)
Ratchet
Part No.: F30027341
Qty.: 1
Used in: 7.14.2 Engine oil – Change (→ Page 118)
DCL-ID: 0000035416 - 001
158 | Appendix B | MS15042/00E 2014-10

Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 7.3.1 Crankcase breather – Oil separator element re-
placement (→ Page 83)
Qty.: 1
Qty.: 1
Used in: 7.9.2 Compressor wheel – Cleaning (→ Page 107)
Ratchet adapter
Part No.: F30027341
Qty.: 1
Ratchet with extension

Part No.: F30006212
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 75)
Qty.: 1
(→ Page 79)
Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
(→ Page 86)
DCL-ID: 0000035416 - 001
MS15042/00E 2014-10 | Appendix B | 159

Steam jet cleaner
Part No.: -
Qty.: 1
Used in: 4.6 Plant – Cleaning (→ Page 41)
Torque wrench, 0.5-5 Nm

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

Part No.: F30452769
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)
Qty.: 1
Qty.: 1
Used in: 7.9.2 Compressor wheel – Cleaning (→ Page 107)
Qty.: 1
Used in: 7.15.3 Centrifugal oil filter – Cleaning and filter-sleeve
replacement (→ Page 124)

Part No.: F30047798
Qty.: 1
(→ Page 145)
DCL-ID: 0000035416 - 001
160 | Appendix B | MS15042/00E 2014-10

Part No.: F30044239
Qty.: 1
Used in: 7.3.1 Crankcase breather – Oil separator element re-
placement (→ Page 83)
Qty.: 1
Used in: 7.15.3 Centrifugal oil filter – Cleaning and filter-sleeve
replacement (→ Page 124)

Part No.: F30452768
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)
Qty.: 1
(→ Page 86)
Qty.: 1
Qty.: 1
Used in: 7.14.2 Engine oil – Change (→ Page 118)
Vacuum cleaner
Part No.:
Qty.:
Used in: 7.19.2 Generator – Cleaning intake air grille
(→ Page 148)
Vernier caliper
Part No.: Y20001743
Qty.: 1
(→ Page 145)
DCL-ID: 0000035416 - 001
MS15042/00E 2014-10 | Appendix B | 161

9.2 Index
A E
Abbreviations 153 Engine
Actuators – Barring
– Overview 21 – Manually 75
ADEC – Cranking with starting system 77
– List of fault messages 48 – Layout 19
Air filter – Main dimensions 35
– Replacement 113 – Performing test run 78
Air filter element – Preparation for extended out-of-service period 40
– Cleaning 112 – Start in manual mode 38
– Removal and installation 114 – Stopping in manual mode 39
– Technical data 16V 4000 R43 24
C Engine cabling
CDC parameters – Check 149
– Reset 150 Engine coolant
Centrifugal oil filter – Analysis
– Cleaning 124 – Sample 133
Charge-air coolant – Change 127
– Change 139 – Check
– Check – Level at external cooler 126
– Level at filler neck 138 – Level at filler neck 126
– Level via level sensor 138 – Level via level sensor 126
– Draining 140 – Draining 128
– Filling 141 – Extraction
Charge-air coolant pump – Sample 133
– Relief bore check 144 – Replenishing 129
Compressor wheel Engine coolant pump
– Cleaning 107 – Relief bore check 132
Connectors Engine data
– Cleaning 151 – 16 V 4000 R43L 28
Contact persons 155 – 16 V 4000 R43R 31
Coolant Engine driving end
– Change 127, 139 – Definition 18
– Replenishing 129 Engine free end
Crankcase breather – Definition 18
– Oil separator element Engine governor
– Replacement 83 – Cleaning 151
Crankshaft – Plug connections
– Transport locking device – Check 152
– Installation/removal 8 Engine mounts
Cylinder – Check 145
– Designation 18 Engine oil
Cylinder head cover – Centrifugal oil filter
– Installation 90 – Cleaning 124
DCL-ID: 0000035416 - 001
– Removal 90 – Change 118

Cylinder liner – Filter sleeve
– Endoscopic examination 79 – Replacement 124
– Instructions and comments on endoscopic and visual – Sample extraction and analysis 120
examination 81 Engine oil filter
– Replacement 121
D Engine oil level
Dust bowl – Check 117
– Cleaning 112 Engine sides
– Designation 18
Exhaust turbocharger
– Turbine housing check 104
162 | Appendix B | MS15042/00E 2014-10

F Putting the engine into operation
Fault messages – Preparation after extended out-of-service periods (>3
– Indication on PAU display 47 months) 36
– List 48
R
Filter sleeve
– Replacement 124 Recommissioning
Firing order 34 – Preparation after scheduled out-of-service period 37
Fuel filter Resilient elements
– Replacement 100 – Check 145
Fuel prefilter
S
– Draining 101
– Filter element replacement 102 Safety notices, standards 17
Fuel system Safety regulations
– Venting 99 – Auxiliary materials 15
– Environmental protection 15
G – Fire prevention 15
Generator – Fluids and lubricants 15
– Cleaning intake air grille 148 – Organizational requirements 6
– Greasing antifriction bearing 147 – Personnel requirements 6
Safety requirements
H – Important requirements 5
Hotline 155 – Maintenance work 12
HP pump – Operation 11
– Filling with engine oil 92 – Repair work 12
– Relief bore check 91 – Safety notices, standards 17
– Startup 11
I Sensors
Injector – Overview 21
– Installation 94 Service indicator
– Removal 94 – Signal ring position check 116
– Replacement 93 Service partners 155
Injectors Spare parts service 155
– Overview 21 Starter
Intercooler – Condition check 115
– Checking condensate drain for coolant leakage 111
T
– Checking condensate drain for obstructions 111
Intermediate fuel filter Transport 7
– Replacement 103 Transport locking device
– Crankshaft
M – Installation/removal 8
Maintenance schedule Troubleshooting 44
– Maintenance task reference table [QL1] 42
V
MTU contact persons 155
Valve clearance
O – Adjustment 86
Oil indicator filter – Check 86
– Checking 122 Valve gear
– Lubrication 85
DCL-ID: 0000035416 - 001
P
W
PAU
– Fault message indication 47 Wiring
Plant – Check
– Cleaning 41 – On engine 149
Preheater unit
– Installation 137
– Removal 136
Preheating unit
– Overview 134
MS15042/00E 2014-10 | Appendix B | 163


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Operating Instructions

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© 2014 Copyright MTU Friedrichshafen GmbH

Downloaded from www.Manualslib.com manuals search engine

5 Maintenance 7.11 Air Filter 112

7.11.1 Air filter element and (optional) dust bowl ‒

MS15042/00E 2014-10 | Table of Contents | 3

DCL-ID: 0000035416 - 001

4 | Table of Contents | MS15042/00E 2014-10

MS15042/00E 2014-10 | Safety | 5

Working clothes and personal protective equipment

TIM-ID: 0000040531 - 003

6 | Safety | MS15042/00E 2014-10

Placement after transport

MS15042/00E 2014-10 | Safety | 7

Transport locking device

Removing guard plates and en-

8 | Safety | MS15042/00E 2014-10

Removing the transport locking

stallation carefully together with this docu-

MS15042/00E 2014-10 | Safety | 9

TIM-ID: 0000004010 - 014

10 | Safety | MS15042/00E 2014-10

Safety requirements for operation

Malfunctions and emergency stop

Operation of electrical equipment

MS15042/00E 2014-10 | Safety | 11

Safety requirements during maintenance and repair work

Ensure that all retainers and dampers are installed correctly.

12 | Safety | MS15042/00E 2014-10

Safety requirements after completing maintenance and repair work

Hydraulic installation and removal

Working with batteries

MS15042/00E 2014-10 | Safety | 13

Working with laser equipment

Measuring component deviations

14 | Safety | MS15042/00E 2014-10

Environmental protection and disposal

Fluids and lubricants and auxiliary materials

coming into contact with ignition sources and do not smoke.

MS15042/00E 2014-10 | Safety | 15

Paints and varnishes

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

• Observe the relevant safety data sheet for all materials.

16 | Safety | MS15042/00E 2014-10

MS15042/00E 2014-10 | Safety | 17

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

18 | General Information | MS15042/00E 2014-10

1 Oil heat exchanger 8 Intercooler 15 Generator

MS15042/00E 2014-10 | General Information | 19

Engine model designation

20 | General Information | MS15042/00E 2014-10

1 Engine governor 6 Sensor B34 (fuel pressure 11 Sensor B1 (camshaft

MS15042/00E 2014-10 | General Information | 21

TIM-ID: 0000012931 - 005

22 | General Information | MS15042/00E 2014-10

A1 Injector Y39.1 A7 Injector Y39.7 B5 Injector Y39.15

MS15042/00E 2014-10 | General Information | 23

Engine model 16V4000

General conditions (for max. power)

24 | Technical Data | MS15042/00E 2014-10

Combustion air / exhaust gas

Coolant system (HT circuit)