Operating Instructions Diesel...

Operating InstructionsDiesel Engine20V4000G44F20V4000G44LF20V4000G94F20V4000G94LF

MS15058/03E

Engine model Power Frequency Application group20V4000G44F 140 kW/cyl. 50 Hz 3B, continuous operation, variable load, ICXN20V4000G44LF 150 kW/cyl. 50 Hz 3E, standby power, overload capability according to

ICXN20V4000G94F 154 kW/cyl. 50 Hz 3D, standby power, fuel stop power, IFN20V4000G94LF 165 kW/cyl. 50 Hz 3D, standby power, fuel stop power, IFNLoad factor: < 75 % (3B)

< 85 % (3D, 3E)Operating hours: No limit for operating hours (3B)

500 h per year or for the duration of an emergency (3D, 3E)Time between major over-haul:

30,000 h to 24,000 h (3B)8,000 h or 18 years (3D, 3E)

Table 1: Applicability

© 2018 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 writ-ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-filming and storage or processing in electronic systems including databases and online services.

All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbHreserves the right to change, delete or supplement the information provided as and when required.

Table of Contents1 Safety

1.1 Important provisions for all products 51.2 Correct use of all products 71.3 Personnel and organizational requirements 81.4 Initial start-up and operation – Safety

regulations 91.5 Assembly, maintenance, and repair work –

Safety regulations 111.6 Fire and environmental protection, fluids

and lubricants 151.7 Standards for warning notices in the text

and highlighted information 17

2 Transport

2.1 Transport 182.2 Lifting requirements 192.3 Crankshaft transport locking device 202.4 Engine mount shipping lock 23

3 General Information

3.1 Engine side and cylinder designations 243.2 Engine layout 253.3 Sensors and actuators – Overview 27

4 Technical Data

4.1 Product data 20V4000G44F,20V4000G44LF 31

4.2 Product data 20V4000G94F,20V4000G94LF 37

4.3 Firing order 424.4 Engine– Main dimensions 43

5 Operation

5.1 Putting the engine into operation afterextended out-of-service periods (>3 months) 44

5.2 Putting into operation after scheduled out-of-service-period 45

5.3 Starting the engine in manual mode (testrun) 46

5.4 Re-starting the engine following anautomatic safety shutdown 47

5.5 Safety system – Override 485.6 Operational monitoring 495.7 Engine – Emergency start (Override mode) 505.8 Engine – Stopping in Manual mode (test

run) 51

5.9 Emergency engine stop 535.10 After stopping the engine – Engine remains

ready for operation 545.11 After stopping the engine – Putting the

engine out of operation 555.12 Plant – Cleaning 56

6 Maintenance

6.1 Maintenance task reference table [QL1] 57

7 Troubleshooting

7.1 Troubleshooting 597.2 Fault messages of the engine governor (ECU

9) for Series 4000 genset engines(preliminary) 62

8 Task Description

8.1 Engine 1118.1.1 Engine – Barring manually 1118.1.2 Engine – Cranking on starting system 1138.1.3 Engine – Test run 114

8.2 Cylinder Liner 1158.2.1 Cylinder liner – Endoscopic examination 1158.2.2 Cylinder liner – Instructions and comments on

endoscopic and visual examination 117

8.3 Crankcase Breather 1198.3.1 Crankcase breather – Oil mist fine separator

replacement 1198.3.2 Crankcase breather – Filter element

replacement 120

8.4 Valve Drive 1228.4.1 Valve protrusion – Measurement 1228.4.2 Valve gear – Lubrication 1268.4.3 Valve clearance – Check and adjustment 1278.4.4 Cylinder head cover – Removal and

installation 130

8.5 Injection Pump / HP Pump 1318.5.1 HP fuel pump – Filling with engine oil 131

8.6 Injector 1338.6.1 Injector – Replacement 1338.6.2 Injector rings – Replacement (single-wall fuel

system) 1348.6.3 Injector – Removal and installation 140

8.7 Fuel System 1468.7.1 Fuel system – Venting 146

8.8 Fuel Filter 148

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8.8.1 Fuel filter – Replacement 1488.8.2 Additional fuel filter – Replacement 1498.8.3 Fuel prefilter – Pressure ratios 1508.8.4 Fuel prefilter – Draining 1518.8.5 Fuel prefilter (non-switchable) – Draining 1528.8.6 Fuel prefilter (switchable) – Draining 1548.8.7 Fuel prefilter (switchable) – Low pressure

indicator check 1578.8.8 Fuel prefilter (non-switchable) – Filter element

replacement 1588.8.9 Fuel prefilter (switchable) – Filter element

replacement 1608.8.10 Fuel prefilter – Venting 163

8.9 Charge-Air Cooling 1658.9.1 Intercooler – Check drain for coolant leakage

and obstruction 165

8.10 Air Filter 1668.10.1 Air filter ‒ Replacement 1668.10.2 Air filter – Check 1678.10.3 Air filter – Removal and installation 1688.10.4 Heavy duty air filter – Filter insert and filter

element removal and installation 169

8.11 Air Intake 1718.11.1 Service indicator – Signal ring position check 171

8.12 Lube Oil System, Lube Oil Circuit 1728.12.1 Engine oil – Change 1728.12.2 Engine oil level – Check 1748.12.3 Engine oil – Sample extraction and analysis 1758.12.4 Oil priming pump – Visual inspection 177

8.13 Oil Filtration / Cooling 1788.13.1 Engine oil filter – Replacement 1788.13.2 Cleaning centrifugal oil filter and replacing

filter sleeve 179

8.14 Coolant Circuit, General, High-TemperatureCircuit 1818.14.1 Engine coolant – Level check 1818.14.2 Engine coolant – Change 1828.14.3 Engine coolant – Draining 1838.14.4 Engine coolant – Filling 1858.14.5 Engine coolant pump – Relief bore check 1898.14.6 Engine coolant – Sample extraction and

analysis 1908.14.7 Preheater – Overview 1928.14.8 Preheater – Overhaul 1938.14.9 Preheater – Function and leak check 194

8.14.10 Preheater – Heating element and housingcheck 195

8.14.11 Preheater – Solenoid switch replacement 1988.14.12 Preheater thermostats – Replacement 200

8.14.13 Coolant expansion tank valve cover – Replacement 203

8.15 Low-Temperature Circuit 2048.15.1 Charge-air coolant level – Check 2048.15.2 Charge-air coolant – Change 2068.15.3 Charge-air coolant – Draining 2078.15.4 Charge-air coolant – Filling 2098.15.5 Charge-air coolant pump – Relief bore check 213

8.16 Battery-Charging Generator 2148.16.1 Drive belt – Condition check 2148.16.2 Battery-charging generator – Drive belt

tension adjustment 2158.16.3 Battery-charging generator drive – Drive belt

replacement 216

8.17 Wiring (General) for Engine/Gearbox/Unit 2178.17.1 Engine cabling – Check 217

8.18 Engine Mounting / Support 2188.18.1 Engine mounting – Checking securing screws

for firm seating 2188.18.2 Engine mounting – Checking resilient element 219

8.19 Generator Mounting 2208.19.1 Generator mounting – Securing screw firm

seating check 2208.19.2 Resilient mounts of generator mounting –

Check 221

8.20 Radiator 2228.20.1 Fuel cooler – External contamination and leak-

tightness check 2228.20.2 Fuel cooler – Cleaning 223

8.21 Accessories for (Electronic) EngineGovernor / Control System 2258.21.1 Resetting CDC parameter and entering IIG

with DiaSys® 2258.21.2 Engine governor and connector – Cleaning 2268.21.3 Engine governor plug connections – Check 2278.21.4 Engine governor ECU 9 – Removal and

installation 228

9 Appendix A

9.1 Conversion tables 2299.2 Abbreviations 2349.3 MTU Contact/Service Partners 237

10 Appendix B

10.1 Special Tools 23810.2 Index 246

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1 Safety

1.1 Important provisions for all products

GeneralThis product may pose a risk of injury or damage in the following cases:• Incorrect use• Operation, maintenance and repair by unqualified personnel• Changes or modifications which are neither made nor authorized by the manufacturer• Noncompliance with the safety instructions and warning notices

NameplatesThe product is identified by nameplate, model designation or serial number. This data must match the speci-fications in these instructions.

Nameplates, model designation or serial number can be found on the product.

All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv-ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/systemis not visible without the removal of components, the system integrator must install the second nameplate ina clearly visible area on the vehicle/system.

Emission specifications and emission label

Responsibility for compliance with emission regulationsModification or removal of any mechanical/electronic components or the installation of additional compo-nents including the execution of calibration processes that might affect the emission characteristics of theproduct are prohibited by emission regulations. Emission-related components must only be serviced, ex-changed or repaired if the components used for this purpose are approved by the manufacturer.

Noncompliance with these specifications will invalidate the design type approval or certification issued bythe emissions regulation authorities. The manufacturer does not accept any liability for violations of theemission regulations.

The product must be operated over its entire life cycle according to the conditions defined as "Intended use"(→ Page 7).

Emission certification applicable to engines with EPA Nonroad Tier 4 emissioncertification in accordance with 40 CFR 1039Extract from the standard:

Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violatesfederal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.

Extract from the standard:

If you install the engine in a way that makes the engine's emission control information label hard to readduring normal engine maintenance, you must place a duplicate label on the equipment, as described in 40CFR 1068.105.

When fitting the second label, the requirements of 40 CFR 1068.105(c) must be followed and observed. Thisparagraph describes the process for requesting and fitting the label, the documentation obligations and stor-age obligations for the required documents.

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Replacing components with emission labelsOn all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-tional life.

Exception: Engines used exclusively in land-based, military applications other than by US government agen-cies.

Please note the following when replacing components with emission labels:• The relevant emission labels must be affixed to the spare part.• Emission labels shall not be transferred from the replaced part to the spare part.• The emission labels must be removed from the replaced part and destroyed.

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1.2 Correct use of all products

Correct useThe product is intended for use in accordance with its contractually-defined purpose as described in the rele-vant technical documents only.

Intended use entails operation:• Within the permissible operating parameters in accordance with the (→ Technical data)• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants

Specifications of the manufacturer)• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-

tion Specifications of the manufacturer)• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-

tact/Service partner)• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-

so applies to engine control/parameters)• In compliance with all safety regulations and in adherence with all warning notices in this manual• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)

throughout the useful life of the product• In compliance with the maintenance and repair instructions contained in this manual, in particular with

regard to the specified tightening torques• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-

pair

The product must not be operated in explosive atmospheres unless the engine fulfills the conditions for suchuse and approval has been granted.

Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improperuse increases the risk of injury and damage when working with the product. The manufacturer shall not beheld liable for any damage resulting from improper, non-intended use.

The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,make sure that the latest version is used. The latest version can be found on the websites:• For drive systems: http://www.mtu-online.com• For power generation: http://www.mtuonsiteenergy.com

Modifications or conversionsUnauthorized changes to the product represent a contravention of its intended use and compromise safety.

Changes or modifications shall only be considered to comply with the intended use when expressly author-ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-ized changes or modifications.

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1.3 Personnel and organizational requirements

Organizational measures of the user/manufacturerThis manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-tion, or transportation.

Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,repair, assembly, installation, and transport personnel at all times.

Personnel must receive instruction on product handling and repair based on this manual. In particular, per-sonnel must have read and understood the safety requirements and warnings before starting work.

This is important in the case of personnel who only occasionally perform work on or around the product.Such personnel must be instructed repeatedly.

Personnel requirementsAll work on the product must be carried out by trained, instructed and qualified personnel only:• Training at the Training Center of the manufacturer• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering

and also for work with live parts

The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-sembly, installation, and transport in writing.

Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.

Clothing and personal protective equipmentAlways wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-tions of the individual activities.

Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-tion, Authorization and restriction of CHemicals): We recommend wearing protective gloves at all times inorder to reduce risk when working.

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1.4 Initial start-up and operation – Safety regulations

Safety regulations for initial start-upInstall the product correctly and carry out acceptance in accordance with the manufacturer's specificationsbefore putting the product into service. All necessary approvals must be granted by the relevant authoritiesand all requirements for initial startup must be fulfilled.

Whenever the product is subsequently taken into operation ensure that:• All personnel is clear of the danger zone surrounding moving parts of the machine.

Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switchedon.

• All maintenance and repair work has been completed.• All loose parts have been removed from rotating machine components.• All safeguards are in place.• All components must be properly grounded. Ground separately by means of a grounding stake as neces-

sary.• No persons wearing pacemakers or any other technical body aids are present.• The service room is adequately ventilated.• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.

These gases may be hazardous to health. Always wear respiratory protection in the operating room duringthis period.

• The exhaust system is leak-tight and that the gases are vented to atmosphere.• The product must be free of any damage, this applies in particular to lines and cabling.• Protect battery terminals, generator terminals or cables against accidental contact.• Check that all connections have been correctly allocated e.g. +/- polarity, fuel line/reduction agent line,

supply/return.

Immediately after putting the product into operation, make sure that all control and display instruments aswell as the monitoring, signaling and alarm systems work properly.

Smoking is prohibited in the area of the product.

Safety regulations during operationThe operator must be familiar with the control and display elements.

The operator must be familiar with the consequences of any operations performed.

During operation, the display instruments and monitoring units must be permanently observed with regard topresent operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stopPractice emergency procedures, especially emergency stopping, at regular intervals.

Take the following steps if any system malfunctions are detected or signaled by the system:• Inform supervisor(s) in charge.• Analyze the message.• Respond by taking any necessary emergency action, e.g. emergency stop.

After a safety shutdown, the engine must only be started after the cause of the shutdown has been eliminat-ed.

Contact Service if the root cause of the malfunction cannot be clearly identified.

OperationDo not remain in the operating room when the product is running unless absolutely necessary. Keep yourstay as short as possible.

Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructedto do so following a written procedure.

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Do not inhale the exhaust gases of the product.

The following requirements must be fulfilled before the product is started:• Wear ear protectors.• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent.

Operation of electrical equipmentWhen electrical equipment is in operation, certain components of these appliances are electrically live.

Follow the applicable operating and safety instructions when operating the devices and heed warnings at alltimes.

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1.5 Assembly, maintenance, and repair work – Safety regulations

Safety regulations for work prior to assembly, maintenance, and repairHave assembly, maintenance, or repair work carried out by qualified and authorized personnel only.

Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants,risk of burning).

Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-ble containers of adequate capacity to catch fluids and lubricants.

Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-surized lines, shut off the lines first, then release the residual pressure.

Work must only be carried out on lines when they are free of fluids and lubricants.

When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.

Never carry out assembly, maintenance, or repair work with the product in operation, unless:• It is expressly permitted to do so following a written procedure.

Lock-out the product to preclude undesired starting, e.g.• Start interlock• Key switch• Close supply line for hydraulic starting.

Attach “Do not operate” sign in the operating area or to control equipment.

Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.

Before starting work on CaPoS, if used:• Switch off the charging system (DC/DC converter).• Discharge the UltraCap modules using the appropriate discharger.• Short-circuit the UltraCap modules with a suitable wire jumper.

Close the main valve on the compressed-air system and vent the compressed-air line when air starters arefitted.

Before working on the exhaust gas aftertreatment system, close the shutoff valve on the reducing agenttank. Note that the reducing agent pumps continue to run for a certain period when the engine is stopped.

Disconnect the control equipment from the product.

Use the recommended special tools or suitable equivalents when instructed to do so.

Safety regulations when performing assembly, maintenance, and repair work

Special tools and lifting equipmentUse only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-bly.

Setting down, lifting and climbingCarry out work only on assemblies or plants which are properly secured.

Use appropriate lifting equipment for all components. Use all specified attachment points and observe thecenter of gravity.

Never work on engines or components when they are held in place by lifting equipment.

Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to preventcomponents/tools from falling down.

Assume a safe standing position when performing assembly work.

Never use the product as a climbing aid.

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When working high on the equipment, always use suitable ladders and work platforms. Special instructionsfor outdoor areas: There must be no risk of slipping e.g. due to icing.

Removing, installing and cleanlinessPay particular attention to cleanliness at all times.

Completely wipe up escaped fluids and lubricants due to the risk of slipping.

Take special care when removing ventilation or plug screws from the product.

Ensure that O-rings are not installed in a slanted/twisted condition.

Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness(e.g. components carrying oil, fuel, or air).

Note cooling time for components which are heated for installation or removal (risk of burning).

Ensure that all mounts and dampers are installed correctly.

Remove any accumulation of condensate after assembling chilled components. Coat the components with asuitable corrosion inhibitor as necessary.

LinesEnsure that lines for all fluids and lubricants and their connections are clean.

Always seal connections with caps or covers if a line is removed or opened.

Fit new seals when re-installing lines.

Never bend lines and avoid damaging lines, particularly the fuel lines.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contactwith other components. Do not place fuel or oil lines near hot components.

MiscellaneousSufficient ventilation must be guaranteed during the work.

Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) when work-ing on exhaust components. Clean the work area with a dust extraction machine of class H. Wear protectivegloves and goggles for protection against acidic condensate.

Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized orresinous appearance.

Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.Only install them after painting the engine or mask them prior to painting.

The following applies to starters with copper-beryllium alloy pinions:• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter

with compressed air. Clean the flywheel housing inside with a class H dust extraction device.• Observe the safety data sheet.

Safety regulations after performing assembly, maintenance, and repair workBefore barring the engine, make sure no one is in the danger zone of the engine.

Check that all access ports/apertures which have been opened to facilitate working are closed again.

Check that all safeguards have been installed and that all tools and loose parts have been removed (especial-ly the barring tool).

Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).

Ensure that the grounding system is properly connected.

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Welding workWelding operations on the product or mounted units are not permitted. Cover the product when welding inits vicinity.

Before starting welding work:• Switch off the power supply master switch.• Disconnect the battery cables or actuate the battery isolating switch.• Separate the electrical ground of electronic equipment from the ground of the unit.

No other assembly, maintenance, or repair work must be carried out in the vicinity of the product while weld-ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-cants.

Do not use product as ground terminal.

Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. Thewelding current can induce interfering voltages in the wiring harnesses which may damage the electrical sys-tem.

Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.

Hydraulic installation and removalCheck the function and safe operating condition of tools and fixtures to be used. Use only the specified devi-ces 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 which are under pressure.

Before starting work, pay attention to the following:• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.• For hydraulic installation, screw on the jig with the piston retracted.• For hydraulic removal, screw on the jig with the piston extended.

For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft enduntil correct sealing is established.

During hydraulic installation and removal of components, ensure that nobody is standing in the immediatevicinity of the component to be installed/removed.

Working with batteriesObserve the safety instructions of the manufacturer when working on batteries.

Gases released from the battery are explosive. Avoid sparks and naked flames.

Do not allow battery acids to come into contact with skin or clothing.

Wear protective clothing, goggles and protective gloves.

Do not place objects on the battery.

Before connecting the cable to the battery, check the battery polarity. The battery may explode and sprayacid if the battery terminals are connected incorrectly.

Working on electrical and electronic assembliesAlways obtain the permission of the person in charge before commencing assembly, maintenance, and repairwork or switching off any part of the electronic system required to do so.

De-energize the relevant areas prior to working on assemblies.

ESD (Electrostatic Discharge): Work on components which could be damaged by electrostatic dischargemust always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically conductivework surfaces or antistatic wristbands.

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Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-ing operation by:• Contact with sharp edges• Chafing on components• Contact with hot surfaces.

Do not secure cables on lines carrying fluids.

Do not use cable ties to secure lines.

Always use connector pliers to tighten union nuts on connectors.

Subject the device as well as the product to functional testing on completion of all repair work. The emergen-cy stop function must be tested in particular. The functional check of the emergency stop, during which thevoltage supply of the ECU is switched off, must only be carried out when the product is cold.

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Packagefaulty electronic components or assemblies properly before dispatching for repair:• Moisture-proof• Shock-proof• Wrapped in antistatic foil (as necessary)

Working with laser equipmentWork with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-structions in the manufacturer's user manual when working with laser equipment.

Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).

Laser equipment must be fitted with the protective devices necessary for safe operation according to typeand application.

Measuring component dimensionsWorkpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-perature of 20 °C.

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1.6 Fire and environmental protection, fluids and lubricants

Fire prevention and fireFire, naked light and smoking are prohibited.

In case of a fire, stop the fuel supply if this is possible without endangering personnel.

The product has hot surfaces that can ignite combustible gases and other substances in the immediate area.The operating company must install and operate the product a safe distance away from danger sources andobserve any relevant safety regulations or recommendations. Products that comply with the SOLAS Conven-tion do not constitute such as danger.

After working with combustible fluids and lubricants (e.g. cleaning agents), ensure the area is well ventilated.The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.

Eliminate leaks of fluids and lubricants immediately. Fluids and lubricants on hot components can causefires, so keep the product clean at all times. Do not leave rags saturated with fluids and lubricants on theproduct. Do not store combustible materials near the product.

Incorrect refueling of the reducing agent system with fuel can result in fire.

Before welding, clean the area to be welded with a nonflammable fluid. Do not carry out welding work onpipes and components carrying oil or fuel.

When starting the engine with an external power source, connect the ground lead last and remove it first. Toavoid sparks in the vicinity of the battery, connect the ground cable from the external power source to theground cable of the engine or to the ground terminal of the starter.

Ensure that suitable extinguishing agents (fire extinguishers) are always available and that staff are familiarwith their correct handling.

A fire can result in the creation of toxic substances. Always wear protective gloves when handling compo-nents and wear additional personal protective equipment is necessary.

NoiseWear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).

Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-ger are compromised.

Environmental protection and disposalDispose of used fluids, lubricants and components in accordance with local regulations.

Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-cled.

Fluids and lubricants/auxiliary materials (process materials)Process materials can also be or contain hazardous or toxic substances. When using process materials andother chemical substances, observe the associated safety data sheet. The safety data sheet may be obtainedfrom the relevant manufacturer or from MTU.

Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi-cations must be used. The most recent respective version must be requested from the manufacturer.

Contamination of process materials with reducing agent (e.g. AdBlue®, DEF): Store process materials in sep-arate containers and their own drip trays. Even extremely small amounts of reducing agent contaminationcan result in malfunctions in sensors and other components.

Used oil contains combustion residues that are harmful to health.

When handling used oil, protective gloves must be used.

Wash relevant areas after contact with used oil.

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Registration, evaluation, approval and restriction of chemicals (REACHordinance)Particularly hazardous substances used with our products are named in a list:

www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products

Compressed air• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-

tainers, risks causing an explosion.• Wear goggles when blowing dirt off workpieces or blowing away chips.• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)

for drying purposes or to check for leaks risks bursting them.• Pay special attention to the pressure in the compressed air system or pressure vessel.• Assemblies or products which are to be connected must be designed to withstand this pressure. Install

pressure-reducing or safety valves set to the admissible pressure if this is not the case.• Hose couplings and connections must be securely attached.• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).• Release residual pressure before removing a compressed air device from the supply line. To depressurize

compressed-air lines, shut off the lines first, then release the residual pressure.• Carry out a leak test in the specified manner.

Painting• Observe the relevant safety data sheet for all materials.• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure

that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.• Avoid open flames in the surrounding area.• No smoking.• Observe fire-prevention regulations.• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen• Observe the relevant safety data sheet for all materials.• Work with liquid nitrogen may be carried out only by qualified personnel.• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.• Avoid body contact (eyes, hands).• Wear protective clothing, protective gloves, closed shoes and safety goggles.• Make sure that the working area is well ventilated.• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

Acids/alkalines/reducing agents (e.g. AdBlue®, DEF)• Observe the relevant safety data sheet for all materials.• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-

ing.• Do not inhale vapors.• If reducing agent is swallowed, rinse out mouth and drink plenty of water.• Remove any wet clothing immediately.• After skin contact, wash affected body areas with plenty of water.• Rinse eyes immediately with eyedrops or clean mains water. Consult a doctor as soon as possible.

Contamination of reducing agent with other process materials: Store reducing agent in separate contain-ers and use separate drip trays. Even extremely slight contamination can lead to malfunctions in the ex-haust aftertreatment system.Mistakenly filling the tank of the reducing agent system with fuel can cause leakage at the seals and inthe hoses.

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1.7 Standards for warning notices in the text and highlightedinformation

DANGERIn the event of immediate danger.Consequences: Death, serious or permanent injury!• Remedial action.

WARNINGIn the event of a situation involving potential danger.Consequences: Death, serious or permanent injury!• Remedial action.

CAUTIONIn the event of a situation involving potential danger.Consequences: Minor or moderate injuries!• Remedial action.

NOTICEIn the event of a situation involving potentially adverse effects on the product.Consequences: Material damage!• Remedial action.• Additional product information.

Warning notices1. This manual with all safety instructions and warning notices must be issued to all personnel involved in oper-

ation, maintenance, repair, assembly, installation, or transportation.2. The highest level warning notice is used if several hazards apply at the same time. Warnings related to per-

sonal injury shall be considered to include a warning of potential damage.

Highlighted informationImportantThis field contains product information which is important or useful for the user.This information must not refer to hazards related to personal injury or material damage.

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2 Transport

2.1 Transport

Special tools, Material, Spare partsDesignation / Use Part No. Qty.

Crossbeam T80091826 1Crossbeam T80092360 1

DANGERSuspended load.Danger to life!• Use suitable equipment and lifting devices.• Never stand beneath a suspended load and keep a safe distance.• Wear personal protective equipment (e.g. protective helmet, safety shoes).

Transport1. Install engine mounting locking devices and engine transportation lock prior to transport (→ Page 20).2. Use lifting eyes provided to transport engine/generator (→ Page 19).3. Use suitable transport and lifting gear only.4. Engine/generator must only be transported in installation position: max. admissible diagonal pull 10°

(→ Page 19).5. Remove any loose parts on engine/generator.6. Raise and lower engine/generator slowly. Do not allow hoist slings or chains to contact engine/generator or

any of their component parts. Adjust lifting gear as necessary.7. For special packaging with aluminum foil: Suspend engine by lifting eyes on bearing pedestal or transport by

means of handling equipment (forklift truck) capable of bearing load.8. Secure engine/generator such as to preclude tipping during transport. Secure such as to preclude slipping

and tipping when driving up or down inclines and ramps.

Setting down after transport1. Set system down on a firm, flat surface only.2. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.3. Never set the engine down on its oil pan unless expressly authorized to do so by MTU.

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2.2 Lifting requirementsDANGER

Suspended load.Danger to life!• Use suitable equipment and lifting devices.• Never stand beneath a suspended load and keep a safe distance.• Wear personal protective equipment (e.g. protective helmet, safety shoes).

1 Max. admissible diagonalpull 10°

2 Center of gravityA 1880 mm

B 1434.2 mmC 12.4 mmD 1318 mm

E 932 mm

Take note of the engine center of gravityRefer to the installation/arrangement drawings for details of the center of gravity of the system or the centerof gravity of the engine/generator.

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2.3 Crankshaft transport locking device


Torque wrench, 10–60 Nm F30452769 1Torque wrench, 60–320 Nm F30452768 1Engine oil

Transport locking devices

Note: The transport locking device on both sides protects the crankshaft bearings from shocks and vibration dam-age during engine transport.

For installation and removal of the transport locking device, follow the in-structions below:

1. The transport locking device must remain installed on both engine sides as long as possible during engineinstallation in order to avoid damage.

2. Prior to every engine transport, the transport locking device must be reinstalled on both engine sides accord-ing to the instructions.

3. If the engine is to be moved together with the generator, the transport locking device for the generator mustalso be installed.

4. Always use the screws supplied with or installed in the transport locking device to secure it on the engine.5. Starting or barring the engine is allowed only with the transport locking device removed. If the generator is

already mounted on the engine, ensure that the transport locking device of the generator is also removed.

Removing guard plates and en-gine mounting brackets (if appli-cable) on driving end (KS)

1. Remove screws (4) on both sides and take offwith washers (3), guard plates (1) and enginesupports (2).

2. Store the removed parts of the transportlocking device carefully for possible reuse.

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Installing the transport lockingdevice on driving end (KS)

Note: Install plate (6) on the upper part of the openings only.1. Secure the plates (6) with screws (4) and washers (5) at the lateral openings on both sides of the flywheel

housing and tighten to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Screw M16 Tightening torque (Engine oil) 250 nm +25 nm

2. Screw locknut (2) onto screws (1) up to the end of the thread.3. The long side of holder (3) must point downwards. Insert holder (3) through the openings of plate (6).

Note: Holder (3) must lock only the flywheel, not the ring gear.4. Screw in screw (1) in bores of holder (3) until holder (3) is locked in position.

Note: Screw (1) must be tightened stepwise and alternately on both sides of the flywheel housing.5. Tighten screw (1) to specified tightening torque.


Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm

6. Install locknut (2) of screw (1) on plate (6) and tighten.

Removing the transport lockingdevice from driving end (KS)

1. Release the locknuts (2) on both sides of theflywheel housing, remove screw (1) and takeoff holder (3).

2. Remove screws (4) and take off with wash-ers (5) and plates (6).

3. Store the removed parts of the transportlocking device carefully together with thisdocumentation for possible reuse.

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Installing guard plates and en-gine mounting brackets (if appli-cable) on driving end (KS)

Note: Always use the screws supplied with the equipment or removed from the guard plates and engine supportsto secure them on the engine.

u Install engine supports (2) on both sides with guard plates (1) washers (3) and screws (4) and tighten tospecified tightening torque tightening.



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2.4 Engine mount shipping lock

Preconditions☑Engine coolant and engine oil must be filled.

Shipping lock

Note: The shipping lock protects the engine mount from damage resulting from shock and vibration during enginetransportation.

For installation and removal of the transport locking device, follow the in-structions below:

1. Remove the transport locking device from all resilient mounts before putting the engine into operation.2. The transport locking device must be installed on all resilient mounts according to the instructions before

transporting.

Removing engine mount trans-portation locks

1. Slacken nuts (2).2. Undo nut (3) and unscrew and remove screw

(1) together with washers and nuts (2 oneach mount).

3. Store removed transportation lock parts in asafe place for later use.

Installing transportation locks1. Insert screws (1) together with washers and

nuts (2) (2 on each mount).2. Screw on and tighten nut (3).3. Tighten nuts (2) evenly in stages against en-

gine mount and base mount.4. Tag the engine with “Shipping Lock Instal-

led”.

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3 General Information

3.1 Engine side and cylinder designations

1 Left engine side (A-side)2 Engine free end in accord-

ance with DIN ISO 1204(KGS = Kupplungsgegen-seite)

3 Right engine side (B-side)4 Engine driving end in ac-

cordance withDIN ISO 1204 (KS = Kup-plungsseite)

Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders ofeach bank are numbered consecutively, starting with x=1 at driving end (4).

The numbering of other engine components also starts with 1 at driving end (4).

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3.2 Engine layout

1 Intercooler2 Exhaust turbocharger3 Crankcase breather4 Coolant pipework

5 Engine mounting6 Charge-air pipework7 Cylinder head8 Cylinder head cover

9 Engine Control Unit ECU10 Starter11 Flywheel

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1 Oil cooler2 Exhaust pipework3 Exhaust pipe bellows4 Intake housing5 Air filter6 Starter

7 Wastegate8 Oil filler neck9 Additional fuel filter

10 Fuel filter11 Fuel hand pump12 Oil filter

13 Gearcase14 HP fuel pump15 Vibration damper16 Coolant distribution housing17 LT thermostat housing18 HT thermostat housing

Engine model designationKey to the engine model designation 20V4000Gx4F/LF20 Number of cylindersV Cylinder arrangement: V engine4000 SeriesG Application (G = Genset)x Power class4 Design indexL Enhanced power/speedF 50 Hz


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3.3 Sensors and actuators – Overview

1 Y39.A10 - Y39.A1 (injector)2 A19 (EIL – Engine Ident La-

bel)

3 B34.3 (fuel pressure beforeintermediate filter)

4 B33 (temperature in HP fuelsystem)

5 B34.1 (fuel pressure afterfilter)

6 B9 (charge-air temperature)


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1 B50 (crankcase pressure)2 B7 (lube oil temperature)3 B5.1 (lube oil pressure after

filter)

4 B48 (fuel pressure in HPsystem (rail))

5 B1 (camshaft speed)6 XB54 (connector for option-

al oil refill pump)

7 B54 (oil refill pump pres-sure, option)

8 B26 (charge-air coolanttemperature)

9 B6 (coolant temperature)


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1 XF33 (HT coolant level (re-mote expansion tank))

2 XF57 (LT coolant level (re-mote expansion tank))

3 Y39.B1 - Y39.B10 (injector)4 B10 (charge-air pressure)

1 B13 (crankshaft speed)


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1 M50.3 (bypass valve forwastegate)

2 B44 (exhaust turbochargerspeed)


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4 Technical Data

4.1 Product data 20V4000G44F, 20V4000G44LFLegend

DL Reference value, continuous power, continuously attainable power under standard conditionsBL Reference value, fuel stop power, maximum engine power. Can not be driven continuously in some

applications (adjustment reserve)A Design value, value required to design an external system (plant)R Approximate value, typical average value for information, not ideally suitable for purposes of designL Limit value, value which must not be violated (lower limit value, min. value / upper limit value, max.

value), not suitable for design purposesN Unspecified value, value (as yet) undefined- Not applicable, module does not apply to this product type

X Applicable, module applies to this product type> Actual value must be greater than the specified value.< Actual value must be less than the specified value.* Value not adequately verified (tolerance +/- 10%)

** Value not adequately verified (tolerance +/- 5%)

ID Product type Application Speed List perform-ance

1 20V4000G44F Power generation3B, continuous opera-tion, variable load,ICXN

1500 rpm50 Hz

2807 kW3764 bhp

Ref. 25 °C/45 °CEPA Nonroad T2 Com-pliant


1500 rpm50 Hz

2807 kW3764 bhp

Ref. 25 °C/55 °COptimized fuel con-sumption


1500 rpm50 Hz

2807 kW3764 bhp

Ref. 25 °C/45 °CNEA Singapore forORDE

4 20V4000G44LF Power generation3E, standby power,overload capability ac-cording to ICXN

1500 rpm50 Hz

3007 kW4032 bhp



1500 rpm50 Hz

3007 kW4032 bhp



1500 rpm50 Hz

3007 kW4032 bhp


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Reference conditionID 1 2 3 4 5 6Intake air temperature °C 25 25 25 25 25 25Charge air coolant tem-perature

°C 45 55 45 45 55 45

Barometric pressure mbar 1000 1000 1000 1000 1000 1000Site altitude above sealevel

m 100 100 100 100 100 100

Data-relevant engine specificationID 1 2 3 4 5 6Engine without sequentialturbocharging (exhaustturbochargers withoutcut-in / cut-out control)

- X X X X X X

RatingID 1 2 3 4 5 6Rated engine speed A rpm 1500 1500 1500 1500 1500 1500Continuous power ISO3046 (10% overload pos-sible) (power range DIN6280, ISO 8528)

A kW 2807 2807 2807 3007 3007 3007

Site conditions (for max. power)ID 1 2 3 4 5 6Intake depression (newfilter)

A mbar 15 15 15 15 15 15

Intake depression, max. L mbar 30 30 30 30 30 30Exhaust gas overpressure(total pressure referencedto atmosphere)

A mbar 30 30 30 30 30 30

Exhaust gas overpres-sure, max. (total pressurereferenced to atmos-phere)

L mbar 50 50 50 50 50 50

Fuel temperature at en-gine inlet connection

R °C 25 25 25 25 25 25

Fuel temperature at en-gine inlet connection,max. (w/o derating)

L °C 55 55 55 55 55 55

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ConsumptionID 1 2 3 4 5 6Specific fuel consumption(be) - 100% DL (+5%; EN590; 42.8 MJ/kg)

R g/kWh 199 193 199 198 * 196 * 198 *

Fuel consumption at zeroload

R kg/h 50 50 50 50 50 50

Model-related data (basic design)ID 1 2 3 4 5 6Engine with exhaust tur-bocharging (ETC) andcharge-air cooling (inter-cooler)

- X X X X X X

Uncooled exhaust lines - X X X X X XOperating method: four-stroke cycle, diesel, sin-gle-action

- X X X X X X

Combustion method: di-rect injection

- X X X X X X

Cooling method: treatedwater

- X X X X X X

Direction of rotation:c.c.w. (facing driving end)

- X X X X X X

Number of cylinders - 20 20 20 20 20 20Cylinder arrangement: Vangle

Degrees(°)

90 90 90 90 90 90

Bore mm 170 170 170 170 170 170Stroke mm 210 210 210 210 210 210Displacement of a cylin-der

Liters 4.77 4.77 4.77 4.77 4.77 4.77

Total displacement Liters 95.4 95.4 95.4 95.4 95.4 95.4Compression ratio - 16.4 16.4 16.4 16.4 16.4 16.4

Air / exhaust gasID 1 2 3 4 5 6Combustion air volumet-ric flow - DL

R m³/s 4.3 4.0 4.3 4.4 * 4.2 4.4

Exhaust gas volume (atexhaust gas temperature)- DL

R m³/s 10.0 9.6 10.0 10.6 * 10.3 10.6

Exhaust gas temperatureafter engine, max. (ex-haust turbocharger)

L °C 550 550 550


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Coolant system (HT circuit)ID 1 2 3 4 5 6Coolant temperature (atengine connection: outletto cooling equipment)

A °C 100.0 100.0 100.0 100.0 100.0 100.0

Coolant temperature afterengine, limit 1

L °C 102.0 102.0 102.0 102.0 102.0 102.0


L °C 104.0 104.0 104.0 104.0 104.0 104.0

Coolant antifreeze con-tent, max.

L % 50 50.0 50 50 50 50

Coolant system (LT circuit)ID 1 2 3 4 5 6Coolant temperature (atengine connection: outletto cooling equipment)

R °C 70.0 80.0 70.0 70.0 80.0 70.0

Coolant temperature be-fore intercooler, limit 1

L °C 75.0 75.0 75.0 75.0 75.0 75.0


L °C 78.0 78.0 78.0 78.0 78.0 78.0


L % 50 50.0 50 50 50 50

Lube oil systemID 1 2 3 4 5 6Lube oil temperature be-fore engine, limit 1

L °C 99 99 99 99 99 99

Lube oil temperature be-fore engine, limit 2

L °C 101 101 101 101 101 101

General operating dataID 1 2 3 4 5 6High idling speed, max.(static)

L rpm 1613 1613 1613 1613 1613 1613

Limit speed for overspeedalarm/emergency shut-down

L rpm 1950 1950 1950 1950 1950 1950

Limit speed for overspeedmessage

L rpm 1950 1950 1950 1950 1950 1950

Firing speed, from R rpm 80 80 80 80 80 80Firing speed, to R rpm 120 120 120 120 120 120


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CapacitiesID 1 2 3 4 5 6Engine coolant, engine-side (w/o cooling equip-ment)

R Liters 260 260 260 260 260 260

Charge-air coolant, en-gine side

R Liters 50 50 50 50 50 50

Fuel, engine side R Liters 9 9 9 9 9 9Total engine oil capacity,initial filling (standard oilsystem) (option: max. op-erating inclinations)

R Liters 390 390 390 390 390 390

Oil change quantity, max.(standard oil system) (op-tion: max. operating incli-nations)

R Liters 340 340 340 340 340 340

Oil pan capacity at dip-stick mark “min.” (stand-ard oil system) (option:max. operating inclina-tions)

L Liters 270 270 270 270 270 270

Oil pan capacity at dip-stick mark “max.” (stand-ard oil system) (option:max. operating inclina-tions)

L Liters 315 315 315 315 315 315

Weights / main dimensionsID 1 2 3 4 5 6Engine dry weight (stand-ard scope of delivery)

R kg 9650 9650 9650 9650 9650 9650

Engine mass, dry (withstandard accessories in-stalled, incl. coupling)

R kg 10050 10050 10050 10050 10050 10050

AcousticsID 1 2 3 4 5 6Exhaust noise, unsilenced- DL (free-field soundpressure level Lp, 1 mdistance, ISO 6798,+3 dB(A) tolerance)

R dB(A) 121 120 121 121 120 121

Exhaust noise, unsilenced- DL (sound power levelLW, ISO 6798, +3 dB(A)tolerance)

R dB(A) 133 132 133 134 133 134


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ID 1 2 3 4 5 6Engine surface noise withattenuated intake noise(filter) - DL (free-fieldsound power level Lp,1 m distance, ISO 6798,+2 dB(A) tolerance)

R dB(A) 111 111 111 109 109 109

Engine surface noise withattenuated intake noise(filter) - DL (sound powerlevel LW, ISO 6798,+2 db(A) tolerance)

R dB(A) 130 130 130 128 128 128


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4.2 Product data 20V4000G94F, 20V4000G94LFLegend

DL Reference value, continuous power, continuously attainable power under standard conditionsBL Reference value, fuel stop power, maximum engine power. Can not be driven continuously in some

applications (adjustment reserve)A Design value, value required to design an external system (plant)R Approximate value, typical average value for information, not ideally suitable for purposes of designL Limit value, value which must not be violated (lower limit value, min. value / upper limit value, max.

value), not suitable for design purposesN Unspecified value, value (as yet) undefined- Not applicable, module does not apply to this product type

X Applicable, module applies to this product type> Actual value must be greater than the specified value.< Actual value must be less than the specified value.* Value not adequately verified (tolerance +/- 10%)

** Value not adequately verified (tolerance +/- 5%)

ID Product type Application Speed List perform-ance

1 20V4000G94F Power generation3D standby power,fuel stop power, IFN

1500 rpm50 Hz

3088 kW4141 bhp



1500 rpm50 Hz

3088 kW4141 bhp



1500 rpm50 Hz

3088 kW4141 bhp


4 20V4000G94LF Power generation3D standby power,fuel stop power, IFN

1500 rpm50 Hz

3308 kW4436 bhp



1500 rpm50 Hz

3308 kW4436 bhp



1500 rpm50 Hz

3308 kW4436 bhp


Reference conditionID 1 2 3 4 5 6Intake air temperature °C 25 25 25 25 25 25Charge air coolant tem-perature

°C 45 55 45 45 55 45

Barometric pressure mbar 1000 1000 1000 1000 1000 1000Site altitude above sealevel

m 100 100 100 100 100 100


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Data-relevant engine specificationID 1 2 3 4 5 6Engine without sequentialturbocharging (exhaustturbochargers withoutcut-in / cut-out control)

- X X X X X X

RatingID 1 2 3 4 5 6Rated engine speed A rpm 1500 1500 1500 1500 1500 1500Fuel stop power ISO3046

A kW 3088 3088 3088 3308 3308 3308

Site conditions (for max. power)ID 1 2 3 4 5 6Intake depression (newfilter)

A mbar 15 15 15 15 15 15

Intake depression for newsystem

A mbar 15

Intake depression, max. L mbar 30 30 30 30 30 30Exhaust gas overpressure A mbar 30Exhaust gas overpressure(total pressure referencedto atmosphere)

A mbar 30 30 30 30 30

Exhaust gas overpres-sure, max. (total pressurereferenced to atmos-phere)

L mbar 50 50 50 50 50 50

Fuel temperature at en-gine inlet connection

R °C 25 25 25 25 25 25

Fuel temperature at en-gine inlet connection,max.

L °C 55 55 55 55 55 55

Fuel temperature at en-gine inlet connection,max. (w/o derating)

L °C 55 55 55

ConsumptionID 1 2 3 4 5 6Specific fuel consumption(be) - 100% BL (+5%; EN590; 42.8 MJ/kg)

R g/kWh 203 196 203 205 * 202 * 205 *

Fuel consumption at zeroload

R kg/h 50 50 50 50 50 50


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Model-related data (basic design)ID 1 2 3 4 5 6Engine with exhaust tur-bocharging (ETC) andcharge-air cooling (inter-cooler)

- X X X X X X

Uncooled exhaust lines - X X X X X XOperating method: four-stroke cycle, diesel, sin-gle-action

- X X X X X X

Combustion method: di-rect injection

- X X X X X X

Cooling method: treatedwater

- X X X X X X

Direction of rotation:c.c.w. (facing driving end)

- X X X X X X

Number of cylinders - 20 20 20 20 20 20Cylinder arrangement: Vangle

Degrees(°)

90 90 90 90 90 90

Bore mm 170 170 170 170 170 170Stroke mm 210 210 210 210 210 210Displacement of a cylin-der

Liters 4.77 4.77 4.77 4.77 4.77 4.77

Total displacement Liters 95.4 95.4 95.4 95.4 95.4 95.4Compression ratio - 16.4 16.4 16.4 16.4 16.4 16.4

Air / exhaust gasID 1 2 3 4 5 6Combustion air volumet-ric flow - BL

R m³/s 4.5 4.3 4.5 4.7 * 4.5 4.7

Exhaust gas volume (atexhaust gas temperature)- BL

R m³/s 11.1 10.6 11.1 11.9 * 11.5 11.9

Exhaust gas temperatureafter engine, max. (ex-haust turbocharger)

L °C 550 550 550

Coolant system (HT circuit)ID 1 2 3 4 5 6Coolant temperature (atengine connection: outletto cooling equipment)

A °C 100.0 100.0 100.0 100.0 100.0 100.0


L °C 102.0 102.0 102.0 102.0 102.0 102.0


L °C 104.0 104.0 104.0 104.0 104.0 104.0


L % 50 50.0 50 50 50 50


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Coolant system (LT circuit)ID 1 2 3 4 5 6Coolant temperature (atengine connection: outletto cooling equipment)

R °C 70.0 80.0 70.0 70.0 80.0 70.0


L °C 75.0 75.0 75.0 75.0 75.0 75.0


L °C 78.0 78.0 78.0 78.0 78.0 78.0


L % 50 50.0 50 50 50 50

Lube oil systemID 1 2 3 4 5 6Lube oil temperature be-fore engine, limit 1

L °C 99 99 99 99 99 99

Lube oil temperature be-fore engine, limit 2

L °C 101 101 101 101 101 101

General operating dataID 1 2 3 4 5 6High idling speed, max.(static)

L rpm 1613 1613 1613 1613 1613 1613

Limit speed for overspeedalarm/emergency shut-down

L rpm 1950 1950 1950 1950 1950 1950

Limit speed for overspeedmessage

L rpm 1950 1950 1950 1950 1950 1950

Firing speed, from R rpm 80 80 80 80 80 80Firing speed, to R rpm 120 120 120 120 120 120

CapacitiesID 1 2 3 4 5 6Engine coolant, engine-side (w/o cooling equip-ment)

R Liters 260 260 260 260 260 260

Charge-air coolant, en-gine side

R Liters 50 50 50 50 50 50

Fuel, engine side R Liters 9 9 9 9 9 9Total engine oil capacity,initial filling (standard oilsystem) (option: max. op-erating inclinations)

R Liters 390 390 390 390 390 390

Oil change quantity, max.(standard oil system) (op-tion: max. operating incli-nations)

R Liters 340 340 340 340 340 340


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ID 1 2 3 4 5 6Oil pan capacity at dip-stick mark “min.” (stand-ard oil system) (option:max. operating inclina-tions)

L Liters 270 270 270 270 270 270

Oil pan capacity at dip-stick mark “max.” (stand-ard oil system) (option:max. operating inclina-tions)

L Liters 315 315 315 315 315 315

Weights / main dimensionsID 1 2 3 4 5 6Engine dry weight (stand-ard scope of delivery)

R kg 9650 9650 9650 9650 9650 9650

Engine mass, dry (withstandard accessories in-stalled, incl. coupling)

R kg 10050 10050 10050 10050 10050 10050

AcousticsID 1 2 3 4 5 6Exhaust noise, unsilenced– BL (free-field soundpressure level Lp, 1 mdistance, ISO 6798,+3 dB(A) tolerance)

R dB(A) 121 120 121 122 121 122

Exhaust noise, unsilenced- BL (sound power levelLW, ISO 6798, +3 dB(A)tolerance)

R dB(A) 134 133 134 135 134 135

Engine surface noise withattenuated intake noise(filter) – BL (free-fieldsound power level Lp,1 m distance, ISO 6798,+2 dB(A) tolerance)

R dB(A) 111 108 111 111 110 111

Engine surface noise withattenuated intake noise(filter) - BL (sound powerlevel LW, ISO 6798,+2 dB(A) tolerance)

R dB(A) 130 128 130 130 129 130


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4.3 Firing orderNumber ofcylinders

Firing order

20V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8


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4.4 Engine– Main dimensions

Engine model Length (A) Width (B) Height (C)20V4000Gx4F/LF 3478.3 mm 1699.2 mm 2251.9 mm


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5 Operation

5.1 Putting the engine into operation after extended out-of-serviceperiods (>3 months)

Preconditions☑Engine is stopped and starting disabled.

☑MTU Preservation and Represervation Specifications (A001070/..) available.

Putting the engine into operation after extended out-of-service-periods (>3months)Item ActionEngine Depreserve (→ MTU Preservation and Represervation Specifications

A001070/.)Valve drive Lubricate valve drive every ≥ 6 months (→ Page 126).HP fuel pump Only for engines without oil priming pump:

Fill HP fuel pump with fresh engine oil (→ Page 131).Lube oil system Check engine oil level (→ Page 174).

Engines with lube oil priming pump: Prime the engine for 20 seconds at apressure of at least 0.3 bar.Only for engines without oil priming pump: Crank engine on starting systemwithout injecting fuel (→ Page 113).

Fuel prefilter Fill with fuel (→ Page 158), (→ Page 160).Fuel prefilter, pressuregauge

Check low pressure indicator on switchable fuel prefilter (→ Page 157).

Coolant circuit If engine is out of service for more than one year, change engine coolant(→ Page 182).Change charge-air coolant (→ Page 206).

Coolant circuit Check engine coolant level (→ Page 181);Check charge-air coolant level (→ Page 204).

Coolant circuit Heat engine coolant with coolant preheater.Engine Control Unit Check plug-in connections (→ Page 227).Monitoring system Carry out lamp test (see manufacturer's documentation).Engine/generator controlsystem

Switch on;Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.

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5.2 Putting into operation after scheduled out-of-service-period


Putting into operationItem ActionLube oil system Check engine oil level (→ Page 174);Coolant circuit Check engine coolant level (→ Page 181).

Check charge-air coolant level (→ Page 204).Coolant circuit Heat engine coolant with coolant preheater.Fuel prefilter Drain water (→ Page 152), (→ Page 154).Monitoring system Carry out lamp test (see manufacturer's documentation).Engine/generator controlsystem

Switch ON;Select operating mode, e.g.: MANUAL, AUTOMATIC OPERATION.

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5.3 Starting the engine in manual mode (test run)

Preconditions☑Generator (if fitted) is not connected to network.

☑External start interlock is not activated.

DANGERRotating and moving engine parts.Risk of crushing, danger of parts of the body being caught or pulled in!• Before cranking the engine with starter system, make sure that there are no persons in the engine's

danger zone.

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

NOTICERe-starting the engine following an automatic safety shutdown.Risk of severe engine damage!• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.• If the root cause cannot be identified or eliminated, contact Service.

PreparationItem ActionOperating mode switch (iffitted)

Change to manual mode.

Preheating pump (if fitted) Switch on.

Starting the engineItem ActionControl cabinet, operatorstation etc. (depending onmanufacturer)

If coolant temperature is• > 40 °C (with preheating system), or• > 5 °C (without preheating system):Press start button.• Automatic starting sequence is performed;• Engine speed display instrument indicates increasing crankshaft speed;• After the starting sequence is completed, engine is running at rated

speed.

Connecting the generator (if fitted) to network, engine warm-up procedure toreach operating temperatureItem ActionControl cabinet, operatorstation etc. (depending onmanufacturer)

Close the generator circuit breaker.

Engine Apply full load only after engine has reached operating temperature (coolanttemperature approx. 75 °C).

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5.4 Re-starting the engine following an automatic safetyshutdown

NOTICERe-starting the engine following an automatic safety shutdown.Risk of severe engine damage!• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.• If the root cause cannot be identified or eliminated, contact Service.

Note: • If an engine has been shutdown by a fault (red alarm), the engine may only be re-started when the faulthas been identified and eliminated.

Procedure following an automatic safety shutdown1. Eliminate fault.2. If the root cause cannot be identified or eliminated, contact Service.

ImportantThe function "Overdrive safety system" (if fitted), which is only used in emergency situations, is not affect-ed.

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5.5 Safety system – OverrideNOTICE

Safety functions and engine shutdown alarms will be disregarded.Severe material damage!• Initiate emergency start only in emergency situations.

NOTICEInadmissible operating status.Severe damage to property!• Use override function only in hazardous situations to ensure full capability in the event of engine

faults.

Preparation

Note: This function is only available when a pushbutton is provided.

Safety system – OverrideItem ActionSwitchgear cabinet, controlpanel etc. (depending onmanufacturer)

Activate pushbutton for Override input of the ECU.• Certain shutdown criteria and/or starting prerequisites are ignored.

Switchgear cabinet, controlpanel etc. (depending onmanufacturer)

Actuate start button, for further starting sequence, refer to engine start(→ Page 46).

Control and display panels During operation, check the displayed operational data (speed, temperature,pressures).Constantly monitor plant limit values.

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5.6 Operational monitoringDANGER

Components are moving or rotating.Risk of crushing, danger of parts of the body being caught or pulled in!• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNINGExhaust gases are harmful to health and may cause cancer.Risk of poisoning and suffocation!• Keep the engine room well-ventilated at all times.• Repair leaking exhaust pipework immediately.


Operational monitoringItem MeasureControl and display panels Check readings of operational data (speed, temperature, pressures).Engine oil Check engine oil level (→ Page 174).Engine under loadEngine at nominal speed

Check engine/plant and piping for leaks, repair leaky pipes with the enginestopped (exhaust lines and turbocharger turbine housings may be red-hot. Ifthe maximum exhaust temperatures are not exceeded, no restrictions in en-gine operation are required)Check for abnormal running noises and vibration.

Fuel prefilter Check reading on differential pressure gauge to ensure that maximum per-missible value is not exceeded (→ Page 150).Drain water and contaminants from fuel prefilter (→ Page 152), (→ Page 154).

Exhaust system Check exhaust color (→ Page 59).Intercooler Check condensate drain(s) for water discharge and obstruction

(→ Page 165).Air filter Check signal ring position of contamination indicator (→ Page 171).

Replace air filter (→ Page 166) if the signal ring is completely visible in thecontamination indicator control window.

Engine coolant pump Check relief bore (→ Page 189).Charge-air coolant pump Check relief bore (→ Page 213).Compressed-air system (ifinstalled)

Check operating pressure on pressure gauge;Always fill compressed-air tank to max. pressure;Drain condensate from compressed-air tank, pressure drop must not exceed1 bar.

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5.7 Engine – Emergency start (Override mode)DANGER

Rotating and moving engine parts.Risk of crushing, danger of parts of the body being caught or pulled in!• Before cranking the engine with starter system, make sure that there are no persons in the engine's

danger zone.



NOTICESafety functions and engine shutdown alarms will be disregarded.Severe material damage!• Initiate emergency start only in emergency situations.

PreparationItem ActionOperating mode selectorswitch

Change to Override mode (Manual mode, if applicable).

Starting the engine in emergency situationsItem ActionControl cabinet Actuate switch/button for ECU override input.Control cabinet • Automatic starting procedure is performed; any safety functions and

alarms leading to engine shutdown are disregarded;• Engine speed display instrument indicates increasing speed;• After the starting sequence is completed, engine is running at rated

speed.

Connecting the generator (if fitted) to mainsItem ActionControl cabinet If generator is not connected to mains: Close the generator circuit breaker.Engine Operate engine at rated power.

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5.8 Engine – Stopping in Manual mode (test run)

Preconditions☑Generator (if applicable) is not connected to network

☑Engine is in Manual mode

DANGERComponents are moving or rotating.Risk of crushing, danger of parts of the body being caught or pulled in!• Operate the engine at low load only. Keep clear of the danger zone of the engine.



NOTICEStopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress-es.Overheating of and, therefore, damage to components is possible!• Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant

levels are indicated.

Preparing the generator drive (only with generator breaker)Item ActionEngine After opening the generator breaker (if applicable), allow to cool down off-

load for approx. 5 minutes.

Preparing the pump drive (diesel-mechanical / diesel-electric)Item ActionEngine Allow to cool down for approx. 5 minutes at reduced engine speed. Observe

natural resonance of engine (installation-dependent)!

Engine shutdownItem ActionControl cabinet, operatorstation etc. (depending onmanufacturer)

Note: The engine may only be shut down using the Stop button in normal op-eration.Press Stop button.• Automatic stopping sequence is performed;• Engine is at standstill.

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After engine shutdownItem ActionCoolant circulating pump Allow to run on for sufficient time after stopping.

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5.9 Emergency engine stopDANGER

Components are moving or rotating.Risk of crushing, danger of parts of the body being caught or pulled in!• Operate the engine at low load only. Keep clear of the danger zone of the engine.



NOTICEAn emergency stop subjects the engine system to an extremely high load.Risk of overheating, damage to components!• Trigger an emergency stop only in emergency situations.

Emergency engine stopItem ActionEmergency stop pushbutton Press EMERGENCY STOP pushbutton.

• Engine is stopped by disconnecting the power supply to the ECU;• Emergency-air shutoff flaps close (if applicable);• Signaling (e.g. by horn, flashing lamp) is tripped.

After emergency engine stopItem ActionControl cabinet, operatorpanel, etc. (depending onmanufacturer)

Press pushbutton for alarm acknowledgment.• Audible and visual alarm signaling stops

Engine Manually open emergency-air shutoff flaps (if applicable).• Switch on ECU power supply• Engine is ready for starting.

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5.10 After stopping the engine – Engine remains ready foroperation

After stopping the engineItem ActionEngine/generator/pumpcontrol

Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.

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5.11 After stopping the engine – Putting the engine out ofoperation

Preconditions☑MTU Preservation and Represervation Specifications (A001070/..) are available.

After stopping the engineItem ActionCoolant circuit Drain engine coolant (→ Page 183);

Drain charge-air coolant (→ Page 207) if:• freezing temperatures are to be expected and the engine is to remain out

of service for an extended period and if no antifreeze has been added tothe coolant;

• 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/generator/pumpcontrol

Switch off.

Air intake and exhaust sys-tem

If the engine is to remain out of service for more than 1 week, seal the en-gine's air and exhaust sides. If the engine is to remain out of service for morethan 1 month, carry out preservation (→ Preservation and RepreservationSpecifications A001070/..).

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5.12 Plant – Cleaning


☑No operating voltage applied.


High-pressure cleaner (→ Tools Catalog) 1Cleaner (Hakupur 50/136) X00056700 1

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

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

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

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

ECUs.

Cleaning the plant1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec-

tion).2. Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning

units carefully and observe the safety precautions.3. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit:

• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.• A minimum distance between spray nozzle and plant of 1 m must be observed.• The temperature of the cleaning medium must not exceed 80 °C.

4. For external cleaning with high-pressure jet, use a fan jet nozzle only.

Note: Never direct compressed air directly at electronic components.5. Carry out external cleaning as follows:

a) Seal all openings in a suitable way.b) Remove coarse dirt.c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.d) Use high-pressure jet to remove loosened dirt.e) Dry engine with compressed air.

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6 Maintenance

6.1 Maintenance task reference table [QL1]The required maintenance tasks and intervals for this product are defined in the Maintenance Schedule. TheMaintenance Schedule is a stand-alone publication.

The task numbers in this table provide reference to the maintenance tasks specified in the MaintenanceSchedule.

Task Item Measures

Opt

ion

WM00296 ENGINE, GENERAL Carry out test run, minimum duration: until steady-state temperature isreached, no less than 1/3 load (monthly)

(→ Page 114)

WM00222 COOLANT CIRCUIT GENERAL, IFAPPLICABLE HIGH-TEMPERA-TURE CIRCUIT

Check function of preheater and inspect for leaks X (→ Page 194)

WM00067 OIL FILTRATION/COOLING Replace oil filter at each oil change or when the time limit (years) is reached, atthe latest

(→ Page 178)


Replace thermostat of preheater (electric) X (→ Page 200)

WM00297 FUEL INJECTOR Replace rings (→ Page 134)

WM00289 ENGINE, GENERAL Check engine for abnormal running noises, exhaust gas color and vibrations (→ Page 49)

WM00288 ENGINE, GENERAL Check relief bore of coolant pump (→ Page 189)(→ Page 213)

WM00285 ENGINE, GENERAL Check engine oil level (→ Page 174)

WM00286 ENGINE, GENERAL Visually inspect engine for leaks and general condition (→ Page 49)

WM00287 ENGINE, GENERAL Check maintenance indicator on air filter (→ Page 171)

WM00063 OIL FILTRATION/COOLING Centrifugal oil filter, automatic: Measure thickness of oil residue layer, clean,replace paper element; accomplish at each engine oil change at the latest

X (→ Page 179)

WM00069 LUBE OIL PUMP WITH DRIVE Inspect pump visually X (→ Page 177)

WM00136 ENGINE MOUNTING Check securing screws for firm seating X (→ Page 218)

WM00050 ENGINE MOUNTING Check general condition of rubber mounts (visual inspection) X (→ Page 219)

WM00086 FUEL FILTER Replace easy-change fuel filter (→ Page 148)

WM00085 FUEL FILTER Additional fuel filter, replace easy-change fuel filter X (→ Page 149)

WM00170 BATTERY-CHARGING GENERA-TOR

Check condition of belt and replace as necessary. Adjust belt tension X (→ Page 214)(→ Page 216)(→ Page 215)

WM00124 EXPANSION TANK Replace valve cover X (→ Page 203)

WM00076 121, 369 Replace air filter (→ Page 166)

WM00098 CYLINDER HEAD Measure valve protrusion (→ Page 122)

WM00094 VALVE DRIVE Check valve clearance, adjust as necessary. IMPORTANT! Initial setting after1,000 operating hours and every overhaul of cylinder heads after 1,000 operat-ing hours

(→ Page 127)

WM00119 CRANKCASE BREATHER Replace filter or filter element X (→ Page 120)

WM00106 CRANKCASE BREATHER Replace oil separator X (→ Page 119)

WM00110 CRANKCASE Perform endoscopic examination of cylinder liner (→ Page 115)

WM00089 FUEL INJECTOR Reset drift compensation (CDC) parameter (→ Page 225)

WM00090 FUEL INJECTOR Replace fuel injection valve/injector (→ Page 133)


Overhaul preheater X (→ Page 193)

WM00189 ENGINE MOUNTING Check general condition of resilient generator mounts (visual inspection) X (→ Page 221)

WM00188 ENGINE MOUNTING Check generator mount securing screws for firm seating X (→ Page 220)

WM00216 FUEL SUPPLY SYSTEM Check reading on vacuum gauge X (→ Page 157)

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Task Item Measures

Opt

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WM00215 FUEL SUPPLY SYSTEM Drain water and contaminants from fuel prefilter X (→ Page 151)

WM00214 FUEL SUPPLY SYSTEM Replace filter element X (→ Page 158)(→ Page 160)

WM00228 FUEL PIPEWORK FROM PUMPTO FILTER

Check cooler elements for external contamination and leak-tightness X (→ Page 222)

Table 2: Maintenance task reference table [QL1]

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7 Troubleshooting

7.1 Troubleshooting

Engine does not turn when starter is actuatedCause Corrective action

Battery low or faulty u Charge or replace (→ manufacturer's documentation).Cable connections faulty u Check cable connections for secure seating (→ manufacturer's

documentation).Starter (electric): Engine cablingor starter faulty

u Check whether cable connections are properly secured.Contact Service.

Starter (compressed air): Cablingon starting valve or starterdefective

u Check whether cable connections are properly secured.Contact Service.

Engine wiring faulty u Check (→ Page 217).Engine / generator control:Assemblies or connectorspossibly loose

u Perform visual inspection (→ manufacturer's documentation).

Engine governor: Plug-inconnections loose

u Check plug-in connections (→ Page 227).

Running gear blocked (enginecannot be barred manually)

u Contact Service.

Engine turns on starting but does not fireCause Corrective action

Poor rotation by (electric) starter:Battery low or faulty

u Charge or replace (→ manufacturer's documentation).

Poor rotation by (air) starter:Pressure too low.

u Check compressed air system.

Engine wiring faulty u Check (→ Page 217).Air in fuel system u Vent fuel system (→ Page 146).Engine governor defective u Contact Service.

Engine fires unevenlyCause Corrective action

Injector defective u Check, replace as necessary (→ Page 133).Engine wiring faulty u Check (→ Page 217).Air in fuel system u Vent fuel system (→ Page 146).Engine governor defective u Contact Service.

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Engine does not reach nominal speedCause Corrective action

Fuel prefilter (not switchable)clogged

u Replace (→ Page 158).

Fuel prefilter (switchable) clogged. u Replace (→ Page 160).Fuel filter clogged u Replace (→ Page 148).Air filter clogged u Check signal ring position of service indicator (→ Page 171).Injector defective u Replace (→ Page 133).Engine wiring faulty u Check (→ Page 217).Engine: Overload u Contact Service.

Engine speed not steadyCause Corrective action

Injector defective u Replace (→ Page 133).Speed transmitter defective u Contact Service.Air in fuel system u Vent fuel system (→ Page 146).Engine governor defective u Contact Service.

Charge-air temperature too highCause Corrective action

Engine coolant treatmentincorrect

u Check (→ MTU test kit).

Intercooler dirty u Contact Service.Engine room: Air-intaketemperature too high

u Check fans and intake/exhaust lines.

Charge-air pressure too lowCause Corrective action

Air pipework leaking u Check air pipework for leakage.Air filter clogged u Check signal ring position of service indicator (→ Page 171).Intercooler dirty u Contact Service.Exhaust turbocharger defective u Contact Service.

Coolant discharge at intercoolerCause Corrective action

Leaking, major coolant discharge u Contact Service.

Black exhaust gasCause Corrective action

Air filter clogged u Check signal ring position of service indicator (→ Page 171).Injector defective u Replace (→ Page 133).Engine: Overload u Contact Service.

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Blue exhaust gasCause Corrective action

Too much engine oil in the engine u Drain engine oil (→ Page 172).Oil separator of crankcasebreather contaminated

u Replace filter (→ Page 120).

Exhaust turbocharger, cylinderhead, piston rings or cylinder linerdefective

u Contact Service.

White exhaust gasCause Corrective action

Engine is not at operatingtemperature

u Run engine to reach operating temperature.

Water in fuel u Check fuel system on fuel prefilter;Drain water from fuel prefilter (not switchable) (→ Page 152).Drain fuel prefilter (switchable) (→ Page 154).

Intercooler leaky u Contact Service.


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7.2 Fault messages of the engine governor (ECU 9) for Series 4000genset engines (preliminary)

Possible engine responses to yellow alarm:Warning, power limitation/reduction, speed limitation, engine shutdown

Possible engine responses to red alarm:Engine shutdown, power limitation/reduction, speed limitation, warning

Procedure following an automatic safety shutdown (→ Page 47)

003 – HI T-FuelZKP-Number: 2.0122.931

Limit value 1

Cause Corrective action

Fuel temperature too high. u Contact Service.

004 – SS T-FuelZKP-Number: 2.0122.932

Limit value 2


Fuel temperature too high. Engineshutdown.

u Contact Service.

005 – HI T-Charge AirZKP-Number: 2.0121.931

Limit value 1


Charge-air temperature too high. 1. Reduce power.2. Check intercooler.

006 – SS T-Charge AirZKP-Number: 2.0121.932

Limit value 2


Charge-air temperature too high.Engine shutdown.

1. Reduce power.2. Check intercooler.


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009 – HI T-Coolant IntercoolerZKP-Number: 2.0124.931

Limit value 1


Coolant temperature inintercooler too high.

u Reduce power.

010 – SS T-Coolant IntercoolerZKP-Number: 2.0124.932

Limit value 2


Coolant temperature inintercooler too high. Engineshutdown.

u Reduce power.

015 – LO P-Lube OilZKP-Number: 2.0100.921

Limit value 1


Lube oil pressure too low. u Check oil level, top up as necessary (→ Page 174).

016 – SS P-Lube OilZKP-Number: 2.0100.922

Limit value 2


Lube oil pressure too low. Enginewill be shut down.

1. Check oil level, top up as necessary (→ Page 174).2. Attempt to restart engine (→ Page 46).

019 – HI T-Exhaust AZKP-Number: 2.0126.931

Limit value 1


Exhaust gas temperature (A-side)too high.

1. Check cabling (→ Page 217).2. Contact Service.

020 – SS T-Exhaust AZKP-Number: 2.0126.932

Limit value 2


Exhaust gas temperature (A side)too high. Engine shutdown.



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021 – HI T-Exhaust BZKP-Number: 2.0127.931

Limit value 1


Exhaust gas temperature (B-side)too high.


022 – SS T-Exhaust BZKP-Number: 2.0127.932

Limit value 2


Exhaust gas temperature (B-side)too high. Engine shutdown.


023 – LO Coolant LevelZKP-Number: 2.0152.921

Limit value 1


Coolant level too low. u Check coolant level in expansion tank(→ Page 181) .

025 – HI P-Diff-Lube OilZKP-Number: 2.0154.931

Limit value 1


Oil filter differential pressure toohigh.

u Replace oil filter (→ Page 178).

026 – SS P-Diff-Lube OilZKP-Number: 2.0154.932

Limit value 2


Oil filter differential pressure toohigh.

u Replace oil filter (→ Page 178).

027 – HI Level Leakage FuelZKP-Number: 2.0151.931

Limit value 1


Leak-fuel level too high. 1. Check fuel system.2. Contact Service.


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029 – HI ETC2 Idle Speed too HighZKP-Number: 1.8004.206


Idle speed ETC 2 too high u Contact Service.

030 – SS Engine OverspeedZKP-Number: 2.2510.932

Limit value 2


Reduced fuel injection. 1. Acknowledge alarm.2. Attempt to restart engine.

031 – HI ETC1 OverspeedZKP-Number: 2.3011.931

Limit value 1


Speed of primary turbochargertoo high.

u Contact Service.

032 – SS ETC1 OverspeedZKP-Number: 2.3012.932

Limit value 2


Speed of primary turbochargertoo high.

1. Engine control system automatically reduces power.2. Check air filters (→ Page 167).

33 – HI P-Diff-FuelZKP-Number: 20.114.931

Limit value 1


Fuel filter differential pressure toohigh.

u Replace fuel filter (→ Page 148).

34 – SS P-Diff-FuelZKP-Number: 20.114.932

Limit value 2


Fuel filter differential pressure toohigh.

u Replace fuel filter (→ Page 148).


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Limit value 1


Speed of first secondaryturbocharger too high.

1. Reduce power.2. Contact Service.


Limit value 2


Speed of first secondaryturbocharger too high.


038 – AL ETC Speed DeviationZKP-Number: 1.8004.205


Synchro fault between primaryturbocharger and one of thesecondary turbochargers.


039 – AL ETC2 Cutin FailureZKP-Number: 1.8004.204


Cut-in of turbocharger ETC 2failed.


044 – LO Coolant Level IntercoolerZKP-Number: 2.0153.921

Limit value 1


Intercooler coolant level too low. u Check coolant level (→ Page 204).

051 – HI T-Lube OilZKP-Number: 2.0125.931

Limit value 1


Lube oil temperature too high. u Reduce power.


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052 – SS T-Lube OilZKP-Number: 2.0125.932

Limit value 2


Lube oil temperature too high.Engine shutdown.

1. Reduce power.2. Check engine oil level (→ Page 174).

057 – LO P-CoolantZKP-Number: 2.0101.921

Limit value 1


Coolant pressure too low. u Check coolant circuit.

058 – SS P-CoolantZKP-Number: 2.0101.922

Limit value 2


Coolant pressure too low. Engineshutdown or reduced fuelinjection quantity.

1. Automatic engine shutdown.2. Check coolant level (→ Page 181).

59 – SS T-Coolant L3ZKP-Number: 20.120.933

Limit value 3


Coolant temperature too high/low 1. Allow engine to cool down.2. Check engine coolant cooler, clean if dirty.3. Contact Service.

60 – SS T-Coolant L4ZKP-Number: 20.120.934

Limit value 4


Coolant temperature too high/low 1. Allow engine to cool down.2. Check engine coolant cooler, clean if dirty.3. Contact Service.


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063 – HI P-Crank CaseZKP-Number: 2.0106.931

Limit value 1


Crankcase pressure too high. 1. Reduce power.2. Replace oil separator element (→ Page 120).

064 – SS P-Crank CaseZKP-Number: 2.0106.932

Limit value 2


Crankcase pressure too high.Engine shutdown.

1. Replace oil separator element (→ Page 120).2. Contact Service.

065 – LO P-FuelZKP-Number: 2.0102.921

Limit value 1


Fuel supply pressure too low. 1. Check fuel lines for leakage.2. Drain water from fuel prefilter (not switchable) (→ Page 152).

Drain water from fuel prefilter (switchable) (→ Page 154).3. Replace filter element of fuel prefilter (not switchable)

(→ Page 158).Replace filter element of fuel prefilter (switchable) (→ Page 160).

4. Replace main fuel filter (→ Page 148), if required, replaceintermediate fuel filter (→ Page 149).

066 – SS P-FuelZKP-Number: 2.0102.922

Limit value 2


Fuel supply pressure too low.Engine shutdown.

1. Check fuel lines for leakage.2. Drain water from fuel prefilter (not switchable) (→ Page 152).

Drain water from fuel prefilter (switchable) (→ Page 154).3. Replace filter element of fuel prefilter (not switchable)

(→ Page 158).Replace filter element of fuel prefilter (switchable) (→ Page 160).

4. Replace main fuel filter (→ Page 148), if required, replaceintermediate fuel filter (→ Page 149).


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067 – HI T-CoolantZKP-Number: 2.0120.931

Limit value 1


Coolant temperature too high. u Reduce power.

068 – SS T-CoolantZKP-Number: 2.0120.932

Limit value 2


Coolant temperature too high.Engine shutdown.

1. Allow engine to cool down.2. Check engine coolant cooler, clean if dirty.3. Restart engine (→ Page 46).4. Contact Service.

081 – AL Rail LeakageZKP-Number: 1.8004.046


Pressure gradient in rail is too lowduring starting or too high duringstopping HP system leaky, air insystem.

u Contact Service.

082 – HI P-Fuel (Common Rail)ZKP-Number: 2.0104.931


Rail pressure > set value. DBR fuellimitation, start of injectionreadjusted towards late; Suctionrestrictor of HP fuel blockjamming or HP fuel control blockwiring faulty.

u Contact Service.

083 – LO P-Fuel (Common Rail)ZKP-Number: 2.0104.921


Rail pressure < set value. Speedlimitation control DBR reduction.Suction restrictor of HP fuelcontrol block faulty or leakage inHP fuel system.

u Contact Service.


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085 – HI T-UmblasenZKP-Number: 2.0128.931

Limit value 1


Recirculation temperature toohigh.

u Reduce power.

086 – HIHI T-UmblasenZKP-Number: 2.0128.932

Limit value 2


Recirculation temperature toohigh.

u Reduce power.

089 – SS Engine Speed too LowZKP-Number: 2.2500.030


Engine speed too low. u Observe any other messages.

090 – SS Idle Speed Not ReachedZKP-Number: 2.1090.925


Idling speed was not attained. u Contact Service.

091 – SS Release Speed Not ReachedZKP-Number: 2.1090.924


Runup speed was not attained. u Contact Service.

092 – SS Starter Speed Not ReachedZKP-Number: 2.1090.923


Starter speed was not attained.Termination of starting sequence.Starter rotates too slowly or doesnot rotate at all.

u Contact Service.


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093 – SS T-PreheatZKP-Number: 2.1090.922

Limit value 2


Preheating temperature too low.Coolant temperature too low forengine start; engine start interlockactive.

u Check preheater.

094 – LO T-PreheatZKP-Number: 2.1090.921

Limit value 1


Preheating temperature too low;coolant temperature too low forengine start.

u Check preheater.

095 – AL Prelubrication FaultZKP-Number: 2.1090.920


Oil priming fault. u Check oil priming system.

102 – AL Fuel Cons. Counter DefectZKP-Number: 1.8004.624


Consumption meter faulty. u Contact Service.

104 – AL Eng Hours Counter DefectZKP-Number: 1.8004.623


Hour meter faulty. u Contact Service.

118 – LO ECU Power Supply VoltageZKP-Number: 2.0140.921

Limit value 1


Supply voltage too low. 1. Check supply voltage of engine governor.2. Contact Service.


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119 – LOLO ECU Power Supply VoltageZKP-Number: 2.0140.922

Limit value 2


Supply voltage too low. 1. Check supply voltage of engine governor.2. Contact Service.

120 – HI ECU Power Supply VoltageZKP-Number: 2.0140.931

Limit value 1


Supply voltage too high. 1. Check supply voltage of engine governor.2. Contact Service.

121 – HIHI ECU Power Supply VoltageZKP-Number: 2.0140.932

Limit value 2


Supply voltage too high. 1. Check supply voltage of engine governor.2. Contact Service.

122 – HI T-ECUZKP-Number: 2.0132.921

Limit value 1


Temperature in ECU too high. 1. Reduce power.2. Improve engine room ventilation.

141 – AL Power too highZKP-Number: 11.088.007


Alarm is triggered if the meanvalue of the power has exceededthe maximum value stipulated byPR1.1088.001 within the last 24hours.

u Reduce power.


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142 – AL MCR exceeded 1 hourZKP-Number: 1.1088.006


The alarm is triggered if the MCRhas been exceeded for more than1 hour within the last 12 hours.

u Reduce power.

176 – AL LifeData not availableZKP-Number: 2.4000.004


No (appropriate) LifeData backupsystem available, ECU reset afterexpiration of time-out period.

u Contact Service.

177 – AL LifeData restore incompleteZKP-Number: 2.4000.006


This fault message is generated ifa CRC is faulty during a dataupload to ADEC (indicated foreach individual module).

u Contact Service.

180 – AL CAN1 Node LostZKP-Number: 2.0500.680


Connection to a node on CAN bus1 failed.

u Contact Service.

181 – AL CAN2 Node LostZKP-Number: 2.0500.681


Connection to a node on CAN bus2 failed.

u Contact Service.

182 – AL CAN Wrong ParametersZKP-Number: 2.0500.682


Wrong parameter value entered indata record.

u Contact Service.


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183 – AL CAN No PU-DataZKP-Number: 2.0500.683


The selected CAN mode initializescommunication by means of theapplication environment datamodule. However, the necessaryPU data module is not present oris invalid.

u Contact Service.

184 – AL CAN PU-Data Flash ErrorZKP-Number: 2.0500.684


A program fault occurred whiletrying to copy a receivedapplication environment datamodule.

u Contact Service.

186 – AL CAN1 Bus OffZKP-Number: 2.0500.686


CAN controller 1 is in “Bus-Off”status.

1. Check CAN bus for short circuit, rectify short circuit as necessary.2. Check shielding, improve shielding as necessary.3. Contact Service.

187 – AL CAN1 Error PassiveZKP-Number: 2.0500.687


CAN controller 1 has indicated awarning.


188 – AL CAN2 Bus OffZKP-Number: 2.0500.688


CAN controller 2 is in “Bus-Off”status. => automatic changeoverto CAN 1. Short circuit, massiveinterference or Baud rateincompatibility.



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189 – AL CAN2 Error PassiveZKP-Number: 2.0500.689


CAN controller 2 has indicated awarning.


190 – AL EMU Parameter Not SupportedZKP-Number: 2.0500.690


EMU parameters are notsupported.

u Contact Service.

201 – SD T-CoolantZKP-Number: 1.8004.570


Coolant temperature sensorfaulty. Short circuit or wire break.

u Check sensor and cabling (B6), replace as necessary.Error cleared after restarting the engine.

202 – SD T-FuelZKP-Number: 1.8004.572


Fuel temperature sensor faulty.Short circuit or wire break.


203 – SD T-Charge AirZKP-Number: 1.8004.571


Charge-air temperature sensorfaulty. Short circuit or wire break.


204 – SD Level Lube OilZKP-Number: 1.8004.602


Lube oil level sensor defective.Short circuit or wire break.

u Check sensor and cabling, replace as necessary.


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205 – SD T-Coolant IntercoolerZKP-Number: 1.8004.574


Intercooler coolant temperaturesensor faulty. Short circuit or wirebreak.


206 – SD T-Exhaust AZKP-Number: 1.8004.576


Exhaust temperature sensor on Aside faulty. Short circuit or wirebreak.

u Check sensor and cabling (B4.21), replace as necessary.Error cleared after restarting the engine.

207 – SD T-Exhaust BZKP-Number: 18.004.577


Exhaust temperature sensor on B-side faulty. Short circuit or wirebreak

u Check sensor and cabling (B4.22), replace as necessary.

208 – SD P-Charge AirZKP-Number: 1.8004.566


Charge-air pressure sensor faulty.Short circuit or wire break.


211 – SD P-Lube OilZKP-Number: 1.8004.563


Lube oil pressure sensor faulty.Short circuit or wire break.


212 – SD P-CoolantZKP-Number: 1.8004.564


Coolant pressure sensor faulty.Short circuit or wire break.



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213 – SD P-Coolant IntercoolerZKP-Number: 1.8004.569


Intercooler coolant pressuresensor faulty. Short circuit or wirebreak.


214 – SD P-CrankCaseZKP-Number: 1.8004.568


Crankcase pressure sensor faulty.Short circuit or wire break.


215 – SD P-HDZKP-Number: 1.8004.567


Rail pressure sensor faulty. High-pressure regulator in emergencymode ==> Short circuit or wirebreak.


216 – SD T-Lube OilZKP-Number: 1.8004.575


Lube oil temperature sensorfaulty. Short circuit or wire break.


219 – SD T-Intake AirZKP-Number: 1.8004.573


Intake air temperature sensorfaulty. Short circuit or wire break.


220 – SD Level Coolant WaterZKP-Number: 1.8004.584


Coolant level sensor faulty. Shortcircuit or wire break.

u Check sensor and cabling (F33), replace as necessary.Error cleared after restarting the engine.


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221 – SD P-Diff Lube OilZKP-Number: 1.8004.585


Lube oil pressure differentialsensor faulty. Short circuit or wirebreak.


222 – SD Level Leakage FuelZKP-Number: 1.8004.582


Leak-off fuel level sensor faulty.Short circuit or wire break.


223 – SD Level Coolant IntercoolerZKP-Number: 1.8004.583


Sensor for intercooler coolantlevel faulty. Short circuit or wirebreak.


227 – SD P-Lube Oil before FilterZKP-Number: 1.8004.620


Sensor for lube oil pressurebefore filter faulty. Short circuit orwire break.


228 – SD P-Fuel before FilterZKP-Number: 18.004.595


Fuel pressure sensor faulty. Shortcircuit or wire break.


229 – AL Stop Camshaft Sensor DefectZKP-Number: 1.8004.562


Engine stop due to camshaftsensor fault (and a previouscrankshaft sensor fault in thesame operating cycle).

u Check connector and cabling to sensor B1, replace as necessary.Error cleared after restarting the engine.


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230 – SD Crankshaft SpeedZKP-Number: 1.8004.498


Crankshaft sensor faulty. Shortcircuit or wire break.


231 – SD Camshaft SpeedZKP-Number: 1.8004.499


Camshaft sensor faulty. Shortcircuit or wire break.


232 – SD Charger 1 SpeedZKP-Number: 1.3011.128


Speed sensor of primaryturbocharger faulty. Short circuitor wire break.


233 – SD Charger 2 SpeedZKP-Number: 1.3011.129


Speed sensor of secondaryturbocharger faulty. Short circuitor wire break.


239 – SD P-Diff FuelZKP-Number: 18.004.598


Fuel differential pressure sensorfaulty.This alarm occurs only incombination with the alarm SD P-Fuel before Filter or SD P-Fuelafter Filter.

u Observe additional message.

240 – SD P-FuelZKP-Number: 1.8004.565


Fuel pressure sensor faulty. Shortcircuit or wire break.



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241 – SD T-UmblasenZKP-Number: 1.8004.581


Recirculation sensor faulty. Shortcircuit or wire break.


242 – SD T-Coolant (R)ZKP-Number: 1.8004.622


Redundant coolant pressuresensor faulty. Short circuit or wirebreak.

u Check sensor and cabling, replace as necessary.Error cleared after restarting the engine.

244 – SD P-Lube Oil (R)ZKP-Number: 1.8004.621


Redundant lube oil pressuresensor faulty. Short circuit or wirebreak.


245 – SD ECU Power Supply VoltageZKP-Number: 2.8006.589


Internal ECU fault. Electronicsfaulty.

u Replace engine governor.

266 – SD Speed DemandZKP-Number: 2.8006.586


Analog speed setting faulty. Shortcircuit or wire break.

1. Check cabling.2. Check speed demand.

268 – SD Spinning ValueZKP-Number: 28.006.591


Analog skid signal faulty. Shortcircuit or wire break.



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269 – SD Loadp.Analog filt.ZKP-Number: 2.8006.588


Filtered analog signal of loadpulse missing. Short circuit orwire break.

u Check wiring, replace as necessary.Error cleared after restarting the engine.

270 – SD Frequency InputZKP-Number: 2.8006.590


Frequency input faulty. Shortcircuit or wire break.

1. Check cabling.2. Check speed demand transmitter.3. Contact Service.

301 – AL Timing Cylinder A1ZKP-Number: 1.8004.500


Time-of-flight measuring fault ofinjector: Flight time valueextremely low or extremely high.

u Replace injector concerned if the fault message appears frequently(→ Page 133).














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311 – AL Timing Cylinder B1ZKP-Number: 1.8004.510

























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321 – AL Wiring Cylinder A1ZKP-Number: 1.8004.520


Cabling fault in injector cabling tocylinder. Result: Misfiring.

1. Check solenoid valve.2. Contact Service.






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331 – AL Wiring Cylinder B1ZKP-Number: 1.8004.530

























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341 – AL Open Load Cylinder A1ZKP-Number: 1.8004.540


Disruption fault in injector cablingto cylinder. Result: Misfiring.











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351 – AL Open Load Cylinder B1ZKP-Number: 1.8004.550





























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361 – AL Power Stage LowZKP-Number: 1.8004.496


Internal electronic fault(electronics possibly faulty: startITS) .Check additional messages ifITS indicates diagnosis"Electronics OK" (e.g. cablingfaulty).

1. Check solenoid valve cabling.2. Replace engine governor.

362 – AL Power Stage HighZKP-Number: 1.8004.497


Internal electronic fault(electronics possibly faulty: startITS) .Check additional messages ifITS indicates diagnosis"Electronics OK" (e.g. cablingfaulty).

1. Check solenoid valve cabling.2. Replace engine governor.


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363 – AL Stop Power StageZKP-Number: 1.8004.560


Internal electronic fault(electronics possibly faulty: startITS).

1. Check cabling.2. Attempt to restart engine.

365 – AL Stop MV-Wiring GroundZKP-Number: 1.8004.561


Injector cabling fault. If bit"1.1020.021" (power stagefailure: Stop engine) is set, engineis additionally stopped in thiscase. 1. Short circuit of injector +connection of one or moreinjectors to ground 2. Shortcircuit of injector – connection ofone or more injectors to ground.

1. Check cabling.2. Attempt to restart engine.

371 – AL Wiring TO 1ZKP-Number: 1.8004.634


Short circuit or wire break ontransistor output 1 (TO 1).

1. Check charger valve/cabling, repair as necessary.2. Replace engine governor.




1. Check recirculation valve/cabling, repair as necessary.2. Replace engine governor.




u -




u -


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381 – AL Wiring TOP 1ZKP-Number: 2.8006.638


Short circuit or wire break ontransistor output, plant-side 1(TOP 1).

u Check cabling to plant.













390 – AL MCR exceededZKP-Number: 1.1085.009


DBR/MCR function: MCRexceeded.

1. No action required if alarm only applied temporarily.2. Contact Service if alarm applied constantly.

392 – HI T-Coolant RedZKP-Number: 2.0129.931

Limit value 1


Redundant coolant temperaturereading too high.

1. Check cabling.2. Contact Service.


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393 – SS T-Coolant RedZKP-Number: 2.0129.932

Limit value 2


Redundant coolant temperaturereading too high; Engineshutdown.

1. Check wiring and sensor.2. Contact Service.

394 – LO P-Lube Oil RedZKP-Number: 2.0112.921

Limit value 1


Redundant lube oil pressurereading too low.


395 – SS P-Lube Oil RedZKP-Number: 2.0112.922

Limit value 2


Redundant lube oil pressurereading too low.


396 – TD T-Coolant Sensor DeviationZKP-Number: 1.0480.193


Maximum coolant temperaturedeviation.


397 – TD P-Oil Sensor DeviationZKP-Number: 1.0480.293


Maximum lube oil pressuredeviation.


400 – AL Open Load Digital Input 1ZKP-Number: 2.8006.625


Line disruption on digital input 1.Cabling faulty or no resistanceover switch.

1. Check cabling.2. Check target device input.3. Contact Service.


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408 – AL Open Load Emerg. Stop Input ESIZKP-Number: 2.8006.633


Line disruption on the input foremergency stop; Cabling faulty orno resistance over switch.


410 – LO U-PDUZKP-Number: 2.0141.921

Limit value 1


Injector voltage too low. 1. Check cabling.2. Check supply.3. Contact Service.

411 – LOLO U-PDUZKP-Number: 2.0141.922

Limit value 2


Injector voltage too low. 1. Check cabling.2. Check supply.3. Contact Service.

412 – HI U-PDUZKP-Number: 2.0141.931

Limit value 1


Injector voltage too high. 1. Check cabling.2. Check supply.3. Contact Service.


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413 – HIHI U-PDUZKP-Number: 2.0141.932

Limit value 2


Injector voltage too high. 1. Check cabling.2. Check supply.3. Contact Service.

414 – HI Level Water Fuel PrefilterZKP-Number: 2.0156.931

Limit value 1


Water level in fuel prefilter toohigh.

u Drain water (→ Page 152), (→ Page 154).

415 – LO P-Coolant InterCoolerZKP-Number: 2.0107.921

Limit value 1


Coolant pressure in intercoolertoo low.

u Top up coolant (→ Page 209).

416 – SS P-Coolant InterCoolerZKP-Number: 2.0107.922

Limit value 2


Coolant pressure in intercoolertoo low. Engine shutdown.

u Top up coolant (→ Page 209).

417 – SD Level Water Fuel PrefilterZKP-Number: 1.8004.594


Sensor for water level in fuelprefilter faulty. Short circuit orwire break.


419 – SD T-Coolant b.EngineZKP-Number: 18.004.604


Coolant inlet temperature sensorfaulty. Short circuit or wire break.

u Check sensor and cabling (B3), replace as necessary.


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420 – AL L1 Aux 1ZKP-Number: 2.0160.921

Limit value 1


Input signal of Aux 1 hasexceeded/not attained limit value1, depending on configuration.

u Determine cause of limit value violation and rectify fault.

421 – AL L2 Aux 1ZKP-Number: 2.0160.922

Limit value 2


Input signal of Aux 1 hasexceeded/not attained limit value2, depending on configuration.


428 – AL L1 T-Aux 1ZKP-Number: 2.0130.921

Limit value 1


Temperature signal of Aux 1 hasexceeded / not attained limitvalue 1, depending onconfiguration.


430 – LO P-Coolant before EngineZKP-Number: 20.168.921

Limit value 1


Coolant pressure too low u Check coolant circuit.

431 – SS P-Coolant before EngineZKP-Number: 20.168.922

Limit value 2


Coolant pressure too low. u Check coolant circuit.


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434 – HI T-Coolant before EngineZKP-Number: 20.173.931

Limit value 1


Coolant temperature too high. u Check coolant circuit.

435 – SS T-Coolant before EngineZKP-Number: 20.173.932

Limit value 2


Coolant temperature too high. u Check coolant circuit.

440 – AL L1 P-Aux 1ZKP-Number: 2.0110.921

Limit value 1


Pressure signal of Aux 1 hasexceeded / not attained limitvalue 1, depending onconfiguration.


442 – AL L2 P-Aux 1ZKP-Number: 2.0110.931

Limit value 2


Pressure signal of Aux 1 hasexceeded / not attained limitvalue 2, depending onconfiguration.


444 – SD U-PDUZKP-Number: 1.8004.578


Injector power stage sensordefect. Internal fault in ECU.


445 – SD P-Ambient AirZKP-Number: 1.8004.580


Ambient air pressure sensorfaulty.



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448 – HI P-Charge AirZKP-Number: 2.0103.931

Limit value 1


Charge-air pressure too high. u Contact Service.

449 – SS P-Charge AirZKP-Number: 2.0103.932

Limit value 2


Charge-air pressure too high. u Contact Service.

450 – SD Idle/End-Torque Input [%]ZKP-Number: 2.8006.592


Input signal for initial/final torquefaulty; Short circuit or wire break.

u Check signal transmitter and cabling, replace as necessary.Error cleared after restarting the engine.

454 – SS Power Reduction ActiveZKP-Number: 2.7000.011


Power reduction is active. 1. Check for additional fault messages.2. Determine cause of power reduction and rectify fault.

455 – AL L1 Aux1 PlantZKP-Number: 2.8006.650

Limit value 1


Input signal of Aux 1 (plant side)has exceeded/not attained limitvalue 1, depending onconfiguration.


456 – AL L2 Aux1 PlantZKP-Number: 2.8006.651

Limit value 2


Input signal of Aux 1 (plant side)has exceeded/not attained limitvalue 2, depending onconfiguration.



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460 – HI T-Exhaust EMUZKP-Number: 2.8006.652

Limit value 1


EMU exhaust gas temperaturevalue too high.


461 – LO T-Exhaust EMUZKP-Number: 2.8006.653

Limit value 1


EMU exhaust gas temperaturevalue too low.


462 – HI T-Coolant EMUZKP-Number: 2.8006.654

Limit value 1


EMU coolant temperature valuetoo high / low.

u Check configuration with DiaSys.

464 – SD P-AUX 1ZKP-Number: 1.8004.589


Analog input signal for Aux 1pressure faulty. Short circuit orwire break.

u Check pressure transmitter and cabling, replace as necessary.Error cleared after restarting the engine.

467 – AL L2 T-Aux 1ZKP-Number: 2.0130.922

Limit value 2


Temperature signal of Aux 1 hasexceeded / not attained limitvalue 2, depending onconfiguration.


468 – SD T-AUX 1ZKP-Number: 1.8004.579


Analog input for Aux 1temperature faulty.



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469 – SD AUX 1ZKP-Number: 1.8004.590


Analog input signal for Aux 1faulty. Short circuit or wire break.

u Check signal transmitter and cabling, replace as necessary.Error cleared after restarting the engine.

470 – SD T-ECUZKP-Number: 1.8004.587


Temperature sensor for ECUfaulty. Short circuit or wire break.


471 – SD Coil CurrentZKP-Number: 1.8004.592


Control of HP fuel control blockfaulty. Short circuit or wire break.


472 – AL Stop SDZKP-Number: 2.8006.593


Engine stop, since all shutdownchannels have "sensor faulty".


473 – AL Wiring PWM_CM2ZKP-Number: 1.8004.593


Cable break or short circuit onchannel PWM_CM2.


474 – AL Wiring FOZKP-Number: 2.8006.655


Cable break or short circuit onchannel FO.



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475 – AL CR Trigger Engine StopZKP-Number: 1.8010.009


Tripped by crash recordertriggering due to engineshutdown.

u Determine and rectify cause of triggering / engine shutdown.

476 – AL Crash Rec. Init. ErrorZKP-Number: 1.8010.007


Initialization error of crashrecorder.

u Check settings with DiaSys.

478 – AL Comb. Alarm Yel (Plant)ZKP-Number: 2.8006.001


Combined alarm YELLOW fromplant.

u Check additional messages.

479 – AL Comb. Alarm Red (Plant)ZKP-Number: 2.8006.002


Combined alarm RED from plant. u Check additional messages.

480 – AL Ext. Engine ProtectionZKP-Number: 20.291.921


External engine protectionfunction active.

u Monitoring of plant signal by ECU active (plant side). Check plantsignal.

482 – SD T-Exhaust CZKP-Number: 18.004.596





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483 – SD T-Exhaust DZKP-Number: 18.004.597




484 – HI T-Exhaust CZKP-Number: 20.133.931

Limit value 1


Exhaust gas temperature (C-side)too high.


485 – SS T-Exhaust CZKP-Number: 20.133.932

Limit value 2


Exhaust gas temperature (C-side)too high.


486 – HI T-Exhaust DZKP-Number: 20.134.931

Limit value 1


Exhaust gas temperature (D-side)too high.


487 – SS T-Exhaust DZKP-Number: 20.134.932

Limit value 2


Exhaust gas temperature (D-side)too high.



Limit value 1


Speed of second secondaryturbocharger too high.

u Reduce power.


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Limit value 2


Speed of second secondaryturbocharger too high.

u Reduce power.


Limit value 1


Speed of the third secondaryturbocharger too high.

u Reduce power.


Limit value 2


Speed of the third secondaryturbocharger too high.

u Reduce power.



ETC4 failed to cut in. u Check control valve at turbocharger 4.



ETC3 failed to cut in. u Check control valve at turbocharger 3.

500 – AL Wiring POM Starter 1ZKP-Number: 14.500.900


A cabling fault in connection ofstarter 1 of CPM has beendetected. This may be due to amissing consumer, wire break or ashort circuit.

u Check connection between POM and starter.


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501 – AL Wiring POM Starter 2ZKP-Number: 14.500.901


A cabling fault in connection ofstarter 2 of CPM has beendetected. This may be due to amissing consumer, wire break or ashort circuit.

u Check connection between POM and starter.

502 – AL Open Load POM AlternatorZKP-Number: 14.500.902


A line interruption was detectedat the battery-chargingconnection for the POM.

u Check connection between POM and battery-charging generator.

503 – AL Battery Not ChargingZKP-Number: 14.500.903


Battery is not charged by battery-charging generator.

u Check battery-charging generator and cabling.

504 – AL CAN POM Node LostZKP-Number: 14.500.904


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

506 – AL Low Starter VoltageZKP-Number: 14.500.906


The battery voltage is too low forthe starting process .

u Check starter battery and cabling.

507 – AL POM ErrorZKP-Number: 14.500.907


A general POM fault occurred. u Replace POM.


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508 – AL Wrong POM-IDZKP-Number: 14.500.908


POM sends a different ID numberthan expected.

u Check POM wiring harness.

510 – AL Override appliedZKP-Number: 27.002.010


Override Acknowledged. u Deactivate Override pushbutton again.

515 – AL Starter Not EngagedZKP-Number: 21.090.926


Starter on CPM / POM could notbe engaged. If the number ofautomatic start attempts from PR2.1090.134 Number of StartAttempts is used up then start iscanceled. Check CPM, starter andcabling.

1. Repeat starting attempt2. Check CPM, starter and cabling.

519 – Oillevel Calibration ErrorZKP-Number: 10.158.921


Error when writing the calibrationvalue to flash memory or levelsensor defect.

1. Check sensor and cabling, replace as necessary.2. Contact Service.

521 – SS P-Lube Oil Mid ValZKP-Number: 20.480.289

Limit value 1


Average oil pressure value fromthree sources is too low.

u Check oil level, top up as necessary.

523 – SS T-Coolant Red Mid ValZKP-Number: 20.480.189

Limit value 2


Average coolant temperaturevalue from three sources is toohigh.

u Reduce power.


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524 – SS Engine Overspeed Mid ValZKP-Number: 20.480.089

Limit value 2


Average engine overspeed valuefrom three sources is too high.

1. Acknowledge alarm.2. Attempt to restart engine.

525 – SD P-Lube Oil (R2)ZKP-Number: 18.004.638


Redundant lube oil pressuresensor faulty. Short circuit or wirebreak.


526 – SD T-Coolant (R2)ZKP-Number: 18.004.639




527 – TD EngineSpd. Sensor DeviationZKP-Number: 10.480.093


Maximum deviation of speedsensors

1. Check speed sensor cabling.2. Observe any other messages.3. Contact Service.

528 – SD Engine Speed 3rd SensorZKP-Number: 12.500.102




529 – SS T-Coolant Red2ZKP-Number: 20.480.195

Limit value 2


Second redundant coolanttemperature too high.

u Check coolant circuit.


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530 – SS P-Lube Oil Red2ZKP-Number: 20.480.295

Limit value 2


Second redundant lube-oilpressure too high.

u Check oil level, top up as necessary.

543 – AL Multiple FDH SlavesZKP-Number: 20.555.005


There is more than one deviceactivated as backup medium forFDH.

u Contact Service.

544 – AL Configuration ChangedZKP-Number: 20.555.003


This fault becomes active in casesin which the system configurationhas been changed, e.g. due toreplacement of an ECU or a SAM.

u Fault remains active until changes are revoked or data has beentransferred by active maintenance. Fault is then automaticallycleared.

549 – AL Power Cut-Off detectedZKP-Number: 27.001.952

This is an alarm from the emergency stop counter function.


ECU operating voltage wasswitched off while the engine wasrunning. This can result inoverpressure in the high-pressuresystem, whereby the engine maybe damaged.

u Instruct operators to switch off the power supply only after theengine has come to a standstill.

550 – SS Engine Overspeed Red2ZKP-Number: 20.480.095

Limit value 2


Redundant engine overspeed. 1. Acknowledge alarm.2. Attempt to restart engine.


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551 – SS Engine Overspeed CamshaftZKP-Number: 22.510.933

Limit value 2


Camshaft overspeed. 1. Acknowledge alarm.2. Attempt to restart engine.

555 – AL Call MTU Field ServiceZKP-Number: 20.555.001


This fault becomes active if amaintenance case has beenprocessed by the ECU Field DataHandling (FDH) feature thatresults in a change of engineparameters.This fault remains active evenafter switching off and back onuntil a valid enabling code isentered via the SAM display andkey controls. This enabling codecan be requested via the internetusing a special procedure.

u Request enabling code via internet.

576 – AL ESCM OverrideZKP-Number: 11.075.083


Violation of corrected MCR orDBR/MCR curve. Engine overload!

u Reduce power.

577 – SD T-Lube Oil PanZKP-Number: 10.137.900


Oil pan temperature sensor faulty.Short circuit or wire break.


578 – AL L1 T-Lube Oil PanZKP-Number: 20.137.921

Limit value 1


L1 T-Lube Oil Pan has violatedlimit value 1.

u


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579 – AL MD CAN Request Idle SpeedZKP-Number: 21.063.511


MD forced idle demand => nodefailure (node 3, 4 or 5)

u

580 – AL MD CAN Speed LimitationZKP-Number: 21.063.513


MD speed limitation demand =>node failure (node 3, 4 or 5)

u

581 – AL MD CAN StopZKP-Number: 21.063.515


MD CAN stop demand => nodefailure (node 3, 4 or 5)

u


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8 Task Description

8.1 Engine

8.1.1 Engine – Barring manually



Barring tool F6555766 1Ratchet with extension F30006212 1

DANGERRotating and moving engine parts.Risk of crushing, danger of parts of the body being caught or pulled in!• Before cranking the engine with starter system, make sure that there are no persons in the engine's

danger zone.

Barring engine manually1. Loosen screws (1) and remove end cover (2)

from flywheel housing.

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2. Engage barring tool (2) in ring gear of fly-wheel and mount on flywheel housing.

3. Fit ratchet (1) on barring tool.

Note: No resistance other than compression resist-ance must be encountered.

4. Rotate crankshaft in engine direction of rota-tion.

Result: If the resistance exceeds the normal com-pression resistance, contact Service.

5. For barring tool removal follow reverse se-quence of working steps.

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8.1.2 Engine – Cranking on starting system

DANGERRotating and moving engine parts.Risk of crushing, danger of parts of the body being caught or pulled in!• Before barring the engine, make sure that there are no persons in the engine's danger zone.• After finishing work on the engine, make sure that all safety devices are put back in place and all

tools are removed from the engine.

Note: Crank the engine on the starting system in the following cases only:• To prime the engine: Procedure for engines without lube oil priming pump only. Use the lube oil priming

pump to prime engines equipped with such (→ Page 44).• Before starting the engine in a contingency situation to maintain operation of a leaking intercooler

(→ Page 165)..

Cranking engine on starting systemNote: • The engine must not start and no fuel may be injected when cranking.

• The ECU must by energized in order to crank the engine.1. Choose one of the following procedures:

a) External starting sequence: The Stop signal is applied at the ECU. The starters are energized by the plantcontroller.

b) Internal starting sequence: The engine can be cranked on the starter without injecting fuel via CAN-J1939, SPN 1206.

Note: Leave intervals between cranking operations to avoid overheating the starter.2. Perform the following steps three times in a row:

a) Crank the engine for 15 seconds.b) Wait 60 seconds.

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8.1.3 Engine – Test run




Engine – Test run1. Start engine (→ Page 46).2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.3. Carry out operational checks (→ Page 49).4. Stop engine (→ Page 51).

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8.2 Cylinder Liner

8.2.1 Cylinder liner – Endoscopic examination

Preconditions☑Engine is stopped and starting disabled


Barring tool F6555766 1Ratchet with extension F30006212 1Endoscope Y20097353 1

Preparatory steps1. Remove cylinder head cover (→ Page 130).2. Remove injector (→ Page 140).

Positioning crankshaft at BDC1. Using barring tool, turn crankshaft until crankshaft journal of the cylinder to be tested has reached BDC.2. Insert endoscope into cylinder liner through injector seat.

Endoscopic examination of cylinder linerFindings Measure• Thin carbon coating around carbon scraper ring• 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

No actions required.

• Dark areas with even or varying degrees of discoloration• Beginning and end of the discoloration are not sharply defined and do

not cover the entire stroke area• Dark areas in the upper section of the cooling bore, remaining circum-

ference are faultless• Piston rings are faultless

Further endoscopic examina-tion required as part of mainte-nance work.

• On the entire circumference, apart from light areas of discoloration (donot impair operation) clearly darker stripes that start at the top pistonring

• Heat discoloration in the direction of stroke and honing pattern dam-age

• Heat discoloration of piston rings

Cylinder liner must be replaced,contact Service.

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1. Compile endoscopic report using the table.2. Use technical terms to describe the liner surface (→ Page 117).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 steps1. Install injector (→ Page 140).2. Install cylinder head cover (→ Page 130).

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8.2.2 Cylinder liner – Instructions and comments on endoscopic and visualexamination

Terms used for endoscopic examinationUse the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina-tion report.

Findings Explanations/ActionMinor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,

particles, broken-off burrs). Removed cylinders clearly show such scoring on therunning 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 areaand cross through the honing pattern in the direction of stroke.Findings not critical

Scored area These areas consist of scores of different length and depth next to one another. Inmost cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/exhaust) along the transverse engine axis.Findings not critical

Polished area Polished areas are on the running surface but almost the whole honing pattern isstill visible. Polished areas appear brighter and more shiny than the surroundingrunning surface.Findings not critical

Bright area Bright areas are on the running surface and show local removal of the honing pat-tern. Grooves from the honing process are not visible any more.

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-ture differences around the liner. It appears rather darker within the honed struc-ture in contrast to the bright metallic running surface. The honing pattern is undis-turbed. Discolorations extend in stroke direction and may be interrupted.Findings not critical

Corrosion fields /spots

Corrosion fields / spots result from moisture (condensate) with the valves in theoverlap (open) position. They are clearly visible due to the dark color of the honinggroove bottom.This corrosion is not critical unless there is corrosion pitting.

Black lines Black lines are a preliminary stage of burn marks. They are visible as a clear discol-oration from TDC to BDC in the running surface and the start of localized damageto the honing pattern.Cylinder liners with a large number of black lines around the running surface havelimited service life and should be replaced.

Burn mark These are caused by a disturbance in the liner / ring tribo system. Usually they runover 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 pronouncedfrom TDC-ring 1. The honing pattern is usually no longer visible and displays aclearly defined (straight) edge to the undisturbed surface. The damaged surface isusually discolored. The circumferential length varies.Liners with burn marks starting in TDC ring 1 have to be replaced.

Seizure marks, scuff-ing

Irregular circumference lengths and depths. Can be caused either by the pistonskirt or the piston crown. Material deposits on the liner (smear), heavy discolora-tion. Severe, visible scoring.Replace liner.

Table 3: Endoscopic examination – Terms used

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Evaluation of findings and further measuresThe findings in the start phase of oxidation discoloration and burn marks are similar. A thorough investigationand compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessarydisassembly work, it is recommended that another inspection be carried out after further operation of theengine.

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8.3 Crankcase Breather

8.3.1 Crankcase breather – Oil mist fine separator replacement



Oil mist fine separator (→ Spare Parts Catalog)O-ring (→ Spare Parts Catalog)

WARNINGOil is hot.Oil can contain residue/substances which are harmful to health.Risk of injury and poisoning!• Allow the product to cool to below 50 °C before beginning work.• Wear protective clothing, protective gloves and goggles/safety mask.• Avoid contact with skin.• Do not inhale oil vapor.

Replacing oil mist fine separator1. Remove screws (1) and take off together with

retainer (2).2. Replace oil mist fine separator (3).3. Replace O-ring (4) if necessary.4. Replace further oil mist fine separators in the

same way.

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8.3.2 Crankcase breather – Filter element replacement



Torque wrench, 10–60 Nm F30452769 1Engine oilFilter insert (→ Spare Parts Catalog) 2Sealing ring (→ Spare Parts Catalog)Locknut (→ Spare Parts Catalog)Disk (→ Spare Parts Catalog)


Crankcase breather – Filter ele-ment replacement

1. Release lines (1) from distributor (2).2. Remove screws (3) on vent lines (4) and re-

move vent lines with O-rings.3. Unscrew screws (5) with washers.4. Remove diaphragm housing (6).

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5. Unscrew nut (2) remove together with wash-ers.

6. Remove cover (1) and sealing ring.7. Replace filter element (3).8. Replace sealing ring as necessary.9. Install sealing ring and cover (1).

10. Screw on new nut (2) with new washers and tighten nut (2) to specified torque using a torque wrench.


Nut Tightening torque 10 Nm ±2 Nm

11. Replace further filter elements in the same way.12. Install diaphragm housing and lines.

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8.4 Valve Drive

8.4.1 Valve protrusion – Measurement



Measuring jig 1 Y4350009 1Depth gage, 200 mm Y20000918 1Measuring jig 2, optional Y4350010 1

Preparatory steps1. Remove cylinder head covers (→ Page 130).2. Install barring tool (→ Page 111).

3. Turn crankshaft in direction of rotation usingbarring tool until TDC mark (1) and pointer (2)are aligned.

Calibrating measuring jigs 1 and2

1. Place measuring unit (2) on calibrationplate (3).

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2. Turn measuring unit screws (1) into the threads and tighten to specified torque using a torque wrench.


Screw M10 Tightening torque 20 Nm

3. Set all dial gages to 0.4. Unscrew measuring unit (2) from calibration plate (3).

Step 1: Measure valve protrusion at the valve head with measuring jig 11. Check TDC position of piston in cylinder A1:

• If rocker arms on cylinder A1 are unloaded, the piston is in firing TDC.• If rocker arms on cylinder A1 are loaded, the piston is in overlap TDC.

2. Measure valve stem end to cylinder head top distance for each valve in two crankshaft positions (firing TDCand overlap TDC) according to the diagram. Diagram (→ Page 127).

3. Place measuring unit 1 (2) on the cylinderhead (3).

4. Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specifiedtorque using a torque wrench.



5. Determine the values with all dial gages.• The valve protrusion value must be ≤ 1.5 mm.• If the value is > 1.5 mm, measure with a depth gage or optionally with measuring jig 2.

6. Unscrew measuring unit (2) from cylinder head (3).

Step 2: Measure valve protrusion at the valve stem with a depth gage1. Check TDC position of piston in cylinder A1:

• If rocker arms on cylinder A1 are unloaded, the piston is in firing TDC.• If rocker arms on cylinder A1 are loaded, the piston is in overlap TDC.


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3. Release adjusting screw (1) and remove valvebridge. Do not remove rocker arm (2).

4. Measure distance (A) between valve stemend and cylinder head top at the injectorbore with depth gage.• The specified value for a new cylinder

head: 93.8 mm.• Admissible wear: 2 mm.• Have the affected cylinder head replaced

by expert personnel ahead of schedule ifthe measured value is > 95.8 mm.

5. Install valve bridge.6. Adjusting valve clearance (→ Page 127)

Step 2 optional: Measure valve protrusion at the valve stem with measuringjig 2

1. Check TDC position of piston in cylinder A1:• If rocker arms on cylinder A1 are unloaded, the piston is in firing TDC.• If rocker arms on cylinder A1 are loaded, the piston is in overlap TDC.


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Note: Do not remove rocker arm (2).3. Release adjusting screw (1) and remove valve

bridge.

4. Place measuring unit 2 (2) on the cylinderhead (3).

5. Turn measuring unit screws (1) into the threads provided for the cylinder head cover and tighten to specifiedtorque using a torque wrench.



6. Determine the values with all dial gages.• The valve protrusion value must be ≤ 2 mm.• Have the affected cylinder head replaced by expert personnel if the value is > 2 mm.

7. Unscrew measuring unit (2) from cylinder head (3).8. Install valve bridge.9. Adjusting valve clearance (→ Page 127)

Final steps1. Remove barring tool (→ Page 111).2. Install cylinder head cover (→ Page 130).

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8.4.2 Valve gear – Lubrication



Engine oil

Valve gear – Lubrication1. Remove cylinder head covers (→ Page 130).2. Fill oil chambers of valve bridges with oil.3. Fill oil chambers of rocker arms and adjusting

screws with oil.4. Install cylinder head covers (→ Page 130).

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8.4.3 Valve clearance – Check and adjustment


☑Engine coolant temperature is max. 40 °C.

☑Valves are closed.


Feeler gage Y20098771 1Torque wrench, 60–320 Nm F30452768 1Socket wrench, 24 mm F30039526 1Ratchet bit F30027341 1Engine oil

Preparatory steps1. Remove cylinder head cover (→ Page 130).2. Install barring device (→ Page 111).

Note: Pointer (1) is located in the lower opening ofthe flywheel housing (arrow).

3. Use barring device to turn crankshaft in di-rection of rotation until the OT/A1 mark onthe rear side of the flywheel and pointer (1)are aligned.

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Note: Risk of confusion: Additional OT/A1 mark (1)on flywheel, if fitted.

4. The additional OT/A1 mark (1) on the perim-eter of the flywheel must not be used for ref-erence.

Diagram for 20V engines (twocrankshaft positions)

Checking valve clearance at two crankshaft positions1. Check TDC position of piston in cylinder A1:

• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.

2. Check valve clearance with cold engine:• Inlet valves (long rocker arm) = 0.2 mm ±0.05 mm• Exhaust valves (short rocker arm) = 0.5 ±0.05 mm

3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as perdiagram:

1 Cylinder A1 is in firing TDC2 Cylinder A1 is in overlap TDCI Inlet valve

X Exhaust valve4. 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.

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Adjusting valve clearance1. Release locknut (1).2. Insert feeler gauge (3) between valve bridge

and rocker arm.

Note: Replace or rectify adjusting screws and/orlocknuts which do not move freely.

3. Using Allen key, set adjusting screw (2) sothat the specified valve clearance is provided.

Note: Feeler gauge must just pass through the gap.4. Pull feeler gauge (3) between valve bridge

and rocker arm.

Note: Hold adjusting screw (2)firmly in position.5. Tighten lock nut (1) to specified tightening torque using a torque wrench.


Locknut M16x1.5 Tightening torque (Engine oil) 90 Nm +9 Nm

6. Check valve clearance, adjust if necessary.

Final steps1. Remove barring device (→ Page 111).2. Install cylinder head cover (→ Page 130).3. Enable engine start.

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8.4.4 Cylinder head cover – Removal and installation



Assembly compound (Kluthe Hakuform 30-15) X00067260 1O-ring (→ Spare Parts Catalog)

Removing cylinder head cover1. Clean very dirty cylinder head covers (1) prior

to removal.2. Remove screws (3, 4) with washers (2, 5).3. Take off cylinder head cover with O-ring (6)

from cylinder head (7).

Installing cylinder head cover1. Clean installation surface.2. Check O-ring (6) for damage, replace as necessary.3. Coat O-ring with assembly compound.4. Insert O-ring in groove on cylinder head cover (1).5. Fit cylinder head cover on cylinder head (7).6. Install cylinder head cover with screws (3, 4) and washers (2, 5).

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8.5 Injection Pump / HP Pump

8.5.1 HP fuel pump – Filling with engine oil



Torque wrench, 10–60 Nm F30452769 1Fuel suction device F30378207 1Engine oil

WARNINGFuels are combustible and explosive.Risk of fire and explosion!• Avoid open flames, electrical sparks and ignition sources.• Do not smoke.• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNINGLiquid or gaseous media, e.g. fuel, are poisonous.Escaping vapors of highly volatile media, e.g. fuel or ether.Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyesand skin!• Seek medical attention immediately; do not induce vomiting.• Do not inhale vapors or mist.• Wear protective clothing, protective gloves, and safety glasses.• If contact is made with skin, wash off with water and soap.

WARNINGOils/oil vapors are combustible/explosive.Risk of fire and explosion!• Avoid open flames, electric sparks and ignition sources.• Do not smoke.

NOTICEHP fuel pump not filled with engine oil.Damage to components, major material damage!• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.

NOTICEContaminated components.Risk of damage to component!• Check components for special cleanliness and clean if necessary.

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Preparatory stepsu Loosen nut (2) and remove oil line (1) from

HP pump.

HP pump – Filling1. Remove union (1).

Note: Excess engine oil runs into gear box.2. Use fuel suction device to fill HP pump with

2 liters of clean engine oil.

3. Screw in union (1) and use torque wrench to tighten to specified tightening torque.


Neck M16x1.5 Tightening torque 40 Nm

Final stepsu Install oil line.

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8.6 Injector

8.6.1 Injector – Replacement


Injector (→ Spare Parts Catalog)

Injector – Replacementu Remove injector and install new one (→ Page 140).

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8.6.2 Injector rings – Replacement (single-wall fuel system)



Installation/removal device F6789889 1Milling cutter F30452739 1Torque screwdriver, 1–5 Nm F30452774 1Torque wrench, 10–60 Nm F30452769 1Ratchet bit F30027340 1Torque wrench, 60–320 Nm F30452768 1Ratchet bit F30027341 1Assembly compound (Molykote P 37) 50564 1Assembly compound (Kluthe Hakuform 30-15) X00067260 1Multi-purpose grease 40320 1Engine oilO-ring (→ Spare Parts Catalog)Sealing ring (consisting of CE ring and support ring) (→ Spare Parts Catalog)Damping ring (→ Spare Parts Catalog)



WARNINGHot components/surfaces.Risk of burns!• Allow the engine to cool down to below 50 °C before beginning work.• Wear suitable protective equipment/thermal gloves.• Avoid unprotected contact with hot surfaces.

WARNINGInternal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.Risk of injury by ejected parts!• Only use specified tools and devices.• Wear goggles/facial protection.

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NOTICEContamination of components.Damage to component!• Observe manufacturer's instructions.• Check components for special cleanliness.

Nameplateu The nameplate contains the following infor-

mation:1. DMC - Data Matrix Code2. L'Orange part number3. MTU part number4. IIG code (Initial Injector Equalization)5. EMI-ID code6. Serial number7. Date of manufacture

Preparatory steps1. Allow HP system to cool down.2. Shut off fuel supply to engine.3. Remove cylinder head cover (→ Page 130).

Removing injector, removingrings

1. Disconnect cable connector at injector (ar-row).

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Note: Be aware of system pressure.2. Slowly loosen union on HP line (4).3. Remove HP fuel line (4).

Note: The fuel stored in the injector drains outwhen the adapter (3) is unscrewed.

4. Remove adapter (3).5. Remove screw (2) and take off hold-down

clamp (1).

6. Install installation/removal tool on the cylin-der head.

7. Remove injector with installation/removaltool.

8. Remove the installation/removal tool.

9. Remove sealing ring (4) from injector or use aself-made wire hook or magnet to take it outof the cylinder head.

10. Dispose of sealing ring (4).11. Remove O-rings (3), O-ring (2) and damper

ring (1) from injector and dispose of.12. Clean all mating and sealing surfaces.13. Cover all connections and bores, or seal with

suitable plugs.

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Installing injector, replacingrings

Note: • Make sure that the sealing ring (consistingof CE-ring and support ring) is correctlyseated: The closed CE-ring side must beabut on the injector, and the protruding(open) CE-ring side must face towards thecombustion chamber.

• A multi-purpose grease without solidsmust be used.

1. Install new sealing ring (1) abutted to (Multi-purpose grease) and ensure that the installa-tion position is correct.

Note: Remove plugs on HP line only before installa-tion of the adapter.

2. Remove plug.3. Use milling cutter to remove oil carbon from

sealing face on cylinder head and protectivesleeve.

4. Fit damper ring (1) on injector and apply (As-sembly compound (Molykote P 37)).

5. Fit new O-rings (3) on injector (2) and apply(Assembly compound (Kluthe Hakuform30-15)).

Note: Make sure that the sealing ring (4) does notfall into the coolant sleeve.

6. Ensure that the sealing ring (4) is correctlyseated.

7. Insert injector into cylinder head, ensuringthat the HP line connection is correctlyaligned.

8. Press in injector with installation/removal de-vice.

9. Remove installation/removal device.

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10. Coat screw mating face (2) and thread withengine oil.

11. Fit hold-down clamp (1) in correct position, fitscrew (2) and tighten by hand.

Note: Make sure parts are perfectly clean.12. Apply engine oil to thread, sealing taper and

thrust ring of adapter (3).13. Apply (Assembly compound (Kluthe Haku-

form 30-15)) to O-rings on adapter (3).14. Install adapter (3).

15. Tighten screw (2) to specified torque using a torque wrench.



16. Tighten adapter (3) to specified torque using a torque wrench.


Adapter Tightening torque (Engine oil) 100 Nm +10 Nm

Note: Make sure parts are perfectly clean.17. Coat thread, sealing cone and thrust ring of HP line (5) with engine oil.18. Coat jacket surface in area of union nut to rail (6) with engine oil.19. Thread in HP line (5), ensuring that the sealing areas are not damage.20. Tighten union nuts (4) and (6) as far as possible by hand.

21. Use torque wrench to tighten HP line (5) according following to tightening sequence to the specified torque.1 Adapter (4)2 Rail (6)


Union nut / thrustscrew

Preload torque (Engine oil) 4 Nm +2 Nm

Note: Holding firmly with hand is not admitted.22. Tighten HP line (5) in the same tightening sequence to specified final tightening torque.

1 Adapter (4)2 Rail (6)



Tightening torque (Engine oil) 30 Nm +5 Nm

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23. Fit cable connector on injector.

Note: Failure to reset drift compensation (CDC) willvoid the emissions certification of the engine.

24. Reset drift compensation (CDC) using Dia-Sys® and enter injector code (IIG) (→ Dialogsystem DiaSys® E531920/..). If DiaSys® isnot available, contact Service.

Final steps1. Install cylinder head cover (→ Page 130).2. Open fuel supply to engine.

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8.6.3 Injector – Removal and installation



Installation/removal jig F6789889 1Milling cutter F30452739 1Torque screwdriver, 1–5 Nm F30452774 1Torque wrench, 10–60 Nm F30452769 1Ratchet adapter F30027340 1Torque wrench, 60–320 Nm F30452768 1Ratchet adapter F30027341 1Assembly compound (Molykote P 37) 50564 1Assembly compound (Kluthe Hakuform 30-15) X00067260 1Multi-purpose grease 40320 1Engine oil




WARNINGInternal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.Risk of injury by ejected parts!• Only use specified tools and devices.• Wear goggles/facial protection.

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NOTICEContamination of components.Damage to component!• Observe manufacturer's instructions.• Check components for special cleanliness.

Nameplateu The nameplate contains the following infor-

mation:1. DMC – Data Matrix Code2. L'Orange part number3. MTU part number4. IIG code (Initial Injector Equalization)5. EMI-ID code6. Serial number7. Date of manufacture

Preparatory steps1. Allow HP system to cool down.2. Shut off fuel supply to engine.3. Remove cylinder head cover (→ Page 130).

Removing injector1. Disconnect cable connector at injector (ar-

rowed).

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Note: Be aware of system pressure.2. Slowly loosen union on HP line (4).3. Remove HP fuel line (4).

Note: When the adapter is unscrewed, the storedvolume of the injector is drained.

4. Remove adapter (3).5. Remove screw (2) and take off hold-down

clamp (1).

6. Install installation/removal jig on the cylinderhead.

7. Remove injector with installation/removal jig.8. Remove the installation/removal jig.

9. Remove sealing ring (4) from injector or use aself-made wire hook or magnet to take it outof the cylinder head.

Note: The sealing ring (4) for sealing the combus-tion chamber must only be used once.

10. Dispose of sealing ring (4) and injector.11. Clean all mating and sealing surfaces.12. Cover all connections and bores, or seal with

suitable plugs.

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Installing new injectorNote: • The new sealing ring is included in the

scope of supply of the injector.• Use a multi-purpose grease without solids

content.1. Install new sealing ring (1) abutted to (Multi-

purpose grease) and ensure that the installa-tion position is correct.

Note: Remove plugs on HP line only before installa-tion of the adapter.

2. Remove plug.3. Use milling cutter to clean oil carbon from

sealing face on cylinder head and protectivesleeve.

4. Coat damper ring (1) with (Assembly com-pound (Molykote P 37)).

5. Coat O-rings (3) and (2) with (Assembly com-pound (Kluthe Hakuform 30-15)).

Note: Make sure that the sealing ring does not fallinto the water sleeve.

6. Ensure that the sealing ring (4) is correctlyseated.

7. Insert injector into cylinder head, ensuringthat the HP line connection is correctlyaligned.

8. Press in injector with installation/removal jig.9. Remove installation/removal jig.

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10. Coat screw mating face (2) and thread withengine oil.

11. Fit hold-down clamp (1) in correct position, fitscrew (2) and tighten by hand.

Note: Make sure parts are perfectly clean.12. Apply engine oil to thread, sealing taper and

thrust ring of adapter (3).13. Apply (Assembly compound (Kluthe Haku-

form 30-15)) to O-rings on adapter (3).14. Install adapter (3).




16. Tighten adapter (3) to specified torque using a torque wrench.


Adapter Tightening torque (Engine oil) 100 Nm +10 Nm

Installing HP lineNote: Make sure parts are perfectly clean.

1. Coat thread, sealing cone and thrust ring of HP line (5) with engine oil.2. Coat jacket surface in area of union nut to rail (6) with engine oil.3. Thread in HP line (5), ensuring that the sealing areas are not damage.4. Tighten union nuts (4) and (6) as far as possible by hand.

5. Tighten HP line (5) in the following order to specified torque using a torque wrench.1 Adapter (4)2 Rail (6)



Preload torque (Engine oil) 4 Nm +2 Nm

Note: Do not hold in place by hand.6. Tighten HP line (5) in the same order to specified final tightening torque.

1 Adapter (4)2 Rail (6)



Tightening torque (Engine oil) 30 Nm +5 Nm

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7. Fit cable connector on injector.

Note: Failure to reset drift compensation (CDC) willvoid the emissions certification of the engine.

8. Reset drift compensation (CDC) using Dia-Sys® and enter injector code (IIG) (→ Dialogsystem DiaSys® E531920/..). If DiaSys® isnot available, contact Service.

Final steps1. Install cylinder head cover (→ Page 130).2. Open fuel supply to engine.

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8.7 Fuel System

8.7.1 Fuel system – Venting



Diesel fuel


Venting low-pressure fuel sys-tem

1. Open threaded vent plug (2) and connectsuitable tube (ID = 6 mm).

2. Provide suitable container to collect escapingfuel.

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Note: See figure (a).3. Unlock hand pump: Hold sleeve (2) firmly.

Turn handle (1) counterclockwise until thesleeve can be pushed backwards (arrow).

Note: • See figure (b).• After pulling the handle, wait briefly until

the chamber is optimally filled.4. Operate the pump with the handle (1) until

bubble-free fuel escapes from the vent plug.5. Close vent plug.6. Continue to operate the pump until resist-

ance is noticeable (at least 50 times), to ach-ieve full filling height.

Note: See figure (c).7. Lock hand pump: Push sleeve (2) forward and

hold it. Turn handle (1) clockwise until bothparts are screwed together hand-tight.

8. Remove hose from vent plug.9. Verify that the fuel hand pump is securely

locked: Handle (1) must be tightened hand-tight.

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8.8 Fuel Filter

8.8.1 Fuel filter – Replacement



Filter wrench F30379104 1Engine oilEasy-change filter (→ Spare Parts Catalog) 2



Replacing fuel filter1. Provide suitable container to collect escaping

fuel.2. Remove easy-change filter (2) with filter

wrench.3. Clean sealing surface on filter head (1).4. Apply a thin film of engine oil to gasket on

easy-change filter (2) (arrow).5. Screw in easy-change filter (2) by hand until

the gasket makes contact and tighten hand-tight.

6. Replace other easy-change filters in the sameway.

7. Vent fuel system (→ Page 146).

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8.8.2 Additional fuel filter – Replacement



Filter wrench F30379104 1Engine oilEasy-change filter (→ Spare Parts Catalog) 2


Additional fuel filter – Replace-ment

1. Provide suitable container to collect escapingfuel.

2. Remove easy-change filter (2) with filterwrench.

3. Clean sealing surface on filter head (1).4. Apply a thin film of engine oil to seal on easy-

change filter (2) (arrow).5. Screw in easy-change filter (2) by hand until

the seal makes contact and tighten hand-tight.

6. Replace other easy-change filters in the sameway.

7. Vent fuel system (→ Page 146).

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8.8.3 Fuel prefilter – Pressure ratios



Pressure ratiosNote: • If the fuel prefilter is above the full level of the fuel tank, during engine operation the fuel pressure in the

filter is lower than ambient pressure (vacuum).• If the fuel prefilter is below the empty level of the fuel tank, during engine operation the fuel pressure in

the filter is higher than ambient pressure (overpressure).In the case of overpressure, fuel can escape under pressure.

u The pressure ratios should be known from commissioning. Pressure ratios can be checked with the engineshut down.

Checking pressure ratios1. Stop engine and disable engine start.

2. Carefully open threaded vent plug (1) slightly:Result: • If no fuel emerges, this is an indication of

vacuum or pressure balance.• If fuel emerges, this is a sign of overpres-

sure.3. Collect fuel as it emerges.

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8.8.4 Fuel prefilter – Draining

Note: The descriptions also apply to heavy-duty fuel prefilters

Fuel prefilter (non-switchable)u Drain water and contaminants from fuel prefilter (→ Page 152).

Fuel prefilter (switchable)u Drain water and contaminants from fuel prefilter (→ Page 154).

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8.8.5 Fuel prefilter (non-switchable) – Draining






WARNINGFuel in the prefilter can be pressurized.Risk of injury through spraying fuel!• Wear protective gloves and eye protectors/safety mask.• Open screw-coupling slowly.

Preparatory stepsu Pressure ratios in the fuel prefilter, see (→ Page 150).

• In case of low pressure, drain fuel prefilter according to version A, see (→ ).• In case of high pressure, drain fuel prefilter according to version B, see (→ Page 153).

Draining fuel prefilter with low pressure, version ANote: The fuel prefilter must only be drained with the engine at a standstill!

1. Provide a suitable container to collect the water.2. Stop engine and disable engine start.3. Close fuel supply if a shutoff valve is available.

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4. Open threaded vent plug (1) of filter to beserviced.

5. Open drain plug (1).6. Allow water to drain until fuel emerges.7. Close drain plug (2) again.8. Drain second filter on module, from

(→ Step 4).9. Close threaded vent plug again.

10. Open fuel supply.11. Vent fuel prefilter (→ Page 163).

Draining fuel prefilter with highpressure, version B

Note: The fuel prefilter can be drained duringengine operation or with the engine at astandstill!

1. Provide a suitable container to collect the wa-ter.

2. Take care when opening drain plug (1) be-cause fuel or water can spurt out.

3. Allow water to drain until fuel emerges.4. Close drain plug (2) again.

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8.8.6 Fuel prefilter (switchable) – Draining








• In case of low pressure, drain fuel prefilter according to version A, see (→ ).• In case of high pressure, drain fuel prefilter according to version B, see (→ Page 156).

Draining fuel prefilter with low pressure, version ANote: • During engine operation, only the cut-out filter module must be drained!

• At engine standstill, both filter modules can be drained!1. Provide a suitable container to collect the water.

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2. During engine operation, turn the switchoverlevel as far as the stop (arrow) to cut out thefilter module to be serviced.

Result: • Filter module (1) is cut in• Filter module (2) is cut out

3. Open threaded vent plug (1) of filter to beserviced.

4. Open drain plug (1).5. Allow water to drain until fuel emerges.6. Close drain plug (2) again.7. Drain the second filter on the module to be

serviced, from (→ Step 3).8. Close threaded vent plug again.9. Vent fuel prefilter (→ Page 163).

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Draining fuel prefilter with high pressure, version BNote: The filter modules can be drained without switchover during engine operation and at engine stand-

still!1. Provide a suitable container to collect the water.

2. Take care when opening drain plug (1) be-cause fuel or water can spurt out.

3. Allow water to drain until fuel emerges.4. Close drain plug (2) again.

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8.8.7 Fuel prefilter (switchable) – Low pressure indicator check

Low pressure indicator onswitchable fuel prefilter

1. Check low pressure indicator reading at lowpressure gauge (3):• Red zone (1): -1.0 bar to -0.4 bar (low

pressure)• Green zone (2): -0.4 bar to +0.5 bar (nor-

mal operation)2. Switch over the fuel prefilter or replace a fil-

ter element (→ Page 160) when the low pres-sure gauge (3) indicates minimum admissiblefuel pressure during operation (1) .

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8.8.8 Fuel prefilter (non-switchable) – Filter element replacement


Torque wrench, 6–50 Nm F30027336 1Ratchet bit F30027340 1Diesel fuelFilter parts kit (→ Spare Parts Catalog)





Replacing filter elementNote: The filter element on the fuel prefilter must only be changed with the engine at a standstill!

1. Provide a suitable container in which to collect the fuel.2. Stop engine and disable engine start.3. Close fuel supply if a shutoff valve is available.

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4. Open threaded vent plug and ensure that fueldoes not emerge continuously.

Result: The filter can now be changed!5. If fuel emerges continuously, check shutoff

valve in fuel supply, notify Service.

Note: • As soon as the filter housing is opened,absolute cleanness is imperative!

• Carefully extract the filter element straightup avoiding contact with the upper edge ofthe cylinder if at all possible to preventcontamination of the fuel remaining in thefilter housing.

6. Unscrew filter cover (1) and withdraw with fil-ter element (3) from filter housing (4).

7. Unclip filter element (3) from filter cover (1).8. Install new O-ring (2) on filter cover (1).9. Coat new O-rings on filter cover and filter ele-

ment with fuel.10. Clip new filter element (3) into filter cover (1).11. Screw filter cover (1) into filter housing.

Result: Filter cover (1) must lie flat on the housing(4).

12. Use a torque wrench to tighten filter cover (1) to specified tightening torque.


Filter cover Tightening torque 40 Nm

13. Replace other filter elements in the same way.14. Close threaded vent plug again.15. Open fuel supply.16. Vent fuel prefilter (→ Page 163).17. Check fuel prefilter for leaks.

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8.8.9 Fuel prefilter (switchable) – Filter element replacement


Torque wrench, 6–50 Nm F30027336 1Ratchet bit F30027340 1Diesel fuelFilter parts kit (→ Spare Parts Catalog)








• In case of low pressure, replace fuel prefilter according to version A, see (→ Page 161).• In case of high pressure, replace fuel prefilter according to version B, see (→ Page 162).

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Replacing fuel prefilter with low pressure, version ANote: • During engine operation, the filter elements must only be replaced on the cut-out filter module!

• At engine standstill, the filter elements on both filter modules can be replaced!1. Provide a suitable container in which to collect the fuel.

2. During engine operation, turn the switchoverlevel as far as the stop (arrow) to cut out thefilter module to be serviced.

Result: • Filter module (1) is cut in• Filter module (2) is cut out

3. Check fuel level in filter.Result: If the fuel level is stable, the filter can be

changed!4. If the fuel level falls, the switchover point is

leaking. Screw on the filter cover again imme-diately and vent the filter (→ Page 163).Check the switchover point, contact Service.





ment with fuel.9. Clip new filter element (3) into filter cover (1).

10. Screw filter cover (1) into filter housing.Result: Filter cover (1) must lie flat on the housing

(4).

11. Tighten filter cover (1) to specified torque using a torque wrench.



12. Replace other filter elements in the same way.13. Close threaded vent plug again.14. Vent fuel prefilter (→ Page 163).15. Check fuel prefilter for leaks.

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Replacing fuel prefilter with high pressure, version BNote: The filter modules must only be replaced with the engine at a standstill!

1. Provide a suitable container in which to collect the fuel.2. Stop engine and disable engine start.3. Close fuel inlet.

4. Open threaded vent plug and ensure that fueldoes not emerge continuously.

Result: The filter can now be changed!5. If fuel emerges continuously, check shutoff

valve in fuel supply, notify Service.





ment with fuel.10. Clip new filter element (3) into filter cover (1).11. Screw filter cover (1) into filter housing.

Result: Filter cover (1) must lie flat on the housing(4).

12. Tighten filter cover (1) to specified torque using a torque wrench.



13. Replace other filter elements in the same way.14. Close threaded vent plug again.15. Open fuel supply.16. Vent fuel prefilter (→ Page 163).17. Check fuel prefilter for leaks.

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8.8.10 Fuel prefilter – Venting







Preparatory steps1. Pressure ratios in the fuel prefilter, see (→ Page 150).

• In case of underpressure, replace fuel prefilter according to version A, see (→ ).• In case of overpressure, replace fuel prefilter according to version B, see (→ Page 164).

2. With the non-switchable fuel prefilter, the engine must be shut down and secured against starting.3. With the switchable fuel prefilter, the cut-out filter module can be vented during engine operation.

Venting fuel prefilter with low pressure, version A1. Open fuel supply as necessary.

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2. Release threaded vent plugs (2, 3) and un-screw at least one rotation.

Note: • Only operate the fuel priming pump man-ually!

• Only hold the pump plunger vertically toavoid damaging the pump!

3. Unlock fuel priming pump, screw out han-dle (1).

Note: Catch escaping fuel with a suitable rag.4. Operate fuel priming pump handle (1) until

bubble-free fuel emerges from the threadedvent plugs (2, 3).

Note: Never actuate the handle with the threadedvent plugs closed!

5. Move handle (1) of fuel priming pump backand screw in.

6. Close threaded vent plugs (2, 3) and tightenby hand.

Venting fuel prefilter with highpressure, version B

1. Open fuel supply as necessary.2. Carefully release threaded vent plugs (1) and

unscrew at least one rotation.3. Leave threaded vent plugs (1) opened until

bubble-free fuel emerges at the vent plugs.4. Close threaded vent plugs (1) and tighten by

hand.

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8.9 Charge-Air Cooling

8.9.1 Intercooler – Check drain for coolant leakage and obstruction




Intercooler – Check water drainfor coolant leakage and obstruc-tion

1. With the engine running, verify that airemerges from the condensate drain bore(s)at driving end, left and right engine side. If noair escapes:• Clean drain bores• Blow out drain bores with compressed air

2. If a large amount of coolant is continuouslydischarged, the intercooler is leaking. Con-tact Service.

Emergency measures prior to engine start with a leaking intercooler1. Remove the injectors (→ Page 140).2. Bar engine manually (→ Page 111).3. Bar engine with starting system to blow out combustion chambers (→ Page 113).4. Install injectors (→ Page 140).

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8.10 Air Filter

8.10.1 Air filter ‒ Replacement


Air filter (→ Spare Parts Catalog)

Air filter ‒ Replacement1. Remove air filter and install new one (→ Page 168).2. Reset signal ring of service indicator (→ Page 171).

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8.10.2 Air filter – Check


Air filter (→ Spare Parts Catalog)

Checking air filter1. Check entire circumference of air filter for damage.2. Fit new air filter if damaged (→ Page 166).

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8.10.3 Air filter – Removal and installation


DANGERFalling from great heights.Risk of serious injury – danger to life!• When working high on the equipment, always use suitable ladders or work platforms.• Use personal protective equipment.

WARNINGFor all described tasks at the genset:Risk of injury!• For all tasks, the respective required personal protective equipment (safety shoes, ear protection,

protective gloves, safety goggles, respiratory protection, etc.) is to be used.

NOTICEStepping or climbing on the genset to perform installation tasks is to be avoided.Otherwise, there is a risk of component damage or leakage!• Use suitable and approved climbing aids or work platforms.

Removing and installing air fil-ter

1. Release clamp (2).2. Remove air filter (1) and clamp (2) from con-

necting flange of intake housing (3).3. Verify that there are no objects in the con-

necting flange of the intake housing (3) andclean it.

4. Place new air filter (1) with clamp (2) onto in-take housing (3).

5. Tighten clamps (2).

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8.10.4 Heavy duty air filter – Filter insert and filter element removal and installation

Preconditions☑Engine-generator set is stopped and starting disabled.

☑Stepladder, platform, or similar equipment is provided.


Filter element (→ Spare Parts Catalog)Filter element (→ Spare Parts Catalog)


WARNINGHeavy part, risk of falling or overturning due to lack of stability.Risk of crushing body or limbs!• Use appropriate lifting gear and appliances.• Wear safety shoes.

Heavy duty air filter – Version A1. Undo wing nut (1) and remove filter insert (2)

from filter housing (5).2. Undo wing nut (3) and remove filter ele-

ment (4) from filter housing (5).3. Wipe out filter housing (5) and sealing surfa-

ces with a damp cloth.4. Insert new filter element (4) and filter in-

sert (2).5. Assemble in reverse order.

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Heavy duty air filter – Version B1. Release closures (1).2. Remove cover (2).3. Remove filter insert (3) and filter element (4).4. Wipe out filter housing (5) and cover (2) with

a damp cloth.5. Insert new filter element (4) and filter in-

sert (3).6. Assemble in reverse order.

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8.11 Air Intake

8.11.1 Service indicator – Signal ring position check


Checking signal ring position1. When the yellow piston (2) has reached the

red-shaded Service lettering (3), replace airfilter (→ Page 166).

2. After installation of new filter, press resetbutton (1).

Result: Signal ring returns to initial position.

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8.12 Lube Oil System, Lube Oil Circuit

8.12.1 Engine oil – Change


☑Engine is at operating temperature.

☑MTU Fluids and Lubricants Specifications (A001061/..) are available.


Torque wrench, 60–320 Nm F30452768 1Ratchet bit F30027341 1Engine oilSealing ring (→ Spare Parts Catalog)


Draining oil at drain plugs on oil pan1. Provide a suitable container in which to collect the engine oil.

2. Unscrew one of the drain plugs (1 to 8) anddrain engine oil.

3. Screw in drain plug (1 to 8) with new sealingring.

Engine oil treatment1. Check layer thickness of oil residues in the centrifugal oil filter, clean centrifugal oil filter and replace filter

sleeve (→ Page 179).2. Replace engine oil filter (→ Page 178).

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Draining residual oil from equip-ment carrier (only with un-scheduled engine oil change)

1. Provide a suitable container in which to col-lect the engine oil.

2. Remove drain plug (1) and drain engine oilfrom engine oil heat exchanger and from en-gine oil filter.

3. Remove drain plugs (2) and (3) and drain en-gine oil.

4. Install drain plug(s) with new sealing ring.

5. Use torque wrench to tighten drain plugs (2) and (3) to specified tightening torque.


Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm

Filling with new engine oil1. Open cover (1) on filler neck.2. Pour oil in at filler neck up to 'max.' mark at

oil dipstick.3. Close cover (1) on filler neck.4. Check engine oil level (→ Page 174).

Note: Observe the following instructions to avoidengine damage: Adequate oil pressure for anengine start is only provided when the quick-start function is deactivated.

5. Make sure the quick-start function is deacti-vated before starting the engine.

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8.12.2 Engine oil level – Check



Checking engine oil level afterextended standstill

1. Pull out dipstick from guide tube and wipe it.2. Insert oil dipstick into guide tube up to the

stop, pull it out after approx. 10 seconds andcheck oil level.

Note: After extended standstill, the oil level may beup to 2 cm above mark (1). This may becaused e.g. by oil from oil filters and heat ex-changers flowing back into the oil pan. Afterextended standstill, the oil level "2 cm abovemark (2)" is the minimum oil level.

3. Oil level must be at least 2 cm abovemark (2).

4. If necessary, top up with oil, maximum tomark (1) (→ Page 172).

5. Insert oil dipstick into guide tube up to thestop.

Checking oil level immediately after engine stop1. 5 minutes after stopping the engine, pull out oil dipstick from guide tube and wipe it.2. Insert oil dipstick into guide tube up to the stop, pull it out after approx. 10 seconds and check oil level.3. Oil level must be between marks (1) and (2).4. If necessary, top up with oil, maximum to mark (1) (→ Page 172).5. Insert oil dipstick into guide tube up to the stop.


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8.12.3 Engine oil – Sample extraction and analysis

Preconditions☑MTU Fluids and Lubricants Specifications (A001061/..) are available.


MTU test kit F6798833 1Engine oil





Engine oil sample extractionand analysis (engine withoutcentrifugal oil filter)

Note: Only take the engine oil sample by openingan oil drain screw with the engine stationary.

1. With the engine shut down, open the screw,e.g. at the oil filter.

2. Drain approx. 1 liter engine oil into a cleancontainer.

3. Seal oil drain screw (arrow) again with a newsealing ring.

4. Use equipment and chemicals in MTU test kitto analyze engine oil for:• Dispersing capacity (spot test)• Proportion of water• Dilution by fuel


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Engine oil, sample extractionand analysis

1. With the engine running at operating temper-ature, open screw (1) on carrier of centrifugaloil filter support by 1 to 2 rotations.

2. Drain approx. 2 liters engine oil to flush outthe oil sludge.

3. Drain approx. 1 liter engine oil into a cleancontainer.

4. Close screw (1) and tighten to specified tightening torque.


Screw - Tightening torque (Engine oil) 20 Nm +2 Nm

5. Use equipment and chemicals in MTU test kit to analyze engine oil for:• Dispersing capacity (spot test)• Proportion of water• Dilution by fuel


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8.12.4 Oil priming pump – Visual inspection


Visually inspecting oil primingpump

1. Inspect oil priming pump and connections forfirm seating and leaks. Retighten loosethreaded connections as necessary.

2. Check leak telltale bore (2) for oil discharge.Result: If oil emerges, the gear pump (1) usually has

to be replaced (→ see manufacturer's docu-mentation).


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8.13 Oil Filtration / Cooling

8.13.1 Engine oil filter – Replacement



Filter wrench F30379104Engine oilOil filter (→ Spare Parts Catalog)


Engine oil filter – Replacement1. Remove engine oil filter using the filter

wrench.2. Clean the sealing surface on the connecting

piece.3. Check sealing ring (1) of new engine oil filter

and apply a thin coat of engine oil.4. Check inscription on filter: must be “Oil Fil-

ter”.5. Screw on and tighten engine oil filter by

hand.6. Replace other engine oil filters in the same

way.

Note: Observe the following instructions to avoidengine damage: Adequate oil pressure for anengine start is only provided when the quick-start function is deactivated.

7. Make sure the quick-start function is deacti-vated before starting the engine.

8. Check engine oil level (→ Page 174).

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8.13.2 Cleaning centrifugal oil filter and replacing filter sleeve



Torque wrench, 4–20 Nm F30044239 1Torque wrench, 10–60 Nm F30452769 1Torque wrench, 60–320 Nm F30452768 1Ratchet bit F30027340 1Oil filter wrench F30455924 1Cold cleaner (Hakutex 60) X00056750 1Assembly compound (Kluthe Hakuform 30-15) X00067260 1Filter sleeve (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)



Disassembling centrifugal oil fil-ter

1. Remove V-band clamp (17).2. Undo cover nut (2) and take off cover (1).3. Carefully lift rotor unit (14), allow oil to drain

and remove from housing.

Note: Do not clamp rotor unit in a bench vise.4. Holding the rotor unit (14) firmly with an oil

filter wrench, release rotor cover (3) by turn-ing a hexagon.

5. Take off rotor cover (3).6. Check layer thickness of oil residues on filter

sleeve (6).Result: Shorten maintenance interval if the oil resi-

dues exceed the maximum thickness of45 mm.

7. Remove filter sleeve (6).8. Disassemble rotor tube (7), conical disk (8)

and rotor base (13).

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Cleaning centrifugal oil filter1. Wash rotor cover (3), rotor tube (7), conical disk (8) and rotor base (13) with cold cleaner.2. Blow out rotor cover (3), rotor tube (7), conical disk (8) and rotor base (13) with compressed air.

Assembling centrifugal oil filter1. Coat new sealing rings (9) and (10) with as-

sembly compound and insert in grooves onbearing shaft (11).

2. Assemble rotor tube (7), conical disk (8) androtor base (13) with new sealing ring (12).

Note: Observe marks and information on the paperelement!

3. Insert new filter sleeve (6) in rotor tube (7)with the smooth paper surface facing the out-er wall.

Note: Check sealing rings (4) and (5) and replace ifnecessary.

4. Fit sealing ring (5) in rotor tube (7) and seal-ing ring (4) in rotor cover (3).

Note: Do not clamp rotor unit in a bench vise. Usean oil filter wrench.

5. Screw on rotor cover (3) by turning at hexa-gon.

6. Tighten rotor cover (3) with torque wrench to specified tightening torque.


Nut Tightening torque 80 Nm ±12 Nm

7. Place rotor (14) in housing (15) and check for ease of movement.

Note: Check sealing ring (16), fit new one as necessary.8. Fit sealing ring (16) on housing (15).9. Fit cover (1).

10. Tighten cover nut (2) by hand.

11. Install V-band clamp (17) and use torque wrench to tighten to specified tightening torque.


Clamp Tightening torque 20 Nm ±3 Nm

12. Use a torque wrench to tighten cover nut (2) to specified tightening torque.


Screw Tightening torque 7 Nm ±1 Nm

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8.14 Coolant Circuit, General, High-Temperature Circuit

8.14.1 Engine coolant – Level check



WARNINGCoolant is hot and under pressure.Risk of injury and scalding!• Let the engine cool down.• Wear protective clothing, gloves, and goggles / safety mask.

Checking coolant level at re-mote cooler:

1. Check coolant level (coolant must be visibleat marking plate).

2. Top up with treated coolant as necessary(→ Page 185).

3. Check and clean breather valve.4. Position breather valve on filler neck and

close.

Checking engine coolant level by means of level sensor:1. Switch on engine control system and check readings on the display.2. Top up with treated coolant as necessary (→ Page 185).

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8.14.2 Engine coolant – Change


Coolant

Engine coolant change1. Drain engine coolant (→ Page 183).2. Fill with engine coolant (→ Page 185).

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8.14.3 Engine coolant – Draining




WARNINGCoolant contains antifreeze and is toxic.Risk of poisoning and slipping!• Avoid contact with eyes and skin.• Do not inhale vapors or mist, wear breathing protection.• Do not eat, drink, smoke when working with antifreeze.• Wear protective clothing, protective gloves and goggles/safety mask.• Wipe up escaped/spilled coolant immediately.

Preparatory steps1. Provide a suitable container to catch the coolant.2. Switch off preheater.

Draining engine coolant1. Turn valve cover of coolant expansion tank

counterclockwise until the first stop and al-low pressure to escape.

2. Continue to turn valve cover counterclock-wise and remove.

3. Draw off separated corrosion inhibitor oil inexpansion tank through the filler neck.

4. Open drain valves and/or drain plugs anddrain coolant at the following points:• At preheater• Thermostat housing (1)• Twin elbow (2)• At elbow (4) of HT coolant pump• Crankcase (3), left and right side

Final steps1. Tighten shutoff cocks (3) and (4) with torque wrench to specified tightening torque.


Spindle 11 A/F Tightening torque 12 Nm


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2. Close all other open drain points.3. Position valve cover on filler neck and close.


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8.14.4 Engine coolant – Filling




Engine coolant





NOTICECold coolant in hot engine can cause thermal stress.Possible formation of cracks in the engine!• Fill / top up coolant only into cold engine.


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Preparatory steps1. Turn valve cover on coolant expansion

tank (1) counterclockwise until the first stopand release pressure.

2. Continue to turn valve cover (1) counter-clockwise and remove.

Filling with coolant from belowusing a pump

1. Open venting point on distributor (arrow).


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Note: Important: Fill engine only from below!2. Connect appropriate pump with hose to drain

valve of engine coolant pump (1).3. Open shutoff cock on elbow of engine cool-

ant pump (2) and pump coolant with at least0.5 bar into engine.

4. When coolant emerges from the ventingpoint, close the venting point.

5. Fill expansion tank until overflow edge isreached.

6. Tighten shutoff cock at elbow of engine cool-ant pump (2) with torque wrench to specifiedtightening torque (→ Page 183).

7. Check proper condition of valve cover oncoolant expansion tank, clean sealing faces ifrequired.

8. Fit valve cover and close it.9. Start engine (→ Page 46).

10. After 10 seconds of running the engine with-out load, shut down the engine (→ Page 51).

11. Turn valve cover of coolant expansion tankcounterclockwise until the first stop and al-low pressure to escape.


13. Check coolant level (→ Page 181) and top upcoolant as required:

a) Fill in coolant in expansion tank until thecoolant level at top edge of filler neck re-mains constant.

b) Fit valve cover and close it.14. Repeat the steps from "Start engine"

(→ Step 9) until coolant is no longer neededto be topped up.

15. Disconnect pump and hose.

Alternatively: Filling coolant atexpansion tank

1. Open venting point on distributor (arrow).


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2. Top up coolant in expansion tank via fillerneck until coolant level at top edge of fillerneck remains constant.

3. When coolant emerges from the ventingpoint, close the venting point.

4. Check proper condition of valve cover (1) oncoolant expansion tank and clean sealingfaces if required.

5. Fit valve cover (1) and close it.6. Start engine (→ Page 46).7. After 10 seconds of running the engine with-

out load, shut down the engine (→ Page 51).8. Turn valve cover (1) on coolant expansion

tank counterclockwise to the first stop andallow pressure to escape.

9. Turn valve cover (1) counterclockwise and re-move.

10. Check coolant level (→ Page 181) and top upwith coolant through the filler neck if re-quired:



(→ Step 6) until coolant is no longer neededto be topped up.

Final steps1. Start the engine and run it without load for some minutes.2. Check coolant level (→ Page 181) and top up coolant as required.


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8.14.5 Engine coolant pump – Relief bore check





Engine coolant pump – Reliefbore check

1. Check relief bore for oil and coolant dis-charge.

Note: Observe safety regulations when carrying outmaintenance and repair work (→ Page 11).

2. Stop engine (→ Page 51) and disable enginestart.

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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8.14.6 Engine coolant – Sample extraction and analysis

Preconditions☑MTU Fluids and Lubricants Specifications (A001061/..) are available.


MTU test kit 5605892099/00 1





Engine coolant – Sample extrac-tion and analysis

1. With the engine running, open drain valve (1).2. Flush sample-extraction point by draining ap-

prox. 1 liter coolant.3. Drain approx. 1 liter coolant into a clean con-

tainer.


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4. Tighten shut-off cock (2) to specified torque using a torque wrench.


Spindle A/F11 Tightening torque 12 Nm

5. Using the equipment and chemicals from the MTU test kit, examine coolant for:• antifreeze concentration• Amount of corrosion protection oil• pH value

6. For engine coolant change intervals, refer to (→ MTU Fluids and Lubricants Specifications (A001061/..)).


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8.14.7 Preheater – Overview

1 Outlet2 24 VDC input3 Main power supply input4 Control box

5 Control thermostat6 Intake7 Safety thermostat8 Housing cover

9 PumpArrow Flow direction

Variant Heating output Rated voltage Frequency Phases1 9 kW 400 V 50 Hz 32 9 kW 480 V 60 Hz 33 12 kW 400 V 50 Hz 34 12 kW 480 V 60 Hz 3


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8.14.8 Preheater – Overhaul


☑All preheater power sources are disconnected.

Replacing solenoid switchu Replace solenoid switch (→ Page 198).

Cleaning heating element and replacing gasketu Clean heating element and housing and check (→ Page 195).

Replacing thermostatu Replace thermostat (→ Page 200).


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8.14.9 Preheater – Function and leak check

Preconditions☑Preheater is switched on.

WARNINGCoolant is hot and highly pressurized.Risk of injury! Risk of scalding!• Allow engine to cool down.• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Function checkNote: The preheater operates properly if the measured value of the coolant temperature is within the control range

of the thermostat.1. Check coolant preheating temperature.2. Contact Service if the temperatures are out of normal range.

Leak check1. Check unit for leaks at coolant inlet and coolant outlet.2. Tighten leaking connections.


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8.14.10 Preheater – Heating element and housing check



Screw locking compound (Loctite 586) 40033 1O-ring (→ Spare Parts Catalog) 1

DANGERElectric voltage supply for operation.Danger of burns and fatal electric shock!• Make certain that the power supply to the product is switched off before starting work. Secure

against unintentional switching on!





Preparatory steps1. Switch off preheater.2. Disconnect all preheater power sources.3. Allow heating elements to cool down.

Removing coolant lines1. Close shutoff valves in coolant return line and coolant supply line.


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2. Open drain plug at coolant inlet (arrow) anddrain coolant.

3. Undo clamps on both lines on preheater side.

Checking heating element andhousing for contamination

1. Undo screws (1) between electrical part (2)and housing.

2. Pull electrical part (2) with heating elementout of housing.

3. Check inside of housing for dirt. Clean with awire brush and/or moist rag as necessary.

4. Check heating element for contamination.Clean with a wire brush as necessary.

5. Fit new O-ring ensuring it is correctly posi-tioned.

6. Insert cleaned or new heating element intohousing.

7. Install electrical part (2) and tightenscrews (1).

Installing coolant lines1. Clean drain plug and screw-in thread (arrow)

at preheater.2. Coat drain plug with screw locking compound

Loctite 586 and screw in.3. Connect coolant return and supply lines to

preheater and tighten clamps.4. Vent coolant preheating circuit:

a) Open return line valve.b) Undo the clamp of the coolant supply

line near the valve.c) Wait until coolant has reached the end of

the coolant supply line.d) Tighten the clamp of the coolant supply

line.5. Fill in engine coolant until the required level

is reached (→ Page 185).


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Final steps1. Connect preheater power sources.2. Switch on preheater.


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8.14.11 Preheater – Solenoid switch replacement



Solenoid switch (→ Spare Parts Catalog) 1





Preparatory steps1. Switch off preheater.2. Disconnect all preheater power sources.3. Allow heating elements to cool down.4. Close shutoff valves in the supply and return line to/from preheater.

Replacing solenoid switch1. Undo screws on control box (1) and open

control box.


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2. Mark all cables (4) prior to disconnection.3. Disconnect all cables (4) from solenoid

switch (1).

Note: The solenoid switch is secured to the rail (2)by a spring clip (3).

4. Pull out the spring clip with a screwdriver andslide the solenoid switch off the rail.

5. Fit a new solenoid switch on the rail and fullyengage the spring clip.

6. Connect up all wires as marked previously.7. Close the control box and tighten the screws.

Final steps1. Open shutoff valves in the supply and return line to/from preheater.2. Disconnect preheater power sources.3. Switch on preheater.


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8.14.12 Preheater thermostats – Replacement



Thermostat (→ Spare Parts Catalog)





Preparatory steps1. Switch off preheater.2. Disconnect all preheater power sources.3. Allow heating elements to cool down.

Replacing safety thermostat1. Undo screws (1) on cover of electrical

part (2) and remove cover.


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2. Mark cables prior to disconnection.3. Disconnect terminals from blade terminals of

measuring unit (2).4. Undo thermostat clip (1) and remove safety

thermostat.5. Insert new safety thermostat in recess.6. Secure thermostat clip.7. Connect cable.8. Fit cover and tighten screws.

Replacing control thermostat1. Undo screws (1) on housing cover (2) of con-

trol thermostat and remove cover.

2. Mark cables prior to disconnection.3. Disconnect wires.4. Remove screws (2) and control thermo-

stat (1).5. Install new control thermostat (1) with

screws (2).6. Connect cable.7. Fit housing cover and tighten screws.


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Final steps1. Connect preheater to power supply.2. Switch on preheater.


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8.14.13 Coolant expansion tank valve cover – Replacement



Valve cover (→ Spare Parts Catalog) 1


Preparatory stepsu Switch off preheater.

Replacing valve coverNote: Schematic diagram. Design may deviate.

1. Turn valve cover (1) on coolant expansiontank counterclockwise until the first stop andrelease pressure.


3. Remove chain with screw (4) and washer (3).4. Draw off separated corrosion inhibitor oil in

expansion tank via filler neck (2).5. Fit new valve cover and close it.6. Install chain.


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8.15 Low-Temperature Circuit

8.15.1 Charge-air coolant level – Check






Checking charge-air coolant level at filler neck1. Turn cover on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.2. Continue to turn cover counterclockwise and remove.

Note: Charge-air coolant must be visible at markerplate.

3. Check charge-air coolant level.4. Top up charge-air coolant as necessary

(→ Page 209).5. Check that cover is in serviceable condition.6. Clean sealing surfaces as necessary.7. Fit cover and close it.

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Checking charge-air coolant level by means of level sensorNote: The charge-air coolant level is monitored automatically by the engine control system.

1. Switch on engine control system and check readings on the display.2. Top up with charge-air coolant as necessary (→ Page 209).

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8.15.2 Charge-air coolant – Change


Coolant

Charge-air coolant – Change1. Drain charge-air coolant (→ Page 207).2. Fill with charge-air coolant (→ Page 209).


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8.15.3 Charge-air coolant – Draining



Sealing ring (→ Spare Parts Catalog)




Charge-air coolant – Draining1. Provide a suitable container in which to collect the charge-air coolant.2. Turn valve cover of coolant expansion tank counterclockwise until the first stop and allow pressure to es-

cape.3. Continue to turn valve cover counterclockwise and remove.4. Extract remaining charge-air coolant in the coolant expansion tank via the filler neck.

5. Unscrew drain plug (1) and drain charge-aircoolant at thermostat housing.

6. Open drain valve (2) and drain charge-aircoolant at charge-air coolant pump.


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7. Drain remaining coolant at intercooler (ar-row).

8. Tighten drain valve to specified torque using a torque wrench.


Spindle 11 A/F Tightening torque 12 Nm

9. Close the remaining drain valves and screw in drain plugs with new sealing rings.10. Fit valve cover on filler neck and close it.


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8.15.4 Charge-air coolant – Filling




Engine coolant







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Preparatory steps1. Turn valve cover on coolant expansion

tank (1) counterclockwise until the first stopand release pressure.

2. Continue to turn valve cover (1) counter-clockwise and remove.

Filling coolant with pump1. Connect appropriate pump with hose to drain

valve (1).


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2. Loosen vent line union at distributor (1).3. Open drain valve and pump coolant into en-

gine at 0.5 bar minimum.4. Tighten union (arrow) if coolant escapes at

loose union.5. Fill expansion tank until overflow edge is

reached.6. To accelerate the venting procedure, open

the venting point at the intercooler after thefirst cycle until no more air emerges.

7. Close drain valve.8. Check proper condition of valve cover and

clean sealing faces if required.9. Fit valve cover on filler neck and close it.

10. Start engine (→ Page 46).11. After 10 seconds of running the engine with-

out load, shut down the engine (→ Page 51).12. Turn valve cover of coolant expansion tank



14. Check coolant level (→ Page 204) and top upcoolant as required:


b) Fit valve cover on filler neck and close it.15. Repeat the steps from "Start engine"

(→ Step 10) until coolant no longer needs tobe topped up.

16. Disconnect pump and hose.

Alternatively: Filling coolantthrough filler neck

1. Loosen vent line union at distributor (1).2. Top up coolant in expansion tank via filler

neck until coolant level at top edge of fillerneck remains constant.

3. Tighten union (arrow) if coolant escapes atloose union.

4. Check proper condition of valve cover oncoolant expansion tank, clean sealing faces ifrequired.


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5. To accelerate the venting procedure, openthe venting point at the intercooler after thefirst cycle until no more air emerges.

6. Fit valve cover and close it.7. Start engine (→ Page 46).8. After 10 seconds of running the engine with-

out load, shut down the engine (→ Page 51).9. Turn valve cover of coolant expansion tank


10. Turn valve cover counterclockwise and re-move.

11. Check coolant level (→ Page 204) and top upwith coolant through the filler neck if re-quired:



(→ Step 7) until coolant no longer needs to betopped up.

Final steps1. Start the engine and run it without load for some minutes.2. Check coolant level (→ Page 204) and top up coolant as required.


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8.15.5 Charge-air coolant pump – Relief bore check





Charge-air coolant pump – Re-lief bore check

1. Check relief bore (arrow) for oil and coolantdischarge.

Note: Observe safety regulations when carrying outmaintenance and repair work (→ Page 11).

2. Stop engine (→ Page 51) and disable enginestart.

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 hour4. If discharge exceeds the specified limits:

Contact Service.


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8.16 Battery-Charging Generator

8.16.1 Drive belt – Condition check


WARNINGExposed rotating parts can eject drawn-in components or draw in body parts.Risk of crushing, limbs or extremities may be pinched, trapped or entangled!Risk of injury due to flying parts!• Install rotating components at a suitable distance from other components.• Never operate the engine without protective covers or safety guards which meet applicable accident

prevention regulations.• Ensure that the safety guards can prevent body parts from being drawn in by rotating components.

Drive belt – Condition check1. Remove cover.

2. Checking drive belt condition:

Item Findings ActionDrive belt A Singular cracks NoneDrive belt B Cracks on entire circumference Replace (→ Page 216)Drive belt C ChunkingDrive belt Belt is oily, shows signs of over-

heating

3. Install cover.

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8.16.2 Battery-charging generator – Drive belt tension adjustment



Torque wrench, 60–320 Nm F30452768 1Ratchet bit F30027341 1Torque wrench, 10–60 Nm F30452769 1Ratchet bit F30027340 1

WARNINGBelt tensioner spring is pretensioned.Risk of hands being crushed!• Lock belt tensioner in position.• Only use specified tools and devices.

Adjusting belt tension1. Slacken screws (1) and (2) by half a turn.

Result: Belt tensioner moves against the drive beltand tensions it.



Screw M10 Tightening torque 60 Nm +5 Nm

3. Tighten screw (1) with a torque wrench.

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8.16.3 Battery-charging generator drive – Drive belt replacement



Torque wrench, 60–320 Nm F30452768 1Ratchet bit F30027341 1Torque wrench, 10–60 Nm F30452769 1Ratchet bit F30027340 1Drive belt (→ Spare Parts Catalog)

WARNINGBelt tensioner spring is pretensioned.Risk of hands being crushed!• Lock belt tensioner in position.• Only use specified tools and devices.

Battery-charging generator drive – Drive belt replacement1. Remove protective cover.

2. Loosen screws (2) and (3) by half a turn.3. Mount socket or box wrench on screw (1)

and press belt tensioner in direction of arrowas far as the stop.

4. Tighten screw (3).5. Remove the used drive belt.6. Fit new drive belt.7. Loosen screw (3) by half a turn.

Result: Belt tensioner moves against the drive beltand tensions it.

8. Tighten screw (3) with torque wrench to specified tightening torque.


Screw M10 Tightening torque 60 Nm +5 Nm

9. Tighten screw (2).10. Install protective cover.11. Readjust drive belt tension after 30 minutes and after 8 hours engine runtime (→ Page 215).

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8.17 Wiring (General) for Engine/Gearbox/Unit

8.17.1 Engine cabling – Check



Solvent (isopropyl alcohol) X00058037 1

Engine cabling – Check1. Check securing screws of cable clamps on engine and tighten loose screw connections.2. Ensure that cables are securely seated in clamps and cannot move freely.3. Check if all cable clips are closed and intact.4. Replace faulty cable clips.5. Check cable clamps for secure fit, tighten loose clamps.6. Replace faulty cable clamps.7. Visually inspect the following electrical components for damage:

• Connector housings• Contacts• Plug connectors• Cables and terminals• Plug-in contacts

Result: If cable conductors are damaged, contact Service.

Note: Close connectors that are not plugged in with the protective cap supplied.8. Use isopropyl alcohol to clean dirty connector housings, plug connectors and contacts.9. Ensure that all connecting plugs of the sensors are correctly engaged.

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8.18 Engine Mounting / Support

8.18.1 Engine mounting – Checking securing screws for firm seating


Engine mounting, checking securing screws for firm seating1. Check securing screws for firm seating.2. Tighten loose threaded connections.

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8.18.2 Engine mounting – Checking resilient element

NOTICEContamination of engine mounts made of natural rubber with fuel or oil.Engine mounts swell. Risk of shorter service life or destruction of the mounts!• Cover engine mounts when working with fuel or oil.• Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them.

Engine mounting – CheckItem Findings ActionVisually inspect resilient elements. • Damage

• Brittleness• Deformation• Crack formation• Swelling

Replace (contact Service).

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8.19 Generator Mounting

8.19.1 Generator mounting – Securing screw firm seating check


Generator mounting, securing screw firm seating check1. Check securing screws for firm seating.2. Tighten loose screws.

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8.19.2 Resilient mounts of generator mounting – Check


Checking resilient mounts of generator mounting1. Wipe rubber surface with dry cloth, do not use organic detergents.2. Visually inspect resilient mounts for cracks and deformation.3. Check rubber surfaces for swelling.4. Have cracked or swollen mounts replaced, contact Service.

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8.20 Radiator

8.20.1 Fuel cooler – External contamination and leak-tightness check


☑All fuel cooler power sources are disconnected.




Fuel cooler – External contamination and leak-tightness checkElement Findings ActionCheck fuel cooler and connectionsfor leakage.

Leakage Contact Service.

Check housing and fuel coolerelectric motor for dust and foreignobjects.

Dust and/or foreign objects Clean fan guard with a soft brush.Clean surface of fuel cooler with adamp rag.Clean fuel cooler if heavily conta-minated (→ Page 223).

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8.20.2 Fuel cooler – Cleaning


☑All fuel cooler power sources are disconnected.





WARNINGChemical substances in cleaners.Risk of irritation and chemical burns!• Always obey manufacturer's instructions for use.

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

NOTICEInappropriate cleaning tool.Risk of damage to component!• Observe manufacturer's instructions.• Use appropriate cleaning tool.

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Cleaning with a compressed-air pistol1. Blow out cooler elements with a jet of compressed air working against the direction of the cooling air parallel

to the cooling fins.2. Remove and dispose of dirt before putting engine into operation.3. Use industrial high-pressure cleaner to clean fuel cooler in case of stubborn contamination.

Cleaning with industrial high-pressure cleanerNote: • To avoid damage to cooling elements, only aim water jet parallel to the cooling fins applying moderate

pressure.• To improve the cleaning effect, add a suitable degreasing agent to the water (in accordance with the rec-

ommendations of the high-pressure cleaner manufacturer). The degreasing agent must be approved forlight metal containing coolers.

1. Use high-pressure cleaner to clean cooling elements working against the direction of the cooling air.2. Thoroughly dry cooler and surrounding areas before putting engine into operation.

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8.21 Accessories for (Electronic) Engine Governor / Control System

8.21.1 Resetting CDC parameter and entering IIG with DiaSys®


Note: The engine will lose its emissions certification of the drift correction parameters (CDC) if not reset.

Parameters for drift correction (CDC) – Resetting with DiaSys®1. Use DiaSys® to reset the CDC parameters (→ Dialog system DiaSys® E531920/..).2. If no DiaSys® is available, contact Service.

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

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8.21.2 Engine governor and connector – Cleaning



Solvent (isopropyl alcohol) X00058037 1

NOTICEInsertion of unsuitable test probe, e.g. test prod.The contacts in the plug connection can be bent!• Carry out check of plug connection only with test connectors.

Engine governor and connector – Cleaning1. Use isopropyl alcohol to remove coarse dirt from housing surface.2. Use isopropyl alcohol to remove dirt from the connector and cable surfaces.3. Check legibility of cable labels. Clean or replace illegible labels.

Heavily contaminated connectors on engine governor – CleaningNote: Close connectors that are not plugged in with the protective cap supplied.

1. Release latches of connectors and withdraw connectors.2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.3. When connectors, sockets and all contacts are dry: Fit connectors and latch them.

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8.21.3 Engine governor plug connections – Check

Preconditions☑Engine stopped and starting disabled.

☑Electronic engine management system is de-energized.

NOTICEInsertion of unsuitable test probe, e.g. test prod.The contacts in the plug connection can be bent!• Carry out check of plug connection only with test connectors.

Checking plug connections at engine governor1. Check all plug connections for secure seating.2. Lock loose connectors.3. Check dust cap on ECU and EXU connectors for damage and correct seating.

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8.21.4 Engine governor ECU 9 – Removal and installation


☑Protective cover over connectors on Heavy-Duty version removed.

NOTICEWrong engine governor installed.Engine damage!• When reassembling an engine, make sure that the governor with the data record for the given engine

is installed.

Removing engine governor fromengine

1. Note or mark assignment of cables andplugs.

2. Remove all screws (2).3. Undo clips (3) on connectors.4. Remove all male connectors.5. Remove screws (1).6. Take off engine governor.

Installing engine governor on engine1. For installation follow reverse sequence of working steps. Ensure that connectors are plugged in the correct

socket.2. Check resilient mounts before installing.

Result: Replace the resilient mounts if the rubber is perished, or the mounts are otherwise defective.

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9 Appendix A

9.1 Conversion tables

LengthUnit A multiplied by factor = Unit Bin 25.4 = mmft 0.3048 = myd 0.9144 = mstat. mile 1.609 = kmNm 1.852 = kmyd 3 = ftyd 36 = in

Unit B multiplied by factor = Unit Amm 0.03937 = inm 3.281 = ftkm 0.6215 = stat. mile

AreaUnit A multiplied by factor = Unit B

in2 645.16 = mm2

ft2 0.0929 = m2

yd2 0.8361 = m2

stat. mile2 2.59 = km2

Unit B multiplied by factor Unit A

mm2 0.00155 = in2

m2 10.764 = ft2

m2 1.1960 = yd2

km2 0.3861 = stat. mile2

VolumeUnit A multiplied by factor = Unit B

in3 16387 = mm3

ft3 0.02832 = m3

yd3 0.7646 = m3

gallon (U.S.) 3.785 = dm3

gallon (UK) 4.546 = dm3

Unit B multiplied by factor = Unit A

cm3 0.06102 = in3

m3 35.31 = ft3

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dm3 0.2642 = gallon (U.S.)

dm3 0.22 = gallon (UK)

Volumetric flowUnit A multiplied by factor = Unit Bgal/min (GPM, U.S.) 3.79 = l/mingal/min (GPM, U.S.) 0.134 = ft3/min (cfm)

ft3/min (cfm) 1.70 = m3/h

Unit B multiplied by factor = Unit Al/min 0.264 = gal/min (U.S.)

ft3/min (cfm) 7.48 = gal/min (U.S.)

m3/h 0.589 = ft3/min (cfm)

VelocityUnit A multiplied by factor = Unit Bft/s 0.3048 = m/sstat. mile/h (mph) 1.609 = km/hknot (UK) 1.852 = km/h

Unit B multiplied by factor = Unit Bm/s 3.281 = ft/skm/h 0.6214 = stat. mile/h (mph)km/h 0.54 = knot (UK)

MassUnit A multiplied by factor = Unit Blb 0.4536 = kgoz 28.35 = gton (imp.) 1.016 = t

Unit B multiplied by factor = Unit Ag 0.03527 = ozkg 2.205 = lbt 0.9842 = ton (imp.)

ForceUnit A multiplied by factor = Unit Blbf 0.4536 = kplbf 4.4482 = Nkp 9.80665 = N

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Unit B multiplied by factor = Unit Akp 2.205 = lbfN 0.10197 = kpN 0.2248 = lbf

DensityUnit A multiplied by factor = Unit B

slug/ft3 515.4 = kg/m3


kg/m3 0.00194 = slug/ft3

TorqueUnit A multiplied by factor = Unit Blbf ft 1.3558 = Nm

Unit B multiplied by factor = Unit ANm 0.7376 = lbf ft

PressureUnit A multiplied by factor = Unit B

lbf/in2 (psi) 703.1 = kp/m2 (mmH2O)

lbf/in2 (psi) 0.06895 = bar

lbf/ft2 (psf) 47.88 = Pa

inHg 0.03386 = barinHg 345.3 = kp/m2 (mmH2O)

Unit B multiplied by factor = Unit Aatm 760 = mmHgatm 1.0133 = baratm 10332 = kp/m2 (mmH2O)

atm 1.0332 = kp/cm2 (at)atm 14.696 = lbf/in2 (psi)bar 14.504 = lbf/in2 (psi)Pa 0.0209 = lbf/ft2 (psf)

2nd moment of massUnit A multiplied by factor = Unit B

slug ft2 1.3558 = kg m2


kg m2 0.7376 = slug ft2

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EnergyUnit A multiplied by factor = Unit Blbf ft 1.356 = Jkcal 4186.8 = JBTU 1055 = JCHU 1899 = J

Unit B multiplied by factor = Unit AJ 0.7376 = lbf ftJ 0.0002388 = kcalJ 0.0009478 = BTUJ 0.00052656 = CHU

PowerUnit A multiplied by factor = Unit BPS 0.7355 = kWHP 0.7457 = kWBTU/s 1.054 = kWkcal/h 1.163 = WHP 550 = lbf ft/s

Unit B multiplied by factor = Unit AkW 1.36 = PSkW 1.341 = HPkW 0.9487 = BTU/sW 0.8598 = kcal/hlbf ft/s 0.0018 = HP

TemperatureCelsius Kelvin

x °C - = x + 273.15 Kx K = x − 273.15 °C -x °F = 5/9(x − 32) °C = 5/9(x − 32) + 273.15 Kx °R = 5/4x °C = (5/4x) + 273.15 K

Fahrenheit Réaumurx °C = 9/5x + 32 °F = (4/5x) °Rx K = 9/5(x − 273.15) + 32 °F = 4/5(x − 273.15) °Rx °F - = 4/9(x − 32) °Rx °R = (9/4x) + 32 °F -

Fuel consumptionUnit A multiplied by factor = Unit Bmile/gal (US) 0.4251 = km/lgal/mile (US) 2.3527 = l/km

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Unit B multiplied by factor = Unit Akm/l 2.3527 = mile/gal (US)l/km 0.4251 = gal/mile (US)

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9.2 AbbreviationsAbbre-viation

Meaning Explanation

A/D Analog/Digital converter Converter: converts sensor voltages into digital val-ues

ADEC Advanced Diesel Engine Controller Engine management systemAFRS Air Filter Restriction SensorAL alarmANSI American National Standards Institute Association of American standardization organiza-

tionsATS Air Temperature SensorBR SeriesBV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica-

tion No. A001061/..CAN Controller Area Network Data bus system, bus standardCDC Calibration Drift Compensation Drift correction setting with DiaSys in engine gover-

norCEL Check Engine Lamp 1st function: Warning lamp (rectify fault as soon as

possible)2nd function: Read out fault codes

CKT CircuitCLS Coolant level sensor Monitors coolant levelCM Current Measurement Current measured valueCPS Coolant pressure sensor Monitors coolant pressureCR Common RailCTS Coolant temperature sensor Monitors coolant temperatureDDEC Detroit Diesel Electronic Controls Engine control system made by Detroit DieselDDL Diagnostic Data Link Diagnostic linesDDR Diagnostic Data Reader Diagnostic unitDia-Sys®

Electronic dialog system

DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards(DIN = “Deutsche Industrie-Norm”)

DL Default Lost Alarm: Default CAN bus failureDMC Data Matrix CodeDOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel particulate

filterDPF Diesel Particulate FilterDT Diagnostic Tool Diagnostic unitECM Electronic Control Module Electronic control unit of the DDEC systemECU Engine Control Unit Engine governorEDM Engine Data Module Memory module for engine dataEE-PROM

Electrically Erasable Programmable ReadOnly Memory

EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal

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Abbre-viation

Meaning Explanation

EGR Exhaust Gas RecirculationEIL Engine Ident LabelEIM-ID Emission Identification NumberEMU Engine Monitoring UnitESCM Extreme Site Condition Management Power reduction for operation in extreme conditionsESD Einzelspeicherdruck Injector accumulator pressureETC Exhaust turbocharger/exhaust turbocharg-

ingEUI Electronic Unit Injector Electronic injection nozzle unitFO Frequency OutputFPS Fuel Pressure Sensor Monitors fuel pressureFRS Fuel Restriction Sensor Monitors differential fuel pressureFTS Fuel Temperature Sensor Monitors fuel temperatureFWCP Fire Water Control Panel Control cabinetGND GroundHP High PressureHI High Alarm: Measured value exceeds 1st maximum limitHIHI High High Alarm: Measured value exceeds 2nd maximum limitHT High TemperatureIDM Interface Data Module Memory module for interface dataIIG Initial injector equalization Initial input of injector code in Engine Control Unit

with DiaSysINJ InjectorISO International Organization for Standardiza-

tionInternational umbrella organization for all nationalstandardization institutes

KGS Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204KS Kupplungsseite Engine driving end in accordance with DIN ISO 1204L1 Limit 1 Limit value, limit 1L2 Limit 2

Reference surface for heights above sealevel

Limit value, limit 2

LED Light Emitting Diode Light emitting diodeLLK Ladeluftkühlung Charge-air coolingLO Low Alarm: Measured value lower than 1st minimum limit

valueLOLO Low Low Alarm: Measured value lower than 2nd minimum lim-

it valueLP Low PressureLSG Limit Speed Governor Maximum-speed governorLSU Lambda Sonde Universal Universal Lambda probeLT Low TemperatureMCR Maximum Continuous Rating Torque limitation curveN/A Not ApplicableNN Normal Null Reference surface for heights above sea level

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Abbre-viation

Meaning Explanation

OEM Original Equipment ManufacturerOI Optimized IdleOLS Oil Level Sensor Monitors oil levelOPS Oil pressure sensor Monitors oil pressureOTS Oil Temperature Sensor Monitors oil temperatureOT Oberer Totpunkt Top Dead Center (TDC)PAN Panel Control panelPIM Peripheral Interface ModulePWM Pulse Width Modulation Modulated signalP-xyz Pressure-xyz Pressure measuring point xyzRL Redundancy Lost Alarm: Redundant CAN bus failurerpm Revolutions per minuteSAE Society of Automotive Engineers U.S. standardization organizationSD Sensor Defect Alarm: Sensor failureSEL Stop Engine Lamp 1st function: Warning lamp (stop engine and rectify

fault); 2nd function: Read out fault codesSID System IdentifierSPC Spare Parts CatalogSRS Synchronous Reference Sensor TDC cylinder 1SS Safety System / Security Shutdown Safety system alarmTBS Turbocharger Boost Sensor Monitors charge-air pressureTC Tool CatalogTCI Turbo Compressor InletTCO Turbo Compressor OutletTD Transmitter Deviation Alarm: Sensor comparison faultTPS Throttle Position SensorTRS Timing Reference SensorT-xyz Temperature-xyz Temperature measuring point xyzU_PDU Voltage Power Driver Unit Distribution voltage for solenoid valve output stagesUDV Überdruckventil Pressure relief valveUT Unterer Totpunkt Bottom Dead Center (BDC)VNT Variable nozzle turbineVSG Variable-speed governorVSS Vehicle Speed SensorZKP Zuordnung - Kategorie - Parameter A number allocated to a parameter describing its

function and assignment

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9.3 MTU Contact/Service PartnersThe worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-er service centers ensure fast and direct support on site and ensure the high availability of our products.

Local SupportExperienced 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 HotlineWith our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase,preventive maintenance and corrective operations in case of a malfunction, for information on changes inconditions of use and for supplying spare parts.

Your contact person in our Customer Assistance Center:

E-mail: [email protected]

Tel.: +49 7541 9077777

Fax.: +49 7541 9077778

Asia/Pacific: +65 6100 2688

North and Latin America: +1 248 560 8000

Spare Parts ServiceFast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right sparepart 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 atheadquarters and on-site stores at our subsidiary companies, agencies and service workshops.

Your contact at Headquarters:

E-mail: [email protected]

Tel.: +49 7541 9077777

Fax.: +49 7541 9077778

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10 Appendix B

10.1 Special ToolsBarring tool

Part No.: F6555766Qty.:Used in:

1 8.1.1 Engine – Barring manually (→ Page 111)

Qty.:Used in:

1 8.2.1 Cylinder liner – Endoscopic examination(→ Page 115)

Crossbeam

Part No.: T80091826Qty.:Used in:

1 2.1 Transport (→ Page 18)

Crossbeam

Part No.: T80092360Qty.:Used in:

1 2.1 Transport (→ Page 18)

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Depth gage, 200 mm

Part No.: Y20000918Qty.:Used in:

1 8.4.1 Valve protrusion – Measurement (→ Page 122)

Endoscope



Feeler gage


1 8.4.3 Valve clearance – Check and adjustment(→ Page 127)

Filter wrench


1 8.8.1 Fuel filter – Replacement (→ Page 148)

Qty.:Used in:

1 8.8.2 Additional fuel filter – Replacement (→ Page 149)

Qty.:Used in:

8.13.1 Engine oil filter – Replacement (→ Page 178)

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Fuel suction device


1 8.5.1 HP fuel pump – Filling with engine oil (→ Page 131)

High-pressure cleaner

Part No.:Qty.:Used in:

1 5.12 Plant – Cleaning (→ Page 56)

Installation/removal device


1 8.6.2 Injector rings – Replacement (single-wall fuel sys-tem) (→ Page 134)

Installation/removal jig


1 8.6.3 Injector – Removal and installation (→ Page 140)

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Measuring jig 1



Measuring jig 2, optional



Milling cutter



Qty.:Used in:


MTU test kit


1 8.12.3 Engine oil – Sample extraction and analysis(→ Page 175)


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MTU test kit

Part No.: 5605892099/00Qty.:Used in:

1 8.14.6 Engine coolant – Sample extraction and analysis(→ Page 190)

Oil filter wrench


1 8.13.2 Cleaning centrifugal oil filter and replacing filtersleeve (→ Page 179)

Ratchet adapter



Ratchet adapter




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Ratchet bit



Qty.:Used in:


Qty.:Used in:

1 8.12.1 Engine oil – Change (→ Page 172)

Qty.:Used in:

1 8.16.2 Battery-charging generator – Drive belt tension ad-justment (→ Page 215)

Qty.:Used in:

1 8.16.3 Battery-charging generator drive – Drive belt re-placement (→ Page 216)

Ratchet bit



Qty.:Used in:

1 8.8.8 Fuel prefilter (non-switchable) – Filter element re-placement (→ Page 158)

Qty.:Used in:

1 8.8.9 Fuel prefilter (switchable) – Filter element replace-ment (→ Page 160)

Qty.:Used in:


Qty.:Used in:


Qty.:Used in:


Ratchet with extension


1 8.1.1 Engine – Barring manually (→ Page 111)

Qty.:Used in:



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Socket wrench, 24 mm



Torque screwdriver, 1–5 Nm



Qty.:Used in:


Torque wrench, 10–60 Nm


1 2.3 Crankshaft transport locking device (→ Page 20)

Qty.:Used in:

1 8.3.2 Crankcase breather – Filter element replacement(→ Page 120)

Qty.:Used in:

1 8.5.1 HP fuel pump – Filling with engine oil (→ Page 131)

Qty.:Used in:


Qty.:Used in:


Qty.:Used in:


Qty.:Used in:


Qty.:Used in:



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1 2.3 Crankshaft transport locking device (→ Page 20)

Qty.:Used in:


Qty.:Used in:


Qty.:Used in:


Qty.:Used in:

1 8.12.1 Engine oil – Change (→ Page 172)

Qty.:Used in:


Qty.:Used in:


Qty.:Used in:




1 8.8.8 Fuel prefilter (non-switchable) – Filter element re-placement (→ Page 158)

Qty.:Used in:

1 8.8.9 Fuel prefilter (switchable) – Filter element replace-ment (→ Page 160)


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10.2 IndexA

Abbreviations 234Actuators – Overview 27Additional fuel filter – Replacement 149After stopping the engine – Engine remains ready for operation 54– Putting the engine out of operation 55Air filter – Check 167– Installation 168– Removal 168– Replacement 166– Service indicator check 171

B

Battery-charging generator – Drive belt replacement 216– Drive belt tension adjustment 215

C

Cabling – Check

– On engine 217CDC – Reset 225Centrifugal oil filter – Assembly 179– Disassembly 179– Filter sleeve

– Replacement 179Charge-air coolant – Change 206– Check

– Level at filler neck 204– Level via level sensor 204

– Draining 207– Filling 209Charge-air coolant pump – Relief bore check 213Connector – Cleaning 226Contact persons 237Conversion tables 229Coolant – Change 182, 206– Filling 185, 209Coolant expansion tank – Valve cover replacement 203Crankcase breather – Filter element replacement 120– Oil separator filter element replacement 119

Crankshaft – Transport locking device

– Installation/removal 20Cylinder – Designation 24Cylinder head cover – Installation 130– Removal 130Cylinder liner – Endoscopic examination 115– Endoscopic inspection

– Instructions and comments on endoscopic and visu-al examination 117

D

Drive belt – Condition check 214

E

ECU 9 – Installation 228– Removal 228Emergency start – Override mode 50Emergency stop – Engine 53Endoscopic inspection – Cylinder liner

– Instructions and comments 117Engine – Barring

– Manually 111– Cranking

– On starting system 113– Emergency start (Override mode) 50– Emergency stop 53– Layout 25– Main dimensions 43– Starting in manual mode (test run) 46– Stopping in Manual mode (test run) 51– Test run 114Engine cabling – Check 217Engine coolant – Analysis

– Sample 190– Change 182– Draining 183– Extraction

– Sample 190– Filling 185Engine coolant level – Check 181

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Engine coolant pump – Check

– Relief bore 189Engine driving end – Definition 24Engine free end – Definition 24Engine governor – Cleaning 226– Plug connections

– Check 227Engine governor ECU 9 – Installation 228– Removal 228Engine mounting – Check 219– Checking securing screws for firm seating 218Engine oil – Change 172– Sample extraction and analysis 175Engine oil filter – Replacement 178Engine oil level – Check 174Engine sides – Designation 24

F

Fault messages of the ADEC (ECU 9) engine governor forSeries 4000 genset engines 62

Filter – Replacement

– Additional fuel 149– Fuel 148

Firing order 42Fuel cooler – Check

– External contamination 222– Leak-tightness 222

– Cleaning 223Fuel filter – Replacement 148Fuel prefilter – Draining 151

– Non-switchable 152– Switchable 154

– Filter element replacement – Non-switchable 158– Switchable 160

– Low pressure indicator check – Switchable 157

– Pressure ratios 150– Venting 163Fuel system – Venting 146

G

Generator mounting – Checking condition of resilient mounts 221– Securing screw firm seating check 220

H

Heating element – Check

– Preheater 195Heavy duty air filter – Filter element

– Installation 169– Removal 169

– Filter insert – Installation 169– Removal 169

Hotline 237Housing – Check

– Preheater 195HP pump – Filling with engine oil 131

I

IIG – Input 225Injector – Installation 140– Removal 140– Replacement 133Injector coding (IIG) – Input 225Injector rings – Replacement 134Intercooler – Check drain for coolant leakage 165– Check drain for obstruction 165

L

Lifting requirements 19

M

Maintenance schedule – Maintenance task reference table [QL1] 57MTU contact persons 237

O

Oil priming pump – Visual inspection 177Operational monitoring 49Overview – Preheater 192

P

Parameters for drift correction (CDC) – Resetting 225Plant – Cleaning 56

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Preheater – Check

– Heating element 195– Housing 195

– Function check 194– Leak check 194– Overhaul 193– Overview 192– Replacement

– Solenoid switch 198– Thermostat 200

Product data – 20V4000G44F 31– 20V4000G44LF 31– 20V4000G94F 37– 20V4000G94LF 37Pump – Charge-air coolant

– Relief bore check 213Putting the engine-generator set into operation after ex-

tended out-of-service-periods (>3 months) 44Putting the engine-generator set into operation after

scheduled out-of-service-period 45

R

Relief bore – Check

– Engine coolant pump 189

S

Safety regulations – Assembly work 11– Auxiliary materials 15– Environmental protection 15– Fire prevention 15– Fluids and lubricants 15– Important provisions 5, 7– Initial start-up 9– Maintenance work 11– Operation 9– Organizational requirements 8– Personnel requirements 8– Repair work 11Safety requirements – Warning notices, standards 17Safety system – Override 48Sensors – Overview 27Service indicator – Check 171Service partners 237Shipping lock – Engine mount

– Installation 23– Removal 23

Solenoid switch – Replacement

– Preheater 198

Spare parts service 237

T

Thermostat – Replacement

– Preheater 200Transport – Description 18Transport locking device – Crankshaft

– Installation/removal 20Transportation – Lifting requirements 19Troubleshooting 59

V

Valve clearance – Adjustment 127– Check 127Valve cover – Replacement 203Valve gear – Lubrication 126Valve protrusion – Measurement 122

W

Warning notices, standards 17

248 | Index | MS15058/03E 2018-07

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