Operating Instructions: Diesel Engine 12 V 4000 T94, T94L

Operating Instructions
Diesel engine
12 V 4000 T94, T94L
MS150096/01E
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Printed in Germany
© 2012 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.

Table of Contents
1 Safety 6 Troubleshooting
1.1 General conditions 5 6.1 Troubleshooting 41
1.2 Personnel and organizational requirements 6 6.2 Fault messages on the SAM display
1.3 Transport 7 (optional) 44
1.4 Crankshaft transport locking device 8 6.3 Fault messages of Engine Control Unit
1.5 Safety regulations for startup and operation 12 ECU 9 for Series 4000 45
1.6 Explosion hazard when removing
inspection port cover on engine 13
1.7 Safety regulations for maintenance and
7 Task Description
repair work 14
1.8 Auxiliary materials, fluids and lubricants, 7.1 Engine 107
fire prevention and environmental 7.1.1 Engine – Barring manually 107
protection 17 7.1.2 Engine – Barring with starting system 108
1.9 Conventions for safety instructions in the 7.1.3 Engine – Test run 109
text 19
7.2 Cylinder Liner 110
7.2.1 Cylinder liner – Endoscopic examination 110
7.2.2 Instructions and comments on endoscopic
2 General Information and visual examination of cylinder liners 112
2.1 Engine side and cylinder designations 20 7.3 Valve Drive 114
7.3.1 Valve gear – Lubrication 114
2.2 Engine layout 21
7.3.2 Valve clearance – Check and adjustment 115
2.3 Sensors, actuators and injectors ‒
7.3.3 Cylinder head cover – Removal and
Overview 22 installation 118
7.4 Injection Pump / HP Pump 119

7.4.1 HP pump – Filling with engine oil 119
3 Technical Data
7.5 Injection Valve / Injector 120
3.1 Engine data 12V 4000 T94, T94L 26 7.5.1 Injector – Replacement 120
3.2 Firing order 30 7.5.2 Injector – Removal and installation 121
3.3 Main engine dimensions 31
7.6 Fuel System 125
7.6.1 Fuel system – Venting 125
4 Operation 7.7 Fuel Filter 126

7.7.1 Fuel filter – Replacement 126
4.1 Putting the engine into operation after 7.7.2 Auxiliary fuel filter – Replacement 127
extended out-of-service periods (>3
months) 32 7.8 Exhaust Turbocharger 128
7.8.1 Exhaust turbocharger – Turbine housing
4.2 Putting the engine into operation after
check 128
scheduled out-of-service-period 33 7.8.2 Exhaust turbocharger (LP) – Turbine housing
4.3 Operational checks 34
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check 129
4.4 Starting the engine in manual mode 35 7.8.3 Exhaust turbocharger (HP) – Turbine housing
4.5 Stopping the engine in manual mode 36 check 134
4.6 After stopping the engine 37
4.7 Plant cleaning 38 7.9 Charge-Air Cooling 139
7.9.1 Intercooler – Leak check 139
7.10 Air Intake 140

7.10.1 Emergency air-shutoff flaps – Functional
5 Maintenance
check with electric actuation 140
5.1 Maintenance task reference table [QL1] 39
7.11 Exhaust Gas Recirculation 141
MS150096/01E 2012-08 | Table of Contents | 3

7.11.1 Exhaust flaps – Overview 141
7.11.2 Exhaust flaps – Checking operation of 7.18 Battery-Charging Generator 174
actuators 143 7.18.1 Battery-charging generator – Check 174
7.18.2 Battery-charging generator drive – Drive belt
7.12 Starting Equipment 144 tension adjustment 175
7.12.1 Starter – Condition check 144 7.18.3 Battery-charging generator drive – Drive belt
replacement 176
7.13 Lube Oil System, Lube Oil Circuit 145
7.13.1 Engine oil – Level check at sight glass 145 7.19 Fan Drive 177
7.13.2 Engine oil – Level check with oil dipstick 146 7.19.1 Fan drive (option) – Drive belt check /
7.13.3 Engine oil – Change 147 adjustment 177
7.13.4 Engine oil – Sample extraction and analysis 149 7.19.2 Fan drive (option) – Drive belt replacement 179
7.14 Oil Filtration / Cooling 150 7.20 Engine Mounting / Support 180
7.14.1 Engine oil filter – Replacement 150 7.20.1 Engine mounting – Check 180
7.14.2 Centrifugal oil filter – Cleaning and filter
sleeve replacement 152 7.21 Wiring (General) for Engine/Gearbox/Unit 181
7.21.1 Engine wiring – Check 181
7.15 Coolant Circuit, General, High-
Temperature Circuit 154 7.22 Accessories for (Electronic) Engine
7.15.1 Engine coolant – Level check 154 Governor / Control System 182
7.15.2 Engine coolant – Change 155 7.22.1 CDC parameters – Reset with DiaSys® 182
7.15.3 Engine coolant – Draining 156 7.22.2 Engine governor and connectors – Cleaning 183
7.15.4 Exhaust flaps – Draining coolant 158 7.22.3 Engine governor – Checking plug-in
7.15.5 Engine coolant – Filling 159 connections 184
7.15.6 Engine coolant pump – Relief bore check 162
7.15.7 Engine coolant – Sample extraction and
analysis 163
7.15.8 Engine coolant filter – Replacement 164
8 Appendix A
7.16 Low-Temperature Circuit 165 8.1 Abbreviations 185
7.16.1 Charge-air coolant – Level check 165
7.16.2 Charge-air coolant – Change 166
8.2 MTU contact persons/service partners 188
7.16.3 Charge-air coolant – Draining 167
7.16.4 Charge-air coolant – Filling 169
7.16.5 Charge-air coolant pump – Relief bore check 172
9 Appendix B
7.17 Belt Drive 173
9.1 Special Tools 189
7.17.1 Drive belt – Condition check 173
9.2 Index 196
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4 | Table of Contents | MS150096/01E 2012-08

1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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MS150096/01E 2012-08 | Safety | 5

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

Wear proper protective clothing for all work.
Use the necessary protective equipment for the given work to be done.
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6 | Safety | MS150096/01E 2012-08

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

Place the engine/genset on a firm, flat surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis.
MS150096/01E 2012-08 | Safety | 7

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

Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30510423 1
Engine oil
Transport locking device

Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine
transport.
For installation and removal of the transport locking device, follow the instructions
below:
1. The transport locking device must remain installed as long as possible during engine installation in order
to avoid damage.
2. Starting or barring the engine is allowed only with the transport locking device removed. If the generator
is already mounted on the engine, ensure that the transport locking device of the generator is removed.
3. Prior to every engine transport, the transport locking device must be reinstalled on both sides according
to the instructions.
4. If the engine is to be moved together with the generator, the transport locking device for the generator
must also be installed.
Removing the transport locking

device from driving end (KS),
version A
1. Remove parts (1) to (8) from engine.
Spacer sleeves (5) are optional.
2. Store the removed parts of the transport
locking device carefully for possible reuse.
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8 | Safety | MS150096/01E 2012-08

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

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

mounting brackets (if applicable)
on driving end (KS)
1. Remove screws (4) on both sides and take
off with washers (3), guard plates (1) and
engine mounting brackets (2).
2. Store the removed parts carefully for possi‐
ble reuse.
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MS150096/01E 2012-08 | Safety | 9

Note: Always use the screws supplied with or installed in the transport locking device to secure it on the en‐
gine.
Fitting the transport locking device
on driving end (KS), version B
1. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel
housing and tighten to the specified tightening torque.
2. Screw nut (3) onto screws (4) up to the end of the thread.
3. Fit the holders (1) through the openings of plates (2) and fasten with the screws (4).
4. Tighten screws (4) alternately with torque wrench to the specified tightening torque.
5. Screw on nuts (3) of both screws (4) at plates (2) and secure.
6. Fit label (7) to mark the engine as "Fitted with transport locking device".
Removing the transport locking

version B
1. Release the locknuts (3) on both sides of
the flywheel housing, remove screws (4)
and take off the two holders (1).
2. Remove screws (6) with washers (5), la‐
bel (7) and plates (2).
3. Store the removed parts carefully for possi‐
ble reuse.
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10 | Safety | MS150096/01E 2012-08

Note: Always use the screws supplied with the or removed from the guard plates and engine mounting brack‐
ets to secure them on the engine.
Installing guard plates and engine
mounting brackets (if applicable)
on driving end (KS)
1. Install engine mounting brackets (2) on both
sides with guard plates (1) washers (3), and
screws (4).
2. Tighten screws (4).
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MS150096/01E 2012-08 | Safety | 11

1.5 Safety regulations for startup and operation
Safety precautions when putting the equipment into operation

Prior to initial operation of the assembly or plant, install the assembly or unit according to the specifica‐
tions and check the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that all persons are clear of the danger zone of moving machine components.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the monitoring, signaling and alarm systems are working properly.
Safety precautions for operation

Emergency procedures must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of all operations to be performed.
During operation, the display instruments and monitoring units must be permanently observed with re‐
gard to present operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protectors.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
• Always run the engine with air filters in as-delivered condition, oiling is not permitted.
Operation of electrical equipment

When operating electrical equipment, certain components of this equipment are live.
Observe the safety instructions for these devices.
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12 | Safety | MS150096/01E 2012-08

1.6 Explosion hazard when removing inspection port cover on
engine
DANGER
Explosion hazard due to oil vapors.
Risk of serious injury – danger to life!
• Allow the engine to cool down before opening the crankcase!
• Avoid open flames, electrical sparks and ignition sources.
Safety instructions
u Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion
due to oil vapors).
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MS150096/01E 2012-08 | Safety | 13

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

Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do
so.
Secure the engine against accidental starting.
Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐
tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐
nents are placed on stable surfaces.
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Observe special cleanness when conducting maintenance and repair work on the assembly or system.
After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐
bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards
have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.
14 | Safety | MS150096/01E 2012-08

Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
Working on electrical/electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment

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When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
MS150096/01E 2012-08 | Safety | 15

For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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16 | Safety | MS150096/01E 2012-08

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

Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐
lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act
and involves the termination of the operating license by the emission authorities. MTU does not accept
any liability for violations of the emission regulations. MTU will provide assistance and advice if emission-
relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐
ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.
Use only fuel of prescribed quality to comply with emission limit values.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are
subjected to proper recycling procedures.
Auxiliary materials, fluids and lubricants

Use only fluids and lubricants that have been tested and approved by MTU.
The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using
them, make sure you have the latest version. The latest version is also available at: http://www.mtu-on‐
line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.
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Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
not smoke.
Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.
MS150096/01E 2012-08 | Safety | 17

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

• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• No open flames.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids and alkaline solutions

• When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and
protective clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately.
• Rinse injured parts of the body thoroughly with clean water.
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• Rinse eyes immediately with eyedrops or clean tap water.
18 | Safety | MS150096/01E 2012-08

1.9 Conventions for safety instructions in the text
DANGER
In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
WARNING
In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
CAUTION
In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
1. Read and familiarize yourself with all safety notices before starting up or repairing the product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
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MS150096/01E 2012-08 | Safety | 19

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

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20 | General Information | MS150096/01E 2012-08

2.2 Engine layout
The actual engine layout may deviate from the configuration shown in the illustration.
1 Engine oil heat ex‐ 11 Intercooler 21 HP fuel pump

changer 12 EGR line 22 Lube oil filter
2 Wiring harness retainer 13 Starter 23 Engine mounting
3 Exhaust outlet 14 Charge-air line 24 Vibration damper
4 Air intake 15 Cylinder head 25 Auxiliary PTO
5 Turbocharger (low-pres‐ 16 Oil pan 26 Battery-charging gener‐
sure) 17 Engine suspension ator
6 Turbocharger (high- 18 Supplementary fuel filter 27 Coolant filter
pressure) 19 Fuel priming pump 28 Centrifugal oil filter
7 Intermediate cooler 20 Fuel filter 29 Crankcase breather
8 EGR cooler KGS Free end
9 Engine coolant line
10 Engine governor
Engine model designation

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Key to the engine model designation 12 V 4000 T94/T94L

12 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
T Application
9 Application segment
4 Design index
L L (enhanced power / speed)
MS150096/01E 2012-08 | General Information | 21

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

2 F70 - Water level in fuel level
prefilter (external) 4 F33 - Engine coolant
level
TIM-ID: 0000018547 - 007

1 M52 - Bypass flap 5 B91.3 - Exhaust pres‐ 9 B13 - Crankshaft speed
2 B44.2 - Turbocharger B sure 10 B10.11 - Charge-air
speed 6 B88 - NOx pressure, B-side
3 B90 - Humidity (pres‐ 7 B16 - Engine coolant
sure, temperature) of in‐ pressure
take air 8 Y39.B1-B6 - Injectors
4 B89 - Lambda B1-B6
The injectors / injection valves (8) are located below the cylinder head covers. Injector replacement and
associated activities (→ Page 120).
TIM-ID: 0000018547 - 007

1 M55 - Donor cylinder 6 B9 - Charge-air temper‐ 11 F46 - Leak-off fuel level
flap ature 12 B5.3 - Lube-oil pressure
2 B44.3 - Turbocharger C 7 Y39.A1-A6 - Injectors before filter
speed A1-A6 13 B7 - Lube-oil tempera‐
3 B10.1 - Charge-air pres‐ 8 B34.3 - Fuel pressure ture
sure, A-side before additional filter 14 B44.1 - Turbocharger A
4 M53 - EGR shutoff flap 9 B34.2 - Fuel pressure speed
5 A19 - EIL connection before filter 15 B4 - Exhaust tempera‐
10 B34.1 - Fuel pressure af‐ ture
ter filter
The injectors / injection valves (6) are located below the cylinder head covers. Injector replacement and
associated activities (→ Page 120).
TIM-ID: 0000018547 - 007

1 B50 - Crankcase pres‐ 5 B48 - Fuel pressure 9 B26 - Charge-air cool‐
sure (Rail) ant temperature
2 Y44 - Fan control 6 M8 - HP fuel pump 10 B6 - Engine coolant
3 B5.1 - Lube-oil pressure 7 B1 - Camshaft speed temperature
after filter 8 B43 - Charge-air coolant
4 B33 - Fuel temperature pressure
(Rail)
TIM-ID: 0000018547 - 007

3 Technical Data
3.1 Engine data 12V 4000 T94, T94L
Explanation
Abbrev. Meaning
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power set‐
ting).
N Not yet defined value
- Not applicable
X Applicable
Reference conditions
Engine model 12V4000 12V4000
T94 T94L
Application group 4D 4D
Intake air temperature °C 25 25
Charge-air coolant temperature °C 45 45
Barometric pressure mbar 1000 1000
Site altitude above sea level m 100 100
Power-related data (power ratings are net brake power as per ISO 3046)
T94 T94L
Rated engine speed A rpm 1900 1900
Effective power (w/o fan) (fuel stop power ISO 3046) A kW 1680 1865
General conditions (for max. power)

TIM-ID: 0000028754 - 003
T94 T94L
Intake depression (new filter) A mbar 15 15
Intake depression, max. L mbar 50 50
Exhaust gas overpressure A mbar 30 30
Exhaust gas overpressure, max. L mbar 85 85
26 | Technical Data | MS150096/01E 2012-08

Model related data (basic design)
T94 T94L
Engine with exhaust turbocharging (ETC) and charge-air cool‐ X X
ing (CAC)
Uncooled exhaust lines X X
Number of cylinders 12 12
Cylinder arrangement: V angle De‐ 90 90
grees (°)
Bore mm 170 170
Stroke mm 210 210
Displacement of a cylinder Liters 4.77 4.77
Total displacement Liters 57.2 57.2
Compression ratio 16.7 16.7
Number of inlet valves per cylinder 2 2
Number of exhaust valves per cylinder 2 2
Standard housing connection flange (engine driving end) SAE 00 00
Combustion air / exhaust gas

T94 T94L
Charge-air pressure before cylinder R bar abs 4.1 4.9
Exhaust temperature after turbocharger R °C 520 490
Coolant system (high-temperature circuit)

T94 T94L
Coolant temperature (at engine connection: outlet to cooling A °C 105 105
system)
Coolant temperature after engine, warning R °C 112 112
Coolant temperature after engine, shutdown L °C 114 114
Coolant antifreeze content, max. L % 50 50
Pressure loss in off-engine cooling system, max. L bar 1.0 1.0
Thermostat: Starts to open R °C 79 79
Thermostat: Fully open R °C 92 92
TIM-ID: 0000028754 - 003
Coolant system (low-temperature circuit)

T94 T94L
Coolant temperature (at engine connection: outlet to cooling R °C - -
system)
Coolant temperature before intercooler, alarm R °C 77 77
MS150096/01E 2012-08 | Technical Data | 27

T94 T94L
Coolant temperature before intercooler, shutdown or power re‐ L °C 80 80
duction
Coolant antifreeze content, max. L % 50 50
Pressure loss in off-engine cooling system, max. L bar 1.0 1.0
Thermostat: Starts to open R °C 38 38
Thermostat: Fully open R °C 51 51
Lube oil system

T94 T94L
Lube oil operating temperature before engine, from R °C 97 97
Lube oil operating temperature before engine, to R °C 101 101
Lube oil temperature before engine, warning R °C 102 102
Lube oil temperature before engine, shutdown L °C 104 104
Lube oil operating pressure before engine, from R bar 6.0 6.0
Lube oil operating pressure before engine, to R bar 7.0 7.0
Fuel system
T94 T94L
Fuel pressure at engine inlet connection, min. (when engine is L bar -0.1 -0.1
starting)
Fuel pressure at engine inlet connection, max. (when engine is L bar 1.5 1.5
starting)
General operating data

T94 T94L
Cold start capability: Air temperature (w/o start aid, w/o preheat‐ R °C 0 0
ing) – (case A)
Coolant preheating: Preheating temperature (min.) R °C 40 40
Firing speed, from R rpm 80 80
Firing speed, to R rpm 120 120
TIM-ID: 0000028754 - 003

Inclinations – standard oil system (reference: waterline)
T94 T94L
Longitudinal inclination, continuous max. driving end down (op‐ L Degrees 5 5
tion: max. operating inclinations) (°)
Longitudinal inclination, continuous max. driving end up (option: L Degrees 5 5
max. operating inclinations) (°)
Transverse inclination, continuous max. (option: max. operating L Degrees 5 5
inclinations) (°)
Capacities
T94 T94L
Engine coolant, engine side (w/o cooling system) R Liters 220 220
Charge-air coolant, engine side R Liters 69 69
Engine oil capacity, initial filling (standard oil system) (option: R Liters 250 250
max. operating inclinations)
Oil change quantity, max. (standard oil system) (option: max. R Liters 210 210
operating inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) L Liters 170 170
(option: max. operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) L Liters 210 210
(option: max. operating inclinations)
Weights / main dimensions

T94 T94L
Dry engine weight (basic-configuration engine) R kg 7685 7685
Sound
T94 T94L
Exhaust noise, unsilenced – BL (free-field sound pressure level R dB(A) 112 112
Lp, 1m distance, ISO 6798, +3dB(A) tolerance)
Exhaust noise, unsilenced – BL (free-field sound pressure level R dB(A) 124 124
LW, ISO 6798, +3dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter)* – BL R dB(A) 107 109
TIM-ID: 0000028754 - 003
(free-field sound power level Lp, 1 m distance, ISO 6798,

+2dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter)* – BL R dB(A) 125 128
(free-field sound power level LW, ISO 6798, +2dB (A) tolerance)
* Filter with housing

3.2 Firing order
Firing order
Num‐ Firing order
ber of
cylin‐
ders
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
TIM-ID: 0000026627 - 001

3.3 Main engine dimensions
Main engine dimensions
Length (A) approx. 2685 mm

Width (B) approx. 1631 mm
Height (C) approx. 1921 mm
TIM-ID: 0000018765 - 003

4 Operation
4.1 Putting the engine into operation after extended out-of-
service periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting into operation after long out-of-service periods (>3 months)

Item Action
Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).
Valve drive Lubricate valve drive every ≥ 6 months (→ Page 114).
Lube oil system Check engine oil level (→ Page 146).
Bar engine with starting equipment (→ Page 108).
Fuel prefilter Fill with fuel (if fitted).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 155).
Change charge-air coolant (→ Page 166).
Coolant circuit Check engine coolant level (→ Page 154);
Check charge-air coolant level (→ Page 165).
Coolant circuit Preheat coolant with coolant preheating unit (if applicable).
Engine governor Check plug connections (→ Page 184).
HP fuel pump Only for engines without oil priming pump
Fill HP fuel pump with new engine oil (→ Page 119).
TIM-ID: 0000002200 - 004
32 | Operation | MS150096/01E 2012-08

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 146).
Coolant circuit Check engine coolant level (→ Page 154);
Check charge-air coolant level (→ Page 165).
Coolant circuit Preheat coolant with coolant preheating unit (if applicable).
Engine control system Put into operation.
TIM-ID: 0000002683 - 005
MS150096/01E 2012-08 | Operation | 33

4.3 Operational checks
DANGER
Unguarded rotating and moving engine components.
• Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
Operational checks
Item Action
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine oil Check engine oil level (→ Page 146).
Engine operation Check engine visually for leaks and general condition;
Check engine for abnormal running noises, exhaust color and vibrations.
Air filter Check signal ring position of service indicator on air filter (if fitted).
Battery-charging generator Check battery-charging generator for contamination, clean as necessary
(→ Page 174).
Exhaust system Check exhaust color (→ Page 41).
Fuel prefilter Drain water and contaminants via drain cock on fuel prefilter (if fitted).
Check reading on vacuum gauge of fuel prefilter (if fitted).
Engine coolant pump Check relief bore (→ Page 162).
Charge-air coolant pump Check relief bore (→ Page 172).
TIM-ID: 0000030232 - 002
34 | Operation | MS150096/01E 2012-08

4.4 Starting the engine in manual mode
Preconditions
☑ Engine is not under load.
☑ External start interlock is not activated.
DANGER
• Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING
Preparation
Item Action
Operating mode switch (if Switch to manual mode.
applicable)
Coolant preheating unit (if Switch ON.
applicable).
Starting the engine

Item Action
Switchgear cabinet, opera‐ 1. If no coolant preheater is fitted, make sure that the coolant tempera‐
tor station etc. (depending ture is > 40 °C.
on manufacturer). 2. Press start button.
• Automatic starting procedure is performed;
• Engine speed instrument indicates increasing speed;
• After the starting sequence is completed, engine is running at idle
speed.
TIM-ID: 0000002233 - 005
MS150096/01E 2012-08 | Operation | 35

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

Item Action
Switch cabinet, operator Press stop button.
station etc. (depending on
• Automatic stopping sequence is executed.
manufacturer)
TIM-ID: 0000002291 - 004
36 | Operation | MS150096/01E 2012-08

4.6 After stopping the engine
Preconditions
Note: If freezing temperatures are to be expected: Coolant pressure sensors installed in vertical position may
be damaged if the coolant does not contain antifreeze additive.
After stopping the engine

Item Action
Coolant circuit Drain engine coolant (→ Page 156);
Drain charge-air coolant (→ Page 167) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera‐
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Engine control system Switch off.
Air intake and exhaust sys‐ If the engine is to remain out of service for more than 1 week, seal the
tem engine's air and exhaust sides. If the engine is to remain out of service for
more than 1 month, carry out preservation (→ MTU Fluids and Lubricants
Specifications A001061/..).
TIM-ID: 0000002709 - 005
MS150096/01E 2012-08 | Operation | 37

4.7 Plant cleaning
Preconditions
☑ Operating voltage is not present.

Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
WARNING
Water jet.
Risk of injury and scalding!
• Do not direct water jet at persons.
• Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• Observe manufacturer's instructions.
NOTICE
Dry with compressed air.
Damage to component!
• Never aim compressed air directly at electronic components.
Plant cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐
tection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.
3. During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must
be observed. The temperature of the cleaning medium must not exceed 80 °C.
TIM-ID: 0000010171 - 024
4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable fashion.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
Note: Never aim compressed air directly at electronic components.
e) Dry engine.
38 | Operation | MS150096/01E 2012-08

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 Measures
W0500 Check engine oil level. (→ Page 146)
W0501 Check engine visually for leaks and general condition. (→ Page 34)
W0502 Check intercooler drain. (→ Page 139)
W0503 Check air filter service indicator. (→ Page 34)
W0505 Check relief bores of coolant pump(s). (→ Page 162)
(→ Page 172)
W0506 Check for abnormal running noises, exhaust color and vibra‐ (→ Page 34)
tions.
W0507 Drain water and contaminants from fuel prefilter. (→ Page 34)
W0508 Check indicator position of differential pressure gauge at fuel (→ Page 34)
prefilter.
W0525 Check battery-charging generator for contamination, clean as (→ Page 174)
necessary.
W1001 Replace fuel filter or fuel filter element. (→ Page 126)
W1006 Replace fuel injectors. (→ Page 120)
W1008 Replace engine oil filter when changing engine oil, or when (→ Page 150)
the interval (years) is reached, at the latest.
W1011 Perform endoscopic examination of cylinder chambers. (→ Page 110)
W1024 Check electrical operation of emergency-air shutoff flaps. (→ Page 140)
W1036 Replace coolant filter. (→ Page 164)
W1207 Check valve clearance, and adjust, if necessary. Attention! (→ Page 115)
First adjustment after 1,000 operating hours!
W1241 Check condition of drive belt and replace if necessary; adjust (→ Page 173)
belt tension.
W1463 Check general condition of engine mounting (visual inspec‐ (→ Page 127)
tion).
W1481 Replace additional fuel filter or filter element of additional fuel (→ Page 180)
TIM-ID: 0000025250 - 003
filter.
W1529 Replace filter cartridge of centrifugal oil filter with every en‐ (→ Page 152)
gine oil change.
W1551 Check operation of exhaust flap actuators. (→ Page 143)
W1577 Check turbine housing externally for cracks, perform endo‐ (→ Page 128)
scopic examination to check it internally for cracks, replace if
necessary.
MS150096/01E 2012-08 | Maintenance | 39

Task Measures
W1610 Check securing screws of trunnion bearings for tight fit. (→ Page 180)
W1636 Reset drift correction parameters (CDC) and enter code of in‐ (→ Page 182)
jectors (IIG).
Table 1: Maintenance task reference table [QL1]
TIM-ID: 0000025250 - 003
40 | Maintenance | MS150096/01E 2012-08

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

Component Cause Action
Battery Low or faulty. Charge or replace (see manufacturer's
documentation).
Cable connections defective Check if cable connections are proper‐
ly secured (see manufacturer's docu‐
mentation).
Starter Engine wiring or starter defective. Check if cable connections are proper‐
ly secured, contact Service.
Engine wiring Defective Check (→ Page 181).
Engine/generator Secure seating of assemblies or con‐ Perform visual inspection (see manu‐
control system nectors not provided. facturer's documentation).
Engine governor Plug-in connections are loose. Check plug connections (→ Page 184).
Engine Running gear blocked (engine cannot Contact Service.
be barred manually).
Engine turns but does not fire

Engine Too cold. Preheat (40 °C)
Starter Poor rotation by starter: Battery low or Charge or replace battery (see manu‐
defective. facturer's documentation).
Fuel system Air in fuel system. Vent fuel system (→ Page 125).
Engine governor Defective Contact Service.
Engine fires unevenly

Fuel injection equip‐ Injector defective. Replace (→ Page 120).
ment
TIM-ID: 0000018860 - 004
Engine does not reach rated speed

Fuel supply Fuel prefilter clogged. Replace
Easy-change fuel filter clogged Replace (→ Page 126).
Air supply Air filter clogged. Clean.
ment
MS150096/01E 2012-08 | Troubleshooting | 41

Engine Overloaded Contact Service.
Engine speed not steady

ment
Speed sensor Defective Contact Service.
Charge-air temperature too high

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

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

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

Air supply Air filter clogged. Check
ment
Engine Overloaded Contact Service.
Blue exhaust gas

TIM-ID: 0000018860 - 004

Engine oil Too much oil in engine. Drain engine oil (→ Page 147).
Oil separator of crankcase breather Replace filter.
contaminated
Exhaust turbocharg‐ Defective Contact Service.
er, cylinder head, pis‐
ton rings, cylinder lin‐
er
42 | Troubleshooting | MS150096/01E 2012-08

White exhaust gas
Engine Not at operating temperature. Run up to operating temperature.
Fuel system Water in fuel. Check fuel system on fuel prefilter.
Drain fuel prefilter.
Intercooler Leaking Contact Service.
TIM-ID: 0000018860 - 004

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

Fault messages can also be caused by faulty sensors/actuators. If the fault cannot be corrected with the
troubleshooting information provided in the following table, contact Service. Our Service will check sen‐
sors/actuators and replace them if necessary.
The following fault codes may appear on the display: (→ Page 45).
TIM-ID: 0000029308 - 002

6.3 Fault messages of Engine Control Unit ECU 9 for Series
4000
3 – HI T-Fuel
ZKP-Number: 2.0122.931
Fuel temperature too high (limit value 1)
Yellow alarm - warning
Cause Corrective action
Fuel tank may be exposed to 1. Reduce power.
heat. 2. Contact Service.
4 – SS T-Fuel
Fuel temperature too high (limit value 2)
Red alarm - engine shutdown
Fuel tank may be exposed to u Contact Service.
heat.
5 – HI T-Charge Air
Charge-air temperature too high (limit value 1)
Intercooler not operating 1. Reduce power.
correctly. 2. Check intercooler.
3. Contact Service.
6 – SS T-Charge Air
Charge-air temperature too high (limit value 2)
TIM-ID: 0000029153 - 006
Intercooler not operating 1. Check intercooler.

correctly. 2. Contact Service.

9 – HI T-Coolant Intercooler
Coolant temperature in intercooler too high (limit value 1)
Coolant circuit for charge air 1. Reduce power.
faulty. 2. Check intercooler and coolant cooler.
3. Contact Service.
10 – SS T-Coolant Intercooler
Coolant temperature in intercooler too high (limit value 2).
Coolant circuit for charge air 1. Check intercooler and coolant cooler.
faulty. 2. Contact Service.
15 – LO P-Lube Oil
Lube oil pressure too low (limit value 1)
Insufficient oil. 1. Check oil level, top up as necessary (→ Page 146).
2. Contact Service.
16 – SS P-Lube Oil
Lube oil pressure too low (limit value 2)
Insufficient oil. 1. Check oil level, top up as necessary (→ Page 146).
2. Acknowledge alarm.
3. Restart engine (→ Page 35).
4. Contact Service.
TIM-ID: 0000029153 - 006

19 – HI T-Exhaust A
Exhaust temperature (A-side) too high (limit value 1)
Cable damage. 1. Check air filter and wiring (→ Page 181).
2. Contact Service.
20 – SS T-Exhaust A
Exhaust temperature (A-side) too high (limit value 2)
2. Contact Service.
21 – HI T-Exhaust B
Exhaust temperature (B-side) too high (limit value 1)
2. Contact Service.
22 – SS T-Exhaust B
Exhaust temperature (B-side) too high (limit value 2)
2. Contact Service.
23 – LO Coolant Level
TIM-ID: 0000029153 - 006
Coolant level too low (limit value 1)
Leak in coolant circuit. u Check coolant level in expansion tank (→ Page 154).

25 – HI P-Diff. Lube Oil
Differential oil pressure at oil filter too high (limit value 1)
Oil filter not operating correctly. u Replace oil filter (→ Page 150).
26 – SS P-Diff. Lube Oil

Differential oil pressure at oil filter too high (limit value 2)
Oil filter not operating correctly. 1. Replace oil filter (→ Page 150).
2. Contact Service.
27 – HI Level Leak-Off Fuel

Leak-off fuel level too high (limit value 1)
Leak in fuel lines. 1. Check fuel system.
2. Contact Service.
30 – SS Engine Overspeed
Engine overspeed (limit value 2)
No fuel injection. 1. Restart engine. Fault can possibly be eliminated through restart
(→ Page 35).
2. Contact Service.
31 – HI ETC1 Overspeed
TIM-ID: 0000029153 - 006
Speed of primary turbocharger too high (limit value 1)
Obstructed charge-air circuit or 1. Reduce power.
fault in turbocharger. 2. Check air filter.
3. Contact Service.

32 – SS ETC1 Overspeed
Speed of primary turbocharger too high (limit value 2)
Obstructed charge-air circuit or 1. Check air filter.
fault in turbocharger. 2. Contact Service.
33 – HI P-Diff. Fuel
Fuel filter differential pressure too high (limit value 1)
Fuel filter not operating correctly. 1. Replace fuel filter (→ Page 126).
2. Contact Service.
34 – SS P-Diff. Fuel
Fuel filter differential pressure too high (limit value 2)
Fuel filter not operating correctly. 1. Replace fuel filter (→ Page 126).
2. Contact Service.
Speed of 1st secondary turbocharger too high (limit value 1)
Obstructed charge-air circuit or 1. Reduce power.
fault in turbocharger. 2. Contact Service.
TIM-ID: 0000029153 - 006
Speed of 1st secondary turbocharger too high (limit value 2)
Obstructed charge-air circuit or u Contact Service.
fault in turbocharger.

44 – LO Coolant Level Intercooler
Coolant level of intercooler too low (limit value 1)
Insufficient charge-air coolant, 1. Check coolant level (→ Page 165).
e.g. due to leaks in charge-air 2. Contact Service.
coolant circuit.
51 – HI T-Lube Oil
Lube oil temperature too high (limit value 1)
Insufficient oil. 1. Reduce power.
2. Check engine oil level (→ Page 146).
3. Contact Service.
52 – SS T-Lube Oil
Lube oil temperature too high (limit value 2)
Insufficient oil. 1. Check engine oil level (→ Page 146).
2. Contact Service.
57 – LO P-Coolant
Coolant pressure too low (limit value 1)
Leak in coolant circuit. 1. Check coolant level (→ Page 154).
2. Check coolant circuit.
TIM-ID: 0000029153 - 006
58 – SS P-Coolant
Coolant pressure too low (limit value 2)
Red alarm - engine shutdown or reduced injection quantity
Leak in coolant circuit. 1. Check coolant level (→ Page 154).
2. Check coolant circuit.

59 – SS T-Coolant L3
Coolant temperature too high / low (limit value 3)
Red alarm - forced idle
Coolant circuit not operating 1. Activate fan emergency operating mode if required.
correctly (e.g. damage, leaks, 2. Allow engine to cool down.
low coolant level). 3. Check engine coolant cooler, clean if dirty.
6. Contact Service.
60 – SS T-Coolant L4
Coolant temperature too high / low (limit value 4)
Coolant circuit not operating 1. Activate fan emergency operating mode if required.
correctly (e.g. damage, leaks, 2. Allow engine to cool down.
low coolant level). 3. Check engine coolant cooler, clean if dirty.
6. Contact Service.
63 – HI P-Crankcase
Crankcase pressure too high (limit value 1)
Crankcase extraction system 1. Reduce power.
obstructed or leaking. 2. Replace oil mist fine separator insert .
3. Contact Service.
64 – SS P-Crankcase
Crankcase pressure too high (limit value 2)
TIM-ID: 0000029153 - 006

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

65 – LO P-Fuel
Fuel supply pressure too low (limit value 1)
Leaky or obstructed fuel lines or 1. Check fuel lines for leaks.
fuel filter. 2. Check filter, fuel on low-pressure side.
3. Replace fuel filter (→ Page 126).
66 – SS P-Fuel
Fuel supply pressure too low (limit value 2)
Leaky or obstructed fuel lines or 1. Check fuel lines for leaks.
fuel filter. 2. Check filter, fuel on low-pressure side.
3. Replace fuel filter (→ Page 126).
4. Contact Service.
67 – HI T-Coolant
Coolant temperature too high (limit value 1)
Coolant circuit not operating 1. Reduce power.
correctly (e.g. damage, leaks, 2. Check coolant circuit.
low coolant level).
68 – SS T-Coolant
Coolant temperature too high (limit value 2)
Coolant circuit not operating u Check coolant circuit.
TIM-ID: 0000029153 - 006
correctly (e.g. damage, leaks,

low coolant level).

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

Rail pressure > set value
Red alarm - DBR fuel limitation, start of injection readjusted towards late
HP fuel block jamming or HP fuel 1. Check wiring (→ Page 181).
control block wiring faulty. 2. Contact Service.
83 – LO P-Fuel (Common Rail)

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

Engine speed too low
Various causes possible. 1. Acknowledge alarm.
2. Observe additional messages.
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3. Contact Service.

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

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

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

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

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

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

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

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Supply voltage too low (limit value 2)

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

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

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

Maximum value exceeded
Average power value has u Contact Service.
exceeded the defined maximum
value over the last 24 hours.
142 – AL MCR 1 Hour Exceeded

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MCR exceeded
MCR was exceeded for longer u Contact Service.
than one hour over the past 12
hours.

180 – AL CAN1 Node Failure
Connection to a node on CAN bus 1 failed
Connection to or communication 1. Check devices connected to CAN.
with a node at CAN bus 1 has 2. Check wiring (→ Page 181).
failed. 3. Contact Service.
181 – AL CAN2 Node Failure

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

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

CAN PU data not present or available
The selected CAN mode 1. Check devices connected to CAN.
initializes communication by 2. Contact Service.
means of the PU data module. A
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fault occurred during an attempt

to copy a received data module
to the engine governor.

184 – AL CAN PU Data Flash Error
CAN PU data flash fault
A programming error occurred u Contact electronic Service.
during attempt to copy a
received PU data module to the
flash module.
186 – AL CAN1 Bus Off

CAN controller 1 is in "Bus-Off" status
Yellow alarm - automatic changeover to CAN 2
Short circuit, massive 1. Check CAN bus for short circuit, rectify short circuit as required.
interference or Baud rate 2. Check shielding, improve shielding if necessary.
incompatibility. 3. Contact Service.
187 – AL CAN1 Error Passive

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

CAN controller 2 is in "Bus-Off" status
Yellow alarm - automatic changeover to CAN 1
Short circuit, massive 1. Check CAN bus for short circuit, rectify short circuit as required.
interference or Baud rate 2. Check shielding, improve shielding if necessary.
incompatibility. 3. Contact Service.
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189 – AL CAN2 Error Passive
CAN controller 2 error
Missing associated nodes, minor 1. Check CAN bus for short circuit, rectify short circuit as required.
disruptions or temporary bus 2. Check shielding, improve shielding if necessary.
overload. 3. Contact Service.
201 – SD T-Coolant
Coolant temperature sensor signal error
Coolant temperature sensor 1. Check sensor and wiring (B6), replace as necessary
faulty. (→ Page 181).
Short circuit or wire break. 2. Fault is rectified when engine is restarted (→ Page 35).
3. Contact Service.
202 – SD T-Fuel
Fuel temperature sensor signal error
Fuel temperature sensor faulty. 1. Check sensor and wiring (B33), replace as necessary
Short circuit or wire break. (→ Page 181).
2. Fault is rectified when engine is restarted (→ Page 35).
3. Contact Service.
203 – SD T-Charge Air

Charge-air temperature sensor signal error
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Charge air temperature sensor 1. Check sensor and wiring (B9), replace as necessary
Short circuit or wire break. 2. Fault is rectified when engine is restarted. (→ Page 35)
3. Contact Service.

204 – SD Level Lube Oil
Lube oil level sensor signal error
Lube oil level sensor faulty. 1. Check sensor and wiring, replace as necessary (→ Page 181).
3. Contact Service.
205 – SD T-Coolant Intercooler

Coolant temperature sensor signal error
Coolant pressure sensor of 1. Check sensor and wiring (B26), replace as necessary
intercooler faulty. (→ Page 181).
3. Contact Service.
206 – SD T-Exhaust A
Signal error, exhaust temperature sensor on A-side
Exhaust temperature sensor on 1. Check sensor and wiring (B4.21), replace as necessary
A-side faulty. (→ Page 181).
3. Contact Service.
207 – SD T-Exhaust B
Signal error, exhaust temperature sensor on B-side
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Exhaust temperature sensor on 1. Check sensor and wiring (B4.22), replace as necessary
B-side faulty. (→ Page 181).
3. Contact Service.

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

Lube oil pressure sensor signal error
Lube oil pressure sensor faulty. 1. Check sensor and wiring (B5), replace as necessary
3. Contact Service.
212 – SD P-Coolant
Coolant pressure sensor signal error
Coolant pressure sensor faulty. 1. Check sensor and wiring (B16), replace as necessary
3. Contact Service.
213 – SD P-Coolant Intercooler

Intercooler coolant pressure sensor signal error
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Intercooler coolant pressure 1. Check sensor and wiring (B43), replace as necessary
sensor faulty. (→ Page 181).
3. Contact Service.

214 – SD P-Crankcase
Crankcase pressure sensor signal error
Crankcase pressure sensor 1. Check sensor and wiring (B50), replace as necessary
3. Contact Service.
215 – SD P-HD
Rail pressure sensor signal error
Yellow alarm - high-pressure regulator emergency operation
Rail pressure sensor faulty. ==> 1. Check sensor and wiring (B48), replace as necessary
High pressure regulator (→ Page 181).
emergency operation mode. 2. Fault is rectified when engine is restarted (→ Page 35).
Short circuit or wire break. 3. Contact Service.
216 – SD T-Lube Oil

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

Intake air temperature sensor signal error
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Intake air temperature sensor 1. Check sensor and wiring (B3), replace as necessary
3. Contact Service.

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

Lube oil pressure differential sensor signal error
Lube oil differential pressure 1. Check sensor and wiring (F25), replace as necessary
sensor faulty. (→ Page 181).
3. Contact Service.
222 – SD Level Leak-Off Fuel

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

Intercooler coolant level sensor signal error
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Intercooler coolant level sensor 1. Check sensor and wiring (F57), replace as necessary
3. Contact Service.

227 – SD Oil Pressure Upstream of Filter
Lube oil pressure sensor upstream of filter, signal error
Lube oil pressure sensor 1. Check sensor and wiring (B5.3), replace as necessary
upstream of filter faulty. (→ Page 181).
3. Contact Service.
228 – SD P-Fuel before Filter

Fuel pressure sensor signal error
Fuel pressure sensor faulty. 1. Check sensor and wiring (B5.3), replace as necessary
3. Contact Service.
229 – AL Stop Camshaft Sensor Defect

Stop camshaft sensor signal error
Camshaft sensor faulty (and a 1. Check sensor and wiring to connector B1, replace as necessary
prior camshaft sensor fault in the (→ Page 181).
same operating cycle). 2. Fault is rectified when engine is restarted (→ Page 35).
3. Contact Service.
230 – SD Crankshaft Speed

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

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

Primary turbocharger speed sensor signal error
Speed sensor of primary 1. Check sensor and wiring (B44.1), replace as necessary
turbocharger faulty. (→ Page 181).
3. Contact Service.
233 – SD Charger 2 Speed

Secondary turbocharger speed sensor signal error
Speed sensor of secondary 1. Check sensor and wiring (B44.2), replace as necessary
turbocharger faulty. (→ Page 181).
3. Contact Service.
239 – SD P-Diff Fuel

Differential pressure sensor for fuel signal error (only occurs with SD alarm "fuel before filter" or "fuel
after filter")
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Fuel differential pressure sensor u Observe additional messages.
faulty.

240 – SD P-Fuel
Fuel pressure sensor signal error
Fuel pressure sensor faulty. 1. Check sensor and wiring (B34), replace as necessary
3. Contact Service.
245 – SD ECU Supply Voltage

Engine governor supply voltage signal error
Internal ECU fault. Electronics 1. Replace engine governor.
266 – SD Speed Setting

Speed setting signal error
Analog speed setpoint incorrect 1. Check speed setting transmitter and wiring, replace as
Short circuit or wire break. necessary (→ Page 181).
3. Contact Service.
268 – SD Skidding Analog Value

Skid signal error
Analog skidding signal faulty. 1. Check sensor and wiring, replace as necessary (→ Page 181).
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3. Contact Service.

269 – SD Load P. Analog Filt.
Load pulse analog signal faulty
The filtered analog signal of load 1. Check wiring, replace as necessary (→ Page 181).
pulse is not present. 2. Fault is rectified when engine is restarted (→ Page 35).
270 – SD Frequency Input

Frequency input signal error
Frequency input faulty. 1. Check wiring (→ Page 181).
Short circuit or wire break. 2. Check speed transmitter setpoint.
3. Contact Service.
321 – AL Wiring Cylinder A1

Wiring faulty, cylinder A1
Yellow alarm - misfiring
Short circuit fault in injector 1. Check injector solenoid valve, replace injector if required
wiring, cylinder A1. (→ Page 120).
3. Contact Service.

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3. Contact Service.

3. Contact Service.

3. Contact Service.

3. Contact Service.

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3. Contact Service.

3. Contact Service.

3. Contact Service.

3. Contact Service.

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3. Contact Service.

331 – AL Wiring Cylinder B1
Wiring faulty, cylinder B1
wiring, cylinder B1. (→ Page 120).
3. Contact Service.

3. Contact Service.

3. Contact Service.

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3. Contact Service.

3. Contact Service.

3. Contact Service.

3. Contact Service.

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3. Contact Service.

3. Contact Service.

3. Contact Service.
341 – AL Open Load Cylinder A1

Injector wiring fault, cylinder A1
Disruption fault in injector wiring, 1. Check injector wiring for disruption.
cylinder A1. 2. Rule out any disruption in injector solenoid valve, replace
injector if required (→ Page 120).
3. Fault rectification after each working cycle.
4. Contact Service.

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4. Contact Service.

4. Contact Service.

4. Contact Service.

4. Contact Service.

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4. Contact Service.

4. Contact Service.

4. Contact Service.

4. Contact Service.

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4. Contact Service.

351 – AL Open Load Cylinder B1
Injector wiring fault, cylinder B1
cylinder B1. 2. Rule out any disruption in injector solenoid valve, replace
4. Contact Service.

4. Contact Service.

4. Contact Service.

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4. Contact Service.

4. Contact Service.

4. Contact Service.

4. Contact Service.

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4. Contact Service.

4. Contact Service.

4. Contact Service.
361 – AL Injector Output Stage Low

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

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Internal electronics fault.

Red alarm - engine shutdown possible
2. Replace engine governor if required.
5. Contact Service.

363 – AL Stop Injector Output Stage
Internal electronics fault.
2. Replace engine governor.
5. Contact Service.
365 – AL Stop SV Ground Wiring

Injector wiring faulty
Red alarm - engine shutdown via protection module possible
Short circuit of injector positive 1. Check wiring (→ Page 181).
connection to ground of one or 2. Engine restart (→ Page 35).
more injectors. 3. Replace wiring harness if necessary (→ Contact Service).
Short circuit of negative injector
connection or of one or more
injectors to ground.
381 – AL Wiring TOP 1

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

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(TOP 2).

(TOP 3).

(TOP 4).
390 – AL MCR Exceeded

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

Wiring faulty. 1. Check wiring (→ Page 181).
No resistance over switch. 2. Check target device input.
3. Contact Service.
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3. Contact Service.

3. Contact Service.

3. Contact Service.

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3. Contact Service.

3. Contact Service.

3. Contact Service.

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

Open circuit at input for emergency stop.
Wiring faulty or no resistance 1. Check wiring (→ Page 181).
over switch. 2. Check target device input.
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3. Contact Service.

410 – LO U-PDU
Injector voltage too low (limit value 1)
Cable damage or faulty power 1. Check wiring (→ Page 181).
supply. 2. Check power supply.
3. Contact Service.
411 – LOLO U-PDU

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

Injector voltage too high (limit value 2)
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4. Contact Service.

414 – HI Water Level Fuel Prefilter
Water level in fuel prefilter too high (limit value 1)
Water content in fuel too high. u Drain fuel prefilter.
Water ingress in fuel tank.
415 – LO P-Coolant Intercooler

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

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

Fuel prefilter water level sensor signal error
Water level sensor of fuel 1. Check sensor and wiring, replace as necessary (→ Page 181).
prefilter is faulty. 2. Contact Service.
Short circuit or wire break.
438 – LO P-Fuel 2 (Common Rail)

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Yellow alarm - DBR fuel limitation
HP fuel control block faulty or u Contact Service.
leakage in HP fuel system.

439 – HI P-Fuel 2 (Common Rail)
Red alarm - DBR fuel limitation, start of injection readjusted towards late
HP fuel block jamming or HP fuel u Contact Service.
control block wiring faulty.
441 – AL System 2 Leaky

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

Ambient air pressure sensor signal error
Ambient air pressure sensor u Replace engine governor.
faulty.
446 – SD P-HD2
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Rail pressure sensor signal error
Yellow alarm - high-pressure regulator emergency operation
Rail pressure sensor faulty. 1. Check sensor and wiring (B48), replace as necessary
2. Contact Service.

448 – HI P-Charge Air
Charge-air pressure too high (limit value 1)
Fault at turbine bypass flap. u Contact Service.
449 – SS P-Charge Air

Charge-air pressure too high (limit value 2)
Fault at turbine bypass flap. u Contact Service.
450 – SD Injection Signal in Percent

Start/end torque signal error
Input signal for start/end torque 1. Check signal transmitter and wiring, replace as necessary
faulty. (→ Page 181)
3. Contact Service.
454 – SS Power Limitation Active

Derating has been activated.
Red alarm - derating has been activated.
Engine operation outside u Observe additional messages.
standard limit values.
This message can be caused by
the following: Intake depression,
exhaust back pressure, charge-
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air coolant temperature or intake

air temperature outside the limit
values

466 – SD T-AUX 2
Signal fault, temperature Aux 2
Analog input for Aux 2 1. Check temperature sensor and wiring, replace as necessary
temperature faulty. (→ Page 181).
468 – SD T-AUX 1
Signal fault, temperature Aux 1
Analog input for Aux 2 1.
temperature faulty. 2.
470 – SD T-ECU
Engine governor, temperature, signal error
Temperature sensor for engine 1. Check sensor and wiring, replace as necessary (→ Page 181).
governor faulty. 2. Engine restart (→ Page 35).
471 – SD Suction Restrictor

Signal error suction restrictor
Actuation of suction restrictor 1. Check sensor and wiring, replace as necessary (→ Page 181).
TIM-ID: 0000029153 - 006

472 – AL Stop SD
Engine stops
Engine stop, since all shutdown 1. Check wiring (→ Page 181).
channels detect "sensor defect". 2. Contact Service.
474 – AL Wiring FO
Wiring fault at FO
Broken line or short circuit at FO 1. Check wiring (→ Page 181).
channel. 2. Contact Service.
475 – AL CR Engine Shutdown Trigger

Crash recorder was triggered by engine shutdown.
Crash recorder was triggered by u Contact Service.
engine shutdown.
476 – AL Crash Rec. Init. Error

Initialization error of crash recorder.
Initialization error of crash u Contact Service.
recorder.
478 – AL Yellow Summary Alarm (Plant)

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Yellow summary alarm from the system

Various causes possible. u Observe additional messages.

479 – AL Red Summary Alarm (Plant)
Red summary alarm from system
Red alarm
Various causes possible. u Observe additional messages.
480 – AL Ext. Engine Protection

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

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

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

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

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

Wiring faulty, connection of starter 1 at POM
Missing consumer. u Check connection between POM and starter.
Short circuit or wire break
501 – AL Wiring POM Starter 2

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

Open circuit at battery-charging generator connection to POM
Wiring faulty or no resistance u Check connection between POM and battery-charging
over switch. generator.
503 – AL No Battery Charge

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No battery charge
Battery is not charged by u Check battery-charging generator and wiring (→ Page 181).
battery-charging generator.

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

The battery voltage is too low for the starting process
Battery flat or wiring defective. u Check starter battery and wiring (→ Page 181).
507 – AL POM Error

A general POM fault occurred
Defect in POM. u Replace POM.
508 – AL Incorrect POM-ID

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

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Override was activated.
Override suppresses other u Disable override key again.
alarms.

514 – Flash memory write error
Value was not transferred to flash memory
Flash memory faulty. u Contact Service.
515 – AL Starter Not Engaged

Yellow alarm – start termination possible
Starter on POM could not be 1. Repeated start attempt.
engaged. 2. Check POM, starter and wiring (→ Page 181).
3. Contact Service.
519 – Oil level calibration error

Error writing calibration value into flash or SD of level sensor.
Oil level sensor or wiring faulty. 1. Check sensor and wiring, replace as necessary (→ Page 181).
2. Contact Service.
536 – AL Wiring PWM_CM1

Wiring problem at PWM_CM1 channel
Cable break or short circuit on 1. Check wiring to connected device or check connected device
channel PWM_CM1. itself (actuator/sensor) and replace if necessary (→ Page 181).
2. Contact Service.
549 – AL Voltage interruption

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Alarm from the emergency stop counter function

Engine governor operating u Instruct operators to switch off the power supply only once the
voltage disconnected with engine has come to a standstill.
engine still running. This may
result in overpressure in the
high-pressure system, which can
damage the engine.

Broken cable or short circuit at 1. Check wiring to connected device or check connected device
2. Contact Service.
576 – AL ESCM Override

Engine overload.
Violation of corrected MCR or u Reduce power.
DBR/MCR curve.
577 – SD T-Lube Oil Pan

Oil pan temperature sensor signal error
Oil pan temperature sensor u Check sensor and wiring, replace as necessary (→ Page 181).
faulty.

2. Contact Service.
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582 – AL Emergency Stop Failed
Emergency stop command was not executed
Flashing pre-alarm and alarm
Engine speed does not come to u Contact Service.
a stop within a parameterizable
time.
586 – LO P-Oil Replenishment Pump

Oil pressure in replenishment pump too low (limit value 1)
Insufficient oil in oil refill tank. 1. Check oil level, top up as necessary (→ Page 146).
2. Contact Service.

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

Replenishment pump oil pressure sensor signal error
Pressure sensor faulty. 1. Check sensor and wiring, replace as necessary (→ Page 181).
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593 – AL T-Lube Oil, Oil Pan Too Low

Lube oil temperature in oil pan too low.
Preheating time not long 1. Extend preheating period.
enough. 2. Contact Service.

594 – AL L1 PRV Faulty
Yellow alarm – warning pressure relief valve, first rail

Red alarm – pressure relief valve, first rail.
596 – AL Test Parameter Record

The parameter set is used for u Contact Service.
trials. The alarm remains set
until a series parameter set is
loaded.

2. Contact Service.

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Yellow alarm – warning pressure relief valve, second rail.

HP fuel block jamming or HP fuel 1. Check wiring and HP fuel control block (→ Page 181).

Red alarm breather valve, second rail.
HP fuel block jamming or HP fuel 1. Check wiring and HP fuel control block (→ Page 181).
600 – SD T-Exhaust A+B

Exhaust temperature sensor signal error, A- and B-side
Exhaust temperature sensor on 1. Check sensor and wiring, replace as necessary (→ Page 181).
A- and B-side faulty. 2. Contact Service.
601 – SD ETC1+ETC2
ETC speed sensor 1 and 2 signal error
ETC speed sensors 1 and 2 1. Check sensor and wiring, replace as necessary (→ Page 181).
602 – AL CAN Engine Start Lock

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

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ECU does not detect monitored CAN bus device.
A node has failed on both CANs. 1. Check wiring and power supply of plant (→ Page 181).
Short circuit or wire break. 2. Acknowledge alarm.
4. Contact Service.

2. Contact Service.

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

Wiring faulty at HP fuel control block 1
Cable break or short circuit on 1. Check wiring (→ Page 181).
PWM channel, HP fuel control 2. Contact Service.
block 1.
611 – AL Wiring HP Fuel Control Block 2

Wiring faulty at HP fuel control block 2
PWM channel, HP fuel control 2. Contact Service.
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block 2.

612 – AL Wiring Pressure Regulating Valve 1
Wiring faulty, pressure regulating valve 1
PWM channel, pressure 2. Contact Service.
regulating valve 1.
613 – AL Wiring Pressure Regulating Valve 2

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

Fuel prefilter differential pressure too high
Fuel prefilter not operating 1. Replace fuel prefilter.
correctly. 2. Contact Service.
615 – AL EIL Protection

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

ECU cannot detect EIL
Incorrect or manipulated EIL. 1. Replace EIL.
2. Contact Service.

625 – SD P-Fuel Upstream of Add. Filter
Fuel pressure sensor before additional filter signal error
Analog input signal for fuel 1. Check pressure transmitter and wiring, replace as necessary
pressure before additional filter (→ Page 181).
faulty. 2. Fault is rectified when engine is restarted (→ Page 35).
Short circuit or wire break. 3. Contact Service

2. Contact Service.

2. Contact Service.

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2. Contact Service.

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

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

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

Dispenser flap faulty
Actuator fault at dispenser flap or 1. Replace actuator or flap.
flap mechanical system 2. Contact Service.
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defective.

633 – SD P-Ambient Air (HDT2800)
Moisture sensor signal error (TRICAN HDT2800)
Moisture sensor (TRICAN 1. Check sensor and wiring, replace as necessary (→ Page 181).
HDT2800) defective. 2. Contact Service.
634 – SD T0-Ambient Air (HDT2800)

635 – SD Air Humidity (HDT2800)

636 – SD Level Lube Oil J1939

Oil level sensor J1939 signal error
Oil level sensor J1939 faulty. 1. Check sensor and wiring, replace as necessary (→ Page 181).
2. Contact Service.
637 – SD T-Lube Oil, Oil Pan J1939

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Oil temperature sensor J1939 signal error
Oil temperature sensor J1939 1. Check sensor and wiring, replace as necessary (→ Page 181)
defective. 2. Contact Service.

640 – SD Smart NOx Oxidation Factor O2
Signal error, Smart NOx Sensor (Oxidation Factor O2)
Smart NOx sensor (oxidation 1. Check sensor and wiring, replace as necessary (→ Page 181).
factor O2) faulty. 2. Contact Service.
643 – SD P-Fuel Upstr.o.F.

Fuel pressure sensor before optional filter signal error
Fuel pressure sensor before 1. Check sensor and wiring (B34.3), replace as necessary
optional filter faulty. (→ Page 181).
3. Contact Service.
644 – AL L1 P-Fuel Upstr.o.F.

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

Fuel supply pressure before optional filter too low (limit value 2)
Leaking or obstructed fuel lines u Check filter, fuel low-pressure side
or fuel tank empty.
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647 – SD P-Exhaust Lambda
Exhaust gas sensor near lambda sensor signal error
Exhaust gas sensor near lambda 1. Check sensor and wiring (B91), replace as necessary
sensor faulty (→ Page 181).
3. Contact Service.
648 – SD P-Charge Air B

Charge-air pressure sensor, B-side, signal error
Charge-air pressure sensor on 1. Check sensor and wiring (B10.11), replace as necessary
B-side faulty (→ Page 181).
662 – SD Smart NOx Heating Element

Smart NOx sensor (heating element) signal error
Smart NOx heating element 1. Check sensor and wiring, replace as necessary (→ Page 181).
faulty 2. Contact Service.
663 – SD Smart NOx Concentration

Smart NOx sensor (NOx concentration) signal error
Smart NOx sensor (NOx 1. Check sensor and wiring, replace as necessary (→ Page 181).
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concentration) faulty 2. Contact Service.


727 – AL L1 Delta T-NT Intercooler
T-max. coolant intercooler has exceeded L1
3. Contact Service.
728 – AL L2 Delta T-NT Intercooler

T-max. coolant intercooler has exceeded L2
Red alarm
3. Contact Service.
745 – AL Emission Fault

Emission fault
NOx regulator not active. 1. Delete all other fault codes (→ Page 181).
Lambda regulator not active. 2. Check Lambda sensor and wiring (→ Page 181).
Charge-air regulator not active. 3. Check charge-air pressure sensor and wiring (→ Page 181).
Lambda regulator at stop. 4. Check NOx sensor and wiring (→ Page 181).
Charge-air pressure regulator at 5. Check turbine bypass, EGR and dispenser cylinder flaps
stop. (→ Page 143).
NOx regulator at stop. 6. Contact Service.
747 – SD P-Intake Air Filter Difference

ZKP-Number: 2-0277.920
Signal error sensor differential pressure intake air
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Sensor faulty. 1. Check sensors and wiring, replace as necessary (→ Page 181).

754 – SD Bosch LSU Lambda Sensor
Signal fault, Lambda sensor
Bosch Lambda sensor faulty. 1. Check sensors and wiring, replace as necessary (→ Page 181).
757 – AL Lim T-Coolant LT Fan

Temperature difference between LT coolant temperature and intake air temperature exceeds limit value
Sensor faulty. 1. Check sensors and wiring (→ Page 181).
Short circuit or wire break. 2. Check radiator.
Radiator blocked. 3. Check fan.
Fan faulty. 4. Cooler – Check
Coolant flow rate too low. 5. Check coolant pump.
6. Contact Service.
763 – AL OL EASF Limit Switch B

Wiring error in monitoring line of emergency-air shutoff flap B
Short circuit or wire break. 1. Check wiring (→ Page 181).
2. Contact Service.
764 – AL EASF B to A Open

Emergency-air shutoff flap B closed, but emergency-air shutoff flap A remained open
Flap A stuck. 1. Check flap A (→ Page 140).
Flap A was not energized. 2. Check wiring (→ Page 181).
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765 – AL OL EASF Limit Switch A

Wiring error in monitoring line of emergency-air shutoff flap A
Short circuit or wire break. 1. Check wiring (→ Page 181).
2. Contact Service.

766 – AL EASF A to B Open
Emergency-air shutoff flap A closed, but emergency-air shutoff flap B remained open
Flap B stuck. u Check flap B (→ Page 140).
Flap B was not energized.
Check wiring (→ Page 181).
Contact Service.
767 – AL EASF Closed

Emergency-air shutoff flaps A and B closed
Status indication only. u Check alarms 763, 764, 765, 766 and take any necessary
action.
778 – AL EASF Not Closed

Emergency-air shutoff flaps A and B not closed
Flaps A and B stuck. 1. Check flap B (→ Page 140).
Flaps A and B were not 2. Check wiring (→ Page 181).
energized. 3. Contact Service.
833 – AL Emission Warning

Emission warning
NOx regulator not active. 1. Delete all other fault codes (→ Page 181).
Lambda regulator not active. 2. Check Lambda sensor and wiring (→ Page 181).
Charge-air regulator not active. 3. Check charge-air pressure sensor and wiring (→ Page 181).
Lambda regulator at stop. 4. Check NOx sensor and wiring (→ Page 181).
Charge-air pressure regulator at 5. Check turbine bypass, EGR and dispenser cylinder flaps
stop. (→ Page 143).
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NOx regulator at stop. 6. Contact Service.

834 – AL Gas Line Warning
Gas line warning
Lambda sensor faulty. 1. Delete all other fault codes.
Lambda regulator at stop. 2. Check sensor and wiring (→ Page 181).
3. Contact Service.
835 – AL Gas Line Fault

Gas line fault
Charge-air pressure sensor 1. Delete all other fault codes.
faulty. 2. Check sensor and wiring (→ Page 181).
Turbine bypass actuator faulty. 3. Contact Service.
EGR flap actuator faulty.
Dispenser cylinder flap actuator
faulty.
Charge-air pressure regulator at
stop.
839 – AL EASF A Not Closed by ECU.

Emergency-air shutoff flap A closed without actuation
Emergency-air shutoff flap A was 1. Check flap A (→ Page 140).
closed manually. 2. Check wiring (→ Page 181).
840 – AL EASF B Not Closed by ECU.

Emergency-air shutoff flap B closed without actuation
Emergency-air shutoff flap B was 1. Check flap B (→ Page 140).
closed manually. 2. Check wiring (→ Page 181).
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4.

7 Task Description
7.1 Engine
7.1.1 Engine – Barring manually
Preconditions

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

installation)
1. Remove cover from flywheel housing.
2. Engage barring device (2) in ring gear and
install on flywheel housing.
• Use barring device F6787910.
3. Set ratchet (1) onto barring device (2).
4. Rotate crankshaft in engine direction of ro‐
tation. Apart from the normal compression
resistance, there should be no resistance.
Result: If the resistance exceeds the normal com‐
pression resistance, contact Service.
5. For barring device removal follow reverse
sequence of working steps.
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MS150096/01E 2012-08 | Task Description | 107

7.1.2 Engine – Barring with starting system
DANGER
• Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
Engine – Barring with starting system

1. Release latch of connector X3.
Note: Seal unused connectors with the supplied protective cap.
2. Remove connector from engine governor.
3. Bar engine in unloaded condition: Press START button.
4. Let the crankshaft rotate until oil pressure is indicated.
5. Engine start is automatically interrupted when specified starting period is expired. If necessary, restart
the engine after approx. 20 seconds.
6. Connect connector X3 to engine governor and latch in position.
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108 | Task Description | MS150096/01E 2012-08

7.1.3 Engine – Test run
DANGER
WARNING
Engine – Test run

1. Start engine (→ Page 35).
2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 34).
4. Stop engine (→ Page 36).
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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 118).
2. Remove injector (→ Page 121).
Positioning crankshaft at BDC

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

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

1. Compile endoscopy report using the table.
2. Use technical terms for description of the liner surface (→ Page 112).
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 121).
2. Install cylinder head cover (→ Page 118).
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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 exami‐
nation report.
Findings Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐
ucts, 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/ex‐
haust) along the transverse engine axis.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pat‐
tern is still visible. Smoothened areas appear brighter and more brilliant than the
surrounding running surface.
Bright area Bright areas are on the running surface and show local removal of the honing
pattern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐
perature differences around the liner. It appears rather darker within the honed
structure in contrast to the bright metallic running surface. The honing pattern is
undisturbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in
spots the overlap (open) position. They are clearly visible due to the dark color of the
honing groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear dis‐
coloration 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.
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Findings Action
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
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
replaced.
Seizure marks, scuff‐ Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora‐
tion. Severe, visible scoring.
Replace liner.
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 fur‐
ther operation of the engine.
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7.3 Valve Drive
7.3.1 Valve gear – Lubrication
Preconditions

Engine oil
Valve gear – Lubrication

1. Remove cylinder head covers
(→ Page 118).
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 118).
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7.3.2 Valve clearance – Check and adjustment
Preconditions
☑ Coolant temperature max. 40 °C.
☑ Valves are closed.

Feeler gauge Y20098771 1
Allen key F30002815 1
Socket wrench, 24 mm F30039526 1
Engine oil
Preparatory steps
2. Install barring device (→ Page 107).
3. The OT mark (1) (if fitted) on the flywheel
must not be used for reference.
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4. Rotate crankshaft with barring device in en‐
gine direction of rotation until "OT-A1" mark
and pointer are aligned.
Diagram for 12V engines (two

crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
Checking valve clearance at two crankshaft positions

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

Adjusting valve clearance
1. Release locknut (1).
2. Insert feeler gauge (3) between valve
bridge and rocker arm.
3. Using Allen key, set adjusting screw (2) so
that the specified valve clearance is provid‐
ed.
4. Feeler gauge (3) must just pass through the
gap.
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 107).
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7.3.3 Cylinder head cover – Removal and installation
Preconditions

Grease (Kluthe Hakuform 30-10/emulsifier) X00058061
O-ring (→ Spare Parts Catalog)
Removing cylinder head cover

1. Clean very dirty cylinder head covers (1)
prior to removal.
2. Unscrew screws (3,4) and take off with
washers (2,5).
3. Remove 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 if necessary.
3. Coat O-ring (6) with grease.
4. Place cylinder head cover (1) with O-ring (6) onto cylinder head (7).
5. Install cylinder head cover (1) with screws (3,4) and washers (2,5).
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7.4 Injection Pump / HP Pump
7.4.1 HP pump – Filling with engine oil
Preconditions

Engine oil
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Do not smoke.
WARNING
Oils/oil vapors are combustible.
Risk of fire!
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.
CAUTION
Fuel system high-pressure pump not filled with engine oil.
Damage to components, major material damage!
• Make sure that the high-pressure fuel pump is filled with engine oil before installation or initial
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. Insert plug screw (1).
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7.5 Injection Valve / Injector
7.5.1 Injector – Replacement

Injector (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new injector (→ Page 121).
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7.5.2 Injector – Removal and installation
Preconditions

Installation/removal device F6789889 1
Milling cutter F30452739 1
Torque wrench, 0.5-5 Nm 0015384230 1
Assembly paste (Optimoly Paste White T) 40477 1
Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1
Engine oil
O-ring (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Preparatory steps
1. Shut off fuel supply to engine.
Removing injector
1. Disconnect cable connector on injector.
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2. Unscrew union nuts (2,5) and remove HP
line (3) from rail (4) and cylinder head.
Note: The injector accumulator will be emptied
when removing the adapter.
3. Remove adapter (1).
4. Remove screw (1).

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

11. Coat thread and sealing cone of adapter (1)
with engine oil.
12. Install adapter (1) and use torque wrench to tighten to the specified initial tightening torque.
Adapter Preload torque (Engine oil) 5 Nm to 10 Nm
13. Tighten screw on hold-down clamp (→ Step 10) with torque wrench to specified tightening torque.
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Screw M12 Tightening torque (Engine oil) 100 Nm + 10 Nm
14. Tighten adapter (1) with torque wrench to the specified tightening torque.
Adapter Tightening torque (Engine oil) 100 Nm + 10 Nm
Note: Ensure special cleanness.
15. Coat thread and sealing cone of HP line (3) with engine oil.

16. Use torque wrench to tighten union nuts (2,5) on HP line (3) to specified tightening torque. Tightening
sequence:
1 Nut on adapter (2)
2 Nut on rail (5)
Union nut / thrust Tightening torque (Engine oil) 40 Nm + 5 Nm
screw
17. Fit cable connector onto injector.
Note: The CDC parameters must be reset, other‐
wise the emission certification of the engine
is no longer applicable.
18. Reset CDC parameters (→ Page 182).
Final steps
2. Open fuel supply to engine.
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7.6 Fuel System
7.6.1 Fuel system – Venting
Preconditions

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

1. Open threaded 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 at the threaded
vent plug (1).
4. Close threaded vent plug (1).
5. Screw in handle by turning it clockwise.
6. Verify that fuel priming pump (2) is locked:
Handle must be tightened.
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7.7 Fuel Filter
7.7.1 Fuel filter – Replacement
Preconditions

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

1. Remove easy-change filter (2) using filter
wrench.
2. Clean sealing surface on filter head (1).
3. Coat the seal on the easy-change filter (2)
lightly with engine oil (arrow).
4. Screw on easy-change filter (2) by hand un‐
til the seal connects and tighten manually.
5. Replace other easy-change filters in the
same way.
6. Vent fuel system (→ Page 125).
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7.7.2 Auxiliary fuel filter – Replacement
Preconditions
☑ Engine shut down and starting disabled.

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

1. Remove easy-change filter (2) with filter
wrench.
2. Clean sealing surface on filter head (1).
3. Coat gasket on easy-change filter (2) slight‐
ly 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 125).
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7.8 Exhaust Turbocharger
7.8.1 Exhaust turbocharger – Turbine housing check

Turbine housing (→ Spare Parts Catalog)
Exhaust turbocharger (low-pressure charger)

u Check turbine housing (→ Page 129).
Exhaust turbocharger (high pressure)

u Check turbine housing (→ Page 134).
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7.8.2 Exhaust turbocharger (LP) – Turbine housing check

Endoscope Y20097353
Engine oil
Assembly paste (Ultra-Therm MTU) 50547 1
Note: Procedure is only described for one LP turbocharger; applies inversely to the other side. Checking of the
turbine housing of the HP exhaust turbocharger requires separate activities (→ Page 134).
Removing heat shield
1. Remove screws (1) and take off with hold‐
er (3) and washers (2).
3. Remove screws (2,4) and take off with heat

shield (1) and washers (3,5).
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Removing exhaust pipe insulation
u Release clamps (1) and remove insula‐
tion (2).
Removing exhaust pipe

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

Note: Mark position of clamp.
1. Unscrew screws (5) and remove from con‐
sole with spacer sleeves (4).
2. Release clamp (2) and take off with sealing
ring (3) and exhaust elbow (1) from turbine
housing.
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Checking turbine housing
1. Check turbine housing from the inside for
cracks.
Note: Cracks are only permissible in the direction
of circumference of the spiral.
2. Cracks larger than max. crack length
(x = 30 mm) or transverse cracks: Replace
turbine housing.
Installing exhaust elbow
1. Install exhaust elbow (1) with clamp (2) and sealing ring (3) on turbine housing and tighten to specified
tightening torque.
Clamp Tightening torque (Assembly paste (Ul‐ 27 Nm + 2 Nm
tra-Therm MTU))
2. Coat screw threads with assembly paste prior to installation.
3. Install screws (5) and spacer sleeves (4) on console and tighten to specified tightening torque.
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Screws Tightening torque (Assembly paste (Ul‐ 42 Nm + 4 Nm
tra-Therm MTU))

Installing exhaust pipe
u Install exhaust pipe bellows (1) with
clamp (2) and sealing ring (3) on turbine
housing.
Installing exhaust pipe insulation

u Install insulation (2) on exhaust pipe and
secure with clamps (1).
Installing heat shield

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1. Install heat shield (1) with washers (3,5) and screws (2,4) and tighten to specified tightening torque.
Screws Tightening torque (Engine oil) 42 Nm + 4 Nm
2. Install holder (6) with washers (5) and
screws (4) and tighten.
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7.8.3 Exhaust turbocharger (HP) – Turbine housing check

Endoscope Y20097353
Engine oil
Assembly paste (Ultra-Therm MTU) 50547 1
Note: The procedure is only described for the exhaust turbocharger (HP). Checking of the exhaust turbocharg‐
er turbine housing (LP) requires separate activities (→ Page 129).
Removing heat shield
2. Remove screws (2) and take off with heat

shield (1) and washers (3).
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Removing exhaust pipe insulation
tion (2).
Removing exhaust pipe

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

pipe bellows
tion (2).
TIM-ID: 0000026621 - 002

Removing exhaust pipe bellows
Note: Mark position of clamp.
u Release clamp (2) and take off with sealing
ring (1) and exhaust pipe bellows (3) from
turbine housing.
Checking turbine housing

1. Check turbine housing from the inside for
cracks.
Note: Cracks are only permissible in the direction
of circumference of the spiral.
2. Cracks larger than max. crack length
(x = 30 mm) or transverse cracks: Replace
turbine housing.
Installing exhaust pipe bellows

u Install exhaust pipe bellows (3) with
clamp (2) and sealing ring (1) on turbine
housing.
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Installing insulation of exhaust pipe
bellows
u Install insulation (2) on exhaust pipe bel‐
lows and secure with clamps (1).
Installing exhaust pipe

u Install exhaust pipe (3) with clamp (1) and
sealing ring (2) on turbine housing ().
Installing exhaust pipe insulation

u Install insulation (2) on exhaust pipe and
secure with clamps (1).
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Installing heat shield
1. Install heat shield (1) with washers (3) and screws (2) and tighten to specified tightening torque.
Screws Tightening torque (Engine oil) 42 Nm + 4 Nm
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7.9 Charge-Air Cooling
7.9.1 Intercooler – Leak check
DANGER
WARNING
WARNING
Compressed air
Risk of injury!
Intercooler – Leak check

u With the engine at standstill, open drain
plugs in charge-air elbows on left and right
engines sides on driving end (arrowed) and
check for coolant discharge.
Result: If a large amount of coolant is discharged,
the intercooler is leaking. (→ Contact Serv‐
ice).
Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 121).
2. Bar engine manually (→ Page 107).
3. Bar engine with starting system to blow out combustion chambers (→ Page 108).
TIM-ID: 0000018644 - 003
4. Install injectors (→ Page 121).

7.10 Air Intake
7.10.1 Emergency air-shutoff flaps – Functional check with electric actuation
DANGER
WARNING
Air flaps close abruptly.
Risk of injury!
• Before actuating, ensure that nobody is in the danger zone.
WARNING
Note: In order not to compromise the engine, reduce the overspeed limit value for the functional check.
Emergency air-shutoff flaps –
Functional check with electric
actuation
2. Activate the appropriate function to trigger
emergency air-shutoff flaps (depending on
installation), e.g. by carrying out an over‐
speed test at a reduced overspeed value.
Check the following items:
• The emergency air-shutoff flaps must
close as soon as the set point is
reached.
• Emergency engine stop must be initiat‐
ed.
3. Open the emergency air-shutoff flaps man‐
ually after completion of test so that the lev‐
ers (1) are in position A.
4. Note fault messages.
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7.11 Exhaust Gas Recirculation
7.11.1 Exhaust flaps – Overview
1 EGR shutoff flap 2 Donor cylinder flap

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1 Bypass flap
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7.11.2 Exhaust flaps – Checking operation of actuators
Preconditions
☑ Operating voltage is not applied.
WARNING
Component is hot.
Risk of burning!
• Wear protective gloves.
Checking operation of actuators – mechanically

1. For installation position of exhaust flaps, refer to overview (→ Page 141).
2. Remove guard plates of exhaust flaps.
3. Check operability and ease of movement of
exhaust flaps and control linkage by moving
the assembly at the points (arrows) and
make sure that there is no excessive play.
Result: If exhaust flap is sluggish or has too much
play: (→ Contact Service).
4. The internal spring should pull the flap to
the fail-safe position.
• Fail-safe position for bypass flap and
EGR shutoff flap:
• Fail-safe position for donor cylinder flap:
closed.
Result: Bypass flap / EGR shutoff flap are closed or
shutoff flap is open: (→ Contact Service).
Checking operation of actuators – electrically

1. For installation position of exhaust flaps, refer to overview (→ Page 141).
2. Switch on ECU.
3. Test run of flap system is performed.
Result: Exhaust flaps do not move: (→ Contact Service).
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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 181).
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7.13 Lube Oil System, Lube Oil Circuit
7.13.1 Engine oil – Level check at sight glass
Preconditions
Engine oil – Level check at sight

glass
1. Engine oil level (2) may be checked in ad‐
vance at sight glass (1).
2. Proper engine oil level check must always
be carried out using the oil dipstick
(→ Page 146).
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7.13.2 Engine oil – Level check with oil dipstick
Checking oil level prior to engine

start
1. Pull out dipstick from guide tube and wipe
it.
2. Insert dipstick into guide tube up to the
stop, pull out after approx. 10 seconds.
Check oil level on oil dipstick side marked
"5 Min. after Stop".
Note: After extended out-of-service periods, the
oil level may be up to 2 cm above the
"max." mark. This might be caused by en‐
gine oil flowing from oil filter and heat ex‐
changer back into the oil pan.
3. The oil level must reach the "max." mark or
exceed it by up to 2 cm.
4. If necessary, top up to "max." mark
(→ Page 147).
5. Insert oil dipstick into guide tube up to the
stop.
Checking engine oil level with the engine running

1. After the engine has run for approx. 10 minutes at a constant speed of 600 to 900 rpm, pull out oil dip‐
stick from guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, pull out after approx. 10 seconds. Check oil level on the
dipstick side marked "IDLE".
3. Oil level must not be lower than the "min" mark.
4. If necessary, top up to "max." mark (→ Page 147).
Checking oil level after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube up to the stop, pull out after approx. 10 seconds. Check oil level on oil
dipstick side marked "5 Min. after Stop".
3. Oil level must be between “min.” and “max.” marks.
4. If necessary, top up to "max." mark (→ Page 147).
5. Insert oil dipstick into guide tube up to the stop. TIM-ID: 0000026776 - 005

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

Ratchet adapter F30027341 1
Engine oil
Sealing ring (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Avoid contact with skin.
• Do not inhale oil vapor.
Oil change without semirotary hand pump: Draining oil at drain plug(s) on oil pan
1. Provide a suitable container in which to collect the engine oil.
2. Remove drain plug(s) and drain engine oil.
3. Install drain plug(s) with new sealing ring.
Oil change using semirotary hand pump: Engine oil extraction

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

equipment carrier (only with
unscheduled engine oil change)
1. Provide a suitable container in which to col‐
lect the engine oil.
2. Remove drain plug (1) and drain engine oil
TIM-ID: 0000037912 - 002
from engine oil heat exchanger and from

engine oil filter.
3. Remove drain plugs (2,3,4) and drain en‐
gine oil.
4. Replace engine oil filter (→ Page 150).

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

1. Open cover (1) on filler neck (2).
2. Pour oil in at filler neck (2) up to "max."
mark at oil dipstick.
3. Close cover (1) on filler neck (2).
TIM-ID: 0000037912 - 002

7.13.4 Engine oil – Sample extraction and analysis
Preconditions

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

analysis
1. With the engine running at operating tem‐
perature, open screw (1) on flange of centri‐
fugal oil filter by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw (1).
5. Using the equipment and chemicals of the
MTU test kit, examine oil for:
• Dispersing capacity (spot test);
• Water content;
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• Fuel dilution.

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

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

1. When the engine is running at operating
temperature, stop engine and open vent
plug (1) at oil heat exchanger (arrow).
2. Wait 5 minutes until the oil system is vented
and the oil has drained off.
Note: Always use a new sealing ring for the vent plug.
TIM-ID: 0000028834 - 003
3. Install the vent plug (1).


4. Remove oil filter with filter wrench.
5. Clean sealing surface on connecting piece.
Note: Use only oil filters with integrated safety
valve.
6. Check condition of the new oil filter sealing
ring and coat it with engine oil.
7. Screw on and tighten new engine oil filter
by hand.
8. Replace other engine oil filters in the same
way.
9. After each oil change and filter replace‐
ment, bar engine with starting system
(→ Page 108).
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7.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions

Cold cleaner (Hakutex 60) 50602 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
Compressed air
Risk of injury!
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Centrifugal oil filter – Cleaning and
filter sleeve replacement
1. Undo screw (1) and remove.
2. Remove clamp (3) and take off hood (2).
3. Carefully remove rotor (5) from housing.
4. Hold rotor assembly (5) firmly in position
with filter wrench and undo knurled nut (7).
5. Take off rotor cap (8).
6. Remove filter sleeve (9), stiffener plate (10)
and sealing ring (11).
7. Measure thickness of oil residues on filter
sleeve.
8. If maximum layer thickness of oil residue
exceeds 30 mm, shorten maintenance in‐
terval.
9. Remove standpipe (12) from lower rotor
section (13).
10. Wash hood (2), rotor cap (8), stiffener
plate, (10) standpipe (12), rotor lower sec‐
tion (13) and nozzles (14) with cold cleaner
and blow out with compressed air. Do not
use sharp objects for cleaning.
11. Check nozzles (14) for obstructions.
12. Press standpipe (12) onto rotor lower sec‐
tion (13).
13. Insert new filter sleeve (9) with stiffener
plate (10) into rotor cap (8), ensuring that
smooth surface of filter sleeve (9) faces ro‐
tor cap (8).
14. Check sealing ring (11), replace if necessa‐
ry. Coat sealing ring with grease and insert
in groove of rotor cap (8).
15. Place rotor cap (8) onto standpipe (12).
16. Hold rotor assembly (5) firmly in position
with filter wrench and tighten knurled
nut (7).
17. Lubricate bearings of rotor (5) with oil, in‐
sert into housing (6) and check for ease of
movement.
18. Check sealing ring (4), replace if necessary.
Fit sealing ring on housing (6).
19. Fit hood (2).
20. Tighten screw (1) by hand.
21. Install clamp (3) and tighten to specified torque using a torque wrench.
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Clamp Tightening torque 6 Nm + 1 Nm

22. Tighten screw (1) to specified torque using a torque wrench.
Screw Tightening torque 6 Nm + 1 Nm

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

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

remote cooler:
1. Check engine coolant level (coolant must
be visible at marker plate).
2. Top up engine coolant if necessary
(→ Page 159).
3. Check and clean breather valve.
4. Place breather valve on filler neck and
close.
Checking engine coolant level via level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up engine coolant if necessary (→ Page 159).
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7.15.2 Engine coolant – Change

Coolant
Engine coolant – Change

1. Drain engine coolant (→ Page 156).
2. Fill with engine coolant (→ Page 159).
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7.15.3 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide a suitable receptacle to catch the coolant.
2. Switch off preheating unit.
Engine coolant – Draining

1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise 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 the preheating unit
• At the elbow of the engine coolant pump
• At crankcase, left and right sides
If an (optional) air compressor is instal‐
led, at the drain point on crankcase (left
side, free end):
Drain point on crankcase is not accessi‐
ble. Open supply hose at air compressor.
• At the EGR cooler, left and right side
(→ Step 6)
5. Drain coolant at drain point, driving end, left
and right side (arrow pointing downwards).
6. Drain residual coolant at the EGR cooler,
left and right side (arrows pointing up‐
wards).
7. Drain coolant at donor cylinder flap
(→ Page 158).
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Final steps
1. Close all open drain points.
2. Set breather valve onto filler neck and close it.
TIM-ID: 0000030760 - 002

7.15.4 Exhaust flaps – Draining coolant
Preconditions
☑ Operating voltage is not applied.
WARNING
Note: The procedure is described for one exhaust flap only but also applicable to the other exhaust flaps. Over‐
view of exhaust flaps (→ Page 141).
Draining coolant
Note: The respective coolant circuit must be emp‐
tied beforehand:
• Engine coolant – Draining(→ Page 156)
• Charge-air coolant – Drain‐
ing(→ Page 167)
1. Release union nut (4) at the lower coolant
line (3). Carefully pull line out of the union.
2. Collect coolant in a suitable container.
3. Release union nut (1) at the upper coolant
line (2) and pull line a little out of the union.
Note: Wait until coolant no longer emerges from
the lines.
4. Tighten both union nuts (1,4) of the coolant
lines (2,3).
TIM-ID: 0000030758 - 002

7.15.5 Engine coolant – Filling
Preconditions

Coolant
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
TIM-ID: 0000018688 - 004

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

tors, exhaust turbochargers and oil heat ex‐
changer (arrows).
3. Open drain valve and pump coolant into en‐
gine at 0.5 bar minimum.
4. When coolant emerges from the vents,
close all vent points, starting at the lowest
and proceeding upwards to the highest
point.
5. Fill expansion tank until overflow edge is
reached.
6. Close drain valve.
7. Check proper condition of breather valve
and clean sealing faces if required.
8. Set breather valve onto filler neck and close
it.
9. Start engine (→ Page 35) and stop it
(→ Page 35) after operation in unloaded
condition for 10 seconds.
11. Check engine coolant level
(→ Page 154)and top up if required .
a) Fill in coolant in expansion tank until the
coolant level at top edge of filler neck
remains constant.
b) Set breather valve onto filler neck and
close it.
c) Repeat the steps from "Start engine"
TIM-ID: 0000018688 - 004
(→ Step 9) until coolant no longer needs

to be topped up.
d) Disconnect pump and hose.

Alternatively: Filling with engine
coolant through filler neck
1. Open vent points on EGR cooler, distribu‐
tors, exhaust turbochargers and oil heat ex‐
changer (arrows).
2. Fill in engine coolant in expansion tank via
filler neck until coolant level at top edge of
filler neck remains constant.
3. When coolant emerges from the vents,
close all vent points, starting at the lowest
and proceeding upwards to the highest
point.
5. Place breather valve onto filler neck and
close until first stop is reached.
6. Start engine (→ Page 35) and stop it after
operation in unloaded condition for 10 sec‐
onds. (→ Page 36)
7. Turn breather valve counterclockwise and
remove.
8. Check engine coolant level (→ Page 154)
and top up if required.
a) Repeat the steps from "Start engine"
to be topped up.
b) Check proper condition of breather
valve and clean sealing faces if re‐
quired.
c) Set breather valve onto filler neck and
close it.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check engine coolant level (→ Page 154) and top up if required.
TIM-ID: 0000018688 - 004

7.15.6 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. Shut down engine (→ Page 36) and disable
engine start, observe general safety instruc‐
tions “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: 0000037916 - 001

7.15.7 Engine coolant – Sample extraction and analysis
Preconditions

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

and analysis
1. Open drain valve (arrowed) with the engine
running.
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 (arrow).
5. Using the equipment and chemicals of the
MTU test kit, check the charge-air coolant
for:
• antifreeze concentration
• corrosion inhibitor concentration;
• pH value
6. Engine coolant change intervals (→ MTU
TIM-ID: 0000037917 - 001
Fluids and Lubricants Specifications).

7.15.8 Engine coolant filter – Replacement
Preconditions

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

1. Close shut-off cock (1).
2. Remove engine coolant filter (2) with filter
wrench.
3. Clean sealing surface on connecting piece.
4. Coat seal on new engine coolant filter (2)
with engine oil.
5. Screw on engine coolant filter (2) and tight‐
en hand-tight.
6. Open shut-off cock (1).
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7.16 Low-Temperature Circuit
7.16.1 Charge-air coolant – Level check
Preconditions
WARNING
Checking charge-air coolant level

at filler neck:
3. Check coolant level (coolant must be visible
at marking plate).
4. Top up coolant if necessary (→ Page 169).
5. Check proper condition of breather valve,
clean sealing faces if required.
6. Fit breather valve and close it.
Checking charge-air coolant level by means of level sensor:

1. Switch on engine control system and check display (coolant level is automatically monitored by engine
control system).
2. Top up coolant if necessary (→ Page 169).
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7.16.2 Charge-air coolant – Change

Coolant
Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 167).
2. Fill with charge-air coolant (→ Page 169).
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7.16.3 Charge-air coolant – Draining
Preconditions

WARNING
Charge-air coolant – Draining

1. Provide an appropriate container to drain
the coolant into.
4. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
5. Open drain valves and/or drain plugs and
drain coolant at the following points:
• at the charge-air coolant pump
• at the thermostat housing, charge-air
coolant circuit
6. Drain residual coolant at intercooler.

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7. Drain residual coolant at intermediate cool‐
er, A side.
8. Drain residual coolant at intermediate cool‐

er, B side.
9. Drain coolant at bypass flap and EGR shut‐
off flap (→ Page 158).
Final steps
1. Close all drain valves and install drain plug with new sealing rings.
2. Set breather valve onto filler neck and close it. TIM-ID: 0000026956 - 003

7.16.4 Charge-air coolant – Filling
Preconditions

Charge-air coolant
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
TIM-ID: 0000026958 - 003

Filling with charge-air coolant using
pump
1. Connect appropriate pump with hose to
drain valve (arrow).
2. Open vent points on intercooler, intermedi‐

ate cooler and distributors (arrows).
3. Open drain valve and pump coolant into en‐
gine at 0.5 bar minimum.
4. Fill expansion tank until overflow edge is
reached.
5. Close drain valve.
7. Set breather valve onto filler neck and close
it.
9. After 10 seconds of running the engine
without load, shut down the engine
(→ Page 36).
12. Check charge-air coolant level
(→ Page 165) and top up if required.
a) Fill in coolant in expansion tank until the
coolant level at top edge of filler neck
remains constant.
b) Set breather valve onto filler neck and
close it.
c) Repeat the steps from "Start engine"
TIM-ID: 0000026958 - 003
to be topped up.
d) Disconnect pump and hose.

Alternatively: Filling with engine
coolant through filler neck
1. Open vent points on intercooler, intermedi‐
ate cooler and distributors (arrows).
2. Fill in coolant in expansion tank via filler
neck until coolant level at top edge of filler
neck remains constant.
4. Place breather valve onto filler neck and
close until first stop is reached.
6. After 10 seconds of running the engine
without load, shut down the engine
(→ Page 36).
7. Turn breather valve counterclockwise and
remove.
8. Check charge-air coolant level
(→ Page 165) and top up if required .
a) Repeat the steps from "Start engine"
to be topped up.
b) Check proper condition of breather
valve and clean sealing faces if re‐
quired.
c) Set breather valve onto filler neck and
close it.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check charge-air coolant level (→ Page 165) and top up if required.
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7.16.5 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. Shut down engine (→ Page 36) and disable
engine start, observe general safety instruc‐
tions “Maintenance and Repair”.
3. Clean the relief bore with a wire if it is dirty.
• Permissible coolant discharge: up to
10 drops per hour
• Permissible oil discharge: up to 5 drops
per hour
4. If discharge exceeds the specified limits:
Contact Service.
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7.17 Belt Drive
7.17.1 Drive belt – Condition check
Preconditions
☑ Guard is removed.
Drive belt – Condition check
Item Findings Action

Drive belt A Singular cracks None
Drive belt Belt is oily, shows signs of over‐ Replace (→ Page 176)
heating
Drive belt B Cracks on entire circumference
Drive belt C Chunking
TIM-ID: 0000000920 - 010

7.18 Battery-Charging Generator
7.18.1 Battery-charging generator – Check
Preconditions
WARNING
Compressed air
Risk of injury!
Checking battery-charging generator

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

Note: Dry-clean battery-charging generator only. Do not insert sharp objects into the ventilation holes.
1. Remove coarse dirt from battery-charging generator.
2. Blow out ventilation area (arrow) with compressed air until all dust is cleared.
TIM-ID: 0000030224 - 002

7.18.2 Battery-charging generator drive – Drive belt tension adjustment
Preconditions
WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
Adjusting belt tension

1. Remove protective cover.
2. Slacken screws (1) and (2) by half a turn.
Result: Belt tensioner moves against the drive belt
and tensions it.
3. Tighten screw (2) with torque wrench to the specified tightening torque.
Screw M10x1.5 Tightening torque 60 Nm +5 Nm
4. Tighten screw (1) to specified tightening torque using a torque wrench.
Screw M10x1.5 Tightening torque 42 Nm
5. Install protective cover.
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7.18.3 Battery-charging generator drive – Drive belt replacement
Preconditions
WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
Battery-charging generator drive –

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

Screw M10x1.5 Tightening torque 60 Nm +5 Nm
9. Tighten screw (2) with torque wrench to the specified tightening torque.
Screw M10x1.5 Tightening torque 42 Nm
10. Install protective cover.
11. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 175).
TIM-ID: 0000031050 - 002

7.19 Fan Drive
7.19.1 Fan drive (option) – Drive belt check / adjustment
Preconditions

Optibell 2 belt tension tester Y4345711 1
Preparatory steps
2. Check belt condition visually (→ Page 173).
Result: For drive belt replacement, (→ Page 179).
Checking Vee belt tension

1. Switch on belt tension tester.
2. Hold measuring tip of belt tension tester over belt drive. Tap drive belt (arrow) with a suitable tool.
3. Hold belt tension tester over belt drive until the measured value is indicated.
Initial operation with fan Belt tension adjustment
60 Hz ± 1 Hz 52 Hz ± 5 Hz
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Adjusting drive belt tension
1. Release screws (2) until fan coupling can
be moved.
2. Tighten stud (1) until the required frequency
is achieved.
3. Using a torque wrench, tighten screws (2) to the specified tightening torque.
Screw Tightening torque 100 Nm ± 10 Nm
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7.19.2 Fan drive (option) – Drive belt replacement
Preconditions

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

1. Loosen screws (2).
2. Slacken off stud (1) until drive belt can be
removed.
3. Clean belt pulleys.
4. Fit new drive belt on belt pulleys, ensuring
that it is not under tension.
5. Adjust belt tension (→ Page 177).
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7.20 Engine Mounting / Support
7.20.1 Engine mounting – Check
Preconditions

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

Item Findings Measure
Visually inspect mounts. • Damage Replace, (→ contact Service.)
• Brittleness
• Deformation
• Crack formation
• Swelling
visible
Checking securing screws for

engine mounting for firm seating
1. Check securing screws for secure seating.
2. Tighten loose threaded connections with torque wrench to specified tightening torque.
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Hex screw M16 x 1.5 Control torque (Engine oil)

7.21 Wiring (General) for Engine/Gearbox/Unit
7.21.1 Engine wiring – Check
Preconditions

Isopropyl alcohol X00058037 1
Engine wiring – Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check that cable ties are firm, tighten loose cable ties.
4. Replace faulty cable ties.
5. Visually inspect the following electrical line components for damage:
• connector housings;
• contacts;
• sockets;
• cables and terminals;
• plug-in contacts.
6. (→ Contact Service) if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
8. Ensure that all sensor connectors are securely engaged.
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7.22 Accessories for (Electronic) Engine Governor / Control
System
7.22.1 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 appli‐
cable.
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 appli‐
cable.
u Contact Service.
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7.22.2 Engine governor and connectors – Cleaning
Preconditions

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

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

Note: Seal unused connectors with the supplied protective cap.
1. Release the latch and pull off connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and lock them.
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7.22.3 Engine governor – Checking plug-in connections
Preconditions
Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the
contacts could be bent.
Checking plug-in connections on engine governor

1. Check all plug-in connections for secure seating.
2. Latch connectors if loose.
TIM-ID: 0000000048 - 005

8 Appendix A
8.1 Abbreviations
Abbreviation Meaning Explanation

A/D Analog/Digital Transformer: transforms sensor voltages into
numeric values
ADEC Advanced Diesel Engine Controller Engine management system
AFRS Air Filter Restriction Sensor
ANSI American National Standards Institute Association of American standardization or‐
ganizations
ATL Abgasturbolader Exhaust turbocharger (ETC)
ATS Air Temperature Sensor
BR Baureihe Series
BV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications,
Publication No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Setting of drift compensation in engine gov‐
ernor with DiaSys
CEL Stop Engine Light 1st function: Warning lamp (rectify fault as
soon as possible)
2nd function: Read out fault codes
CKT Circuit
CLS Coolant Level Sensor Monitors coolant level
CPS Coolant Pressure Sensor Monitors coolant pressure
CTS Coolant Temperature Sensor Monitors coolant temperature
DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Die‐
sel
DDL Diagnostic Data Link Diagnostic lines
DDR Diagnostic Data Reader Diagnostic unit
DIN Deutsches Institut für Normung e. V. At the same time identifier of German stand‐
ards (DIN = “Deutsche Industrie-Norm”)
DL Default Lost Alarm: Default CAN bus failure
DOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel
particulate filter
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DPF Diesel Particulate Filter

DT Diagnostic Tool Diagnostic unit
ECM Electronic Control Module Electronic control unit of the DDEC system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EEPROM Electrically Erasable Programmable
Read Only Memory
EFPA Electronic Foot Pedal Assembly
MS150096/01E 2012-08 | Appendix A | 185

EGR Exhaust Gas Recirculation
EMU Engine Monitoring Unit
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
EUI Electronic Unit Injector
FPS Fuel Pressure Sensor Monitors fuel pressure
FRS Fuel - Differential Pressure Sensor
FTS Fuel Temperature Sensor Monitors fuel temperature
FWCP Fire Water Control Panel Control cabinet
GND Ground
HD Hochdruck High Pressure (HP)
HI High Alarm: Measured value exceeds 1st maxi‐
mum limit
HIHI High High Alarm: Measured value exceeds 2nd maxi‐
mum limit value
HT High Temperature
IDM Interface Data Module Memory module for interface data
INJ Injector
ISO International Organization for Stand‐ International umbrella organization for all na‐
ardization tional standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO
1204
KS Kraftseite Engine driving end in accordance with DIN
ISO 1204
LED Light Emitting Diode
LO Low Alarm: Measured value lower than 1st mini‐
mum limit value
LOLO Low Low Alarm: Measured value lower than 2nd mini‐
mum limit value
LSG Limiting Speed Governor
N/A Not Applicable
LP Low Pressure
OEM Original Equipment Manufacturer
OI Optimized Idle
OLS Oil Level Sensor Monitors oil level
OPS Oil Pressure Sensor Monitors oil pressure
TIM-ID: 0000000858 - 009
OTS Oil Temperature Sensor Monitors oil temperature

OT Oberer Totpunkt Top Dead Center (TDC)
PAN Panel Control panel
PIM Peripheral Interface Module
PWM Modulated signal
P-xyz Pressure-xyz Pressure measuring point, xyz specifies the
measuring point designation
RL Redundancy Lost Alarm: Redundant CAN bus failure
186 | Appendix A | MS150096/01E 2012-08

SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SEL Stop Engine Light 1st function: Warning lamp (stop engine and
rectify fault)
2nd function: Read out fault codes
SID System Identifier
SRS Synchronous Reference Sensor TDC cylinder 1
SS Safety System Safety system alarm
TBS Turbocharger Boost Sensor Monitors charge-air pressure
TCI Turbo Compressor Inlet
TCO Turbo Compressor Outlet
TD Transmitter Deviation Alarm: Deviation in transmitter values
TPS Throttle Position Sensor
TRS Timing Reference Sensor
T-xyz Temperature-xyz Temperature measuring point, xyz specifies
the measuring point designation
UT Unterer Totpunkt Bottom Dead Center (BDC)
VNT Variable Nozzle Turbine
VSG Variable-Speed Governor
VSS Vehicle Speed Sensor
WZK Werkzeugkatalog Tool Catalog (TC)
TIM-ID: 0000000858 - 009
MS150096/01E 2012-08 | Appendix A | 187

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

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Phone: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 014
188 | Appendix A | MS150096/01E 2012-08

9 Appendix B
9.1 Special Tools
Allen key
Part No.: F30002815
Qty.: 1
Used in: 7.3.2 Valve clearance – Check and adjustment (→ Page
115)
Barring device
Part No.: F6787910
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 107)
Barring device
Part No.: F6555766
Qty.: 1
Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page
110)
Endoscope
Part No.: Y20097353
Qty.: 1
110)
Qty.:
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Used in: 7.8.2 Exhaust turbocharger (LP) – Turbine housing

check (→ Page 129)
Qty.:
Used in: 7.8.3 Exhaust turbocharger (HP) – Turbine housing
check (→ Page 134)
MS150096/01E 2012-08 | Appendix B | 189

Feeler gauge
Part No.: Y20098771
Qty.: 1
115)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.7.1 Fuel filter – Replacement (→ Page 126)
Qty.: 1
Used in: 7.7.2 Auxiliary fuel filter – Replacement (→ Page 127)
Qty.:
Used in: 7.14.1 Engine oil filter – Replacement (→ Page 150)
Qty.: 1
Used in: 7.14.2 Centrifugal oil filter – Cleaning and filter sleeve
replacement (→ Page 152)
Qty.: 1
Used in: 7.15.8 Engine coolant filter – Replacement (→ Page
164)
Installation/removal device
Part No.: F6789889
Qty.: 1
Used in: 7.5.2 Injector – Removal and installation (→ Page 121)
Milling cutter
Part No.: F30452739
Qty.: 1
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190 | Appendix B | MS150096/01E 2012-08

MTU test kit
Part No.: 5605892099/00
Qty.: 1
Used in: 7.13.4 Engine oil – Sample extraction and analysis (→
Page 149)
Qty.: 1
Used in: 7.15.7 Engine coolant – Sample extraction and analysis
(→ Page 163)
Optibell 2 belt tension tester

Part No.: Y4345711
Qty.: 1
Used in: 7.19.1 Fan drive (option) – Drive belt check / adjustment
(→ Page 177)
Ratchet
Part No.: F30006212
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 107)
Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 7.13.3 Engine oil – Change (→ Page 147)
DCL-ID: 0000009793 - 004
MS150096/01E 2012-08 | Appendix B | 191

Ratchet adapter
Part No.: F30450902
Qty.: 1
Ratchet adapter
Part No.: F30027339
Qty.: 1
Ratchet with extension

Part No.: F30006212
Qty.: 1
110)
Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
115)
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192 | Appendix B | MS150096/01E 2012-08

Steam jet cleaner
Part No.: -
Qty.: 1
Used in: 4.7 Plant cleaning (→ Page 38)
Torque wrench, 0.5-5 Nm

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

Part No.: F30452769
Qty.: 1

Part No.: F30510423
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)

Part No.: F30047798
DCL-ID: 0000009793 - 004
Qty.: 1
MS150096/01E 2012-08 | Appendix B | 193

Part No.: F30027337
Qty.: 1

Part No.: F30027336
Qty.: 1

Part No.: F30452768
Qty.: 1
115)
Qty.: 1

Part No.: F30047446
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)
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194 | Appendix B | MS150096/01E 2012-08

Torque wrench, 80 to 400 Nm
Part No.: F30027338
Qty.: 1
Used in: 7.20.1 Engine mounting – Check (→ Page 180)
DCL-ID: 0000009793 - 004
MS150096/01E 2012-08 | Appendix B | 195

9.2 Index
A Cylinder liner
Abbreviations 185 – Endoscopic examination 110
Actuators – Instructions and comments on endoscopic and visual
– Overview 22 examination 112
Actuators (exhaust flaps)
D
– Function check 143
After stopping the engine 37 Drive belt
Auxiliary fuel filter – Condition check 173
– Replacement 127
E
Auxiliary materials 17
ECU9
B – Fault messages 45
Battery-charging generator Emergency air-shutoff flaps
– Check 174 – Functional check with electric actuation 140
– Drive belt replacement 176 Engine
– Drive belt tension adjustment 175 – Barring manually 107
– Barring with starting system 108
C – Layout 21
CDC parameters – Main dimensions 31
– Reset 182 – Mounting check 180
Centrifugal oil filter – Start in manual mode 35
– Cleaning 152 – Stopping in manual mode 36
– Filter sleeve replacement 152 – Test run 109
Chareg-air coolant – Wiring check 181
– Pump - Relief bore check 172 Engine coolant
Charge-air coolant – Change 155
– Change 166 – Draining 156
– Draining 167 – Filling 159
– Filling 169 – Filter replacement 164
– Level check 165 – Level check 154
Charge-air coolant level – Sample extraction and analysis 163
– Check 165 Engine coolant filter
Charge-air coolant pump – Replacement 164
– Relief bore check 172 Engine coolant pump
Connectors – Relief bore check 162
– Cleaning 183 Engine data 12V 4000 T94, T94L 26
Contact persons 188 Engine governor
Coolant – Checking plug-in connections 184
– Change 166 – Cleaning 183
– Draining (exhaust flaps) 158 Engine layout 21
– Pump - Relief bore check 162 Engine mounting
Coolant - charge air – Check 180
– Draining 167 Engine oil
– Filling 169 – Analysis 149
– Level check 165 – Change 147
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Coolant pump - charge air – Filter replacement 150

– Relief bore check 172 – Level check with oil dipstick 146
Crankshaft transport locking device – Sample extraction 149
– Removal/installation 8 Engine oil level
Cylinder – Check at sight glass 145
– Designation 20 – Check with oil dipstick 146
Cylinder head cover Engine side
– Removal and installation 118 – Designation 20
Engine wiring
– Check 181
Environmental protection 17
196 | Appendix B | MS150096/01E 2012-08

Exhaust flaps Plant
– Draining coolant 158 – Cleaning 38
– Overview 141 Putting engine into operation
Exhaust flaps (exhaust gas recirculation) 141, 143 – Preparation after extended out-of-service periods (>3
Exhaust flaps – actuators months) 32
– Function check 143 Putting the engine into operation
Exhaust turbocharger – Preparation after scheduled out-of-service-period
– Turbine housing check 128 33
– Turbine housing (LP) check 129
– Turbine (HP) housing check 134 R
Exhaust turbocharger turbine housing Repair work
– Check 128 – Safety regulations 14
F S
Fan drive Safety instructions 19
– Drive belt check / adjustment 177 Safety regulations 12, 14
– Drive belt replacement 179 Sensors
Fault messages – Overview 22
– List 45 Service partners 188
Fault messages on the SAM display 44 Spare parts service 188
Fire prevention 17 Starter
Firing order 30 – Condition check 144
Fluids and lubricants 17 Startup
Fuel filter – Safety regulations 12
– Replacement 126
Fuel system T
– Venting 125 Technical data (engine data) 26
Transport 7
G Troubleshooting 41
General conditions 5
V
H Valve clearance
Hotline 188 – Adjustment 115
HP pump – Check 115
– Filling with engine oil 119 Valve gear
– Lubrication 114
I
Injector 121 W
– Removal and installation 121 Wiring - engine
– Replacement 120 – Check 181
Injectors
– Overview 22
Inspection port cover
– Explosion hazard 13
Intercooler
– Leak check 139
M
DCL-ID: 0000009793 - 004
Maintenance work
– Safety regulations 14
MTU contact persons 188
O
Operation
– Safety regulations 12
Operational checks 34
P
Personnel and organizational requirements 6
MS150096/01E 2012-08 | Appendix B | 197


Operating Instructions: Diesel Engine 12 V 4000 T94, T94L

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7.4 Injection Pump / HP Pump 119

4 Operation 7.7 Fuel Filter 126

7.10 Air Intake 140

MS150096/01E 2012-08 | Table of Contents | 3

DCL-ID: 0000009793 - 004

4 | Table of Contents | MS150096/01E 2012-08

MS150096/01E 2012-08 | Safety | 5

Working clothes and protective equipment

TIM-ID: 0000000874 - 018

6 | Safety | MS150096/01E 2012-08

Placement after transport

MS150096/01E 2012-08 | Safety | 7

Special tools, Material, Spare parts

Transport locking device

Removing the transport locking

TIM-ID: 0000027593 - 002

8 | Safety | MS150096/01E 2012-08

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

Removing guard plates and engine

MS150096/01E 2012-08 | Safety | 9

Removing the transport locking

10 | Safety | MS150096/01E 2012-08

MS150096/01E 2012-08 | Safety | 11

Safety precautions when putting the equipment into operation

Safety precautions for operation

Operation of electrical equipment

12 | Safety | MS150096/01E 2012-08

MS150096/01E 2012-08 | Safety | 13

Safety regulations for maintenance and repair work

14 | Safety | MS150096/01E 2012-08

Hydraulic installation and removal

Working on electrical/electronic assemblies

Working with laser equipment

MS150096/01E 2012-08 | Safety | 15

TIM-ID: 0000000879 - 023

16 | Safety | MS150096/01E 2012-08

Environmental protection and disposal

Auxiliary materials, fluids and lubricants

MS150096/01E 2012-08 | Safety | 17

Paints and lacquers

Acids and alkaline solutions

• Rinse eyes immediately with eyedrops or clean tap water.

18 | Safety | MS150096/01E 2012-08

MS150096/01E 2012-08 | Safety | 19

1 Left engine side 3 Right engine side

20 | General Information | MS150096/01E 2012-08

1 Engine oil heat ex‐ 11 Intercooler 21 HP fuel pump

Engine model designation

Key to the engine model designation 12 V 4000 T94/T94L

MS150096/01E 2012-08 | General Information | 21

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

TIM-ID: 0000018547 - 007

22 | General Information | MS150096/01E 2012-08

MS150096/01E 2012-08 | General Information | 23

TIM-ID: 0000018547 - 007

24 | General Information | MS150096/01E 2012-08

MS150096/01E 2012-08 | General Information | 25

General conditions (for max. power)

26 | Technical Data | MS150096/01E 2012-08

Combustion air / exhaust gas