MTU 16V2000S56, 12V2000S56, 12V2000C66R, 12V2000S96, 12V2000C66 Operating Instructions Manual

Operating Instructions

Diesel engine

12V2000S56
16V2000S56
12V2000C66
16V2000C66
12V2000C66R
12V2000S96
16V2000S96

MS150094/02E

© 2015 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ­ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro­filming and storage or processing in electronic systems including databases and online services.

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

Table of Contents

1 Safety

1.1 Important provisions for all products 5

1.2 Personnel and organizational requirements 7

1.3 Transport 8

1.4 Safety precautions when working on the
engine 9

1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 12

1.6 Standards for safety notices in the text 14

2 Product Summary

2.1 Engine – Overview 15

2.2 Engine side and cylinder designations 17

2.3 Engine – Main dimensions 18

2.4 Firing order 19

2.5 Technical Data 20

2.5.1 12/16V 2000 C66 engine data 20

2.5.2 Engine data 12V2000C66R 24

2.5.3 Engine data 12/16V2000S56 28

2.5.4 12/16V 2000 S96 engine data 31

3 Operation

3.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 34

3.2 Putting the engine into operation after
scheduled out-of-service-period 35

3.3 Starting the engine 36

3.4 Operational checks 37

3.5 Engine shutdown 38

3.6 Emergency engine stop 39

3.7 After stopping the engine – Putting the
engine out of operation 40

3.8 Plant – Cleaning 41

4 Maintenance

4.1 Maintenance task reference table [QL1] 42

5 Troubleshooting

5.1 Troubleshooting 43

5.2 Engine Control Unit – ECU9 fault messages 46

6 Task Description

6.1 Engine 74

6.1.1 Engine – Barring manually 74

6.1.2 Engine – Barring with starting system 75

6.2 Crankcase Breather 76

6.2.1 Crankcase breather – Oil mist fine separator
replacement 76

6.3 Valve Drive 77

6.3.1 Valve clearance – Check and adjustment 77

6.3.2 Cylinder head cover – Removal and
installation 80

6.4 Injector 81

6.4.1 Injector – Replacement 81

6.4.2 Injector – Removal and installation 82

6.5 Fuel System 87

6.5.1 HP fuel line and pressure pipe neck –
Replacement 87

6.5.2 Fuel system – Venting 89

6.5.3 Fuel – Draining 90

6.6 Fuel Filter 91

6.6.1 Fuel filter – Replacement 91

6.6.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 92

6.6.3 Fuel prefilter – Draining 93

6.6.4 Fuel prefilter – Flushing 94

6.6.5 Fuel prefilter – Filter element replacement 96

6.7 Air Filter 98

6.7.1 Air filter – Replacement 98

6.8 Air Intake 99

6.8.1 Service indicator – Check 99

6.9 Exhaust Gas Recirculation 100

6.9.1 Exhaust gas recirculation flaps – Overview 100

6.9.2 Exhaust gas circulation ‒ Checking flap
operation 101

6.10 Lube Oil System, Lube Oil Circuit 102

6.10.1 Engine oil – Level check 102

6.10.2 Engine oil – Change 103

6.11 Oil Filtration / Cooling 104

6.11.1 Engine oil filter – Replacement 104

6.11.2 Centrifugal oil filter – Cleaning and filter­sleeve replacement 105

6.12 Coolant Circuit, General, High-Temperature
Circuit 107

6.12.1 Drain and vent points 107

6.12.2 Engine coolant – Level check 112

6.12.3 Engine coolant – Change 113

6.12.4 Engine coolant – Draining 114

6.12.5 Engine coolant – Filling 115

6.12.6 Engine coolant pump – Relief bore check 117

6.12.7 Engine coolant – Sample extraction and
analysis 118

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6.12.8 Coolant filter – Replacement 119

6.13 Low-Temperature Circuit 120

6.13.1 Intercooler – Vent and drain points 120

6.13.2 Charge-air coolant – Level check 121

6.13.3 Charge-air coolant – Change 122

6.13.4 Charge-air coolant – Filling 123

6.13.5 Charge-air coolant – Draining 125

6.13.6 Charge-air coolant pump – Relief bore check 126

6.14 Belt Drive 127

6.14.1 Drive belt – Condition check 127

6.14.2 Drive belt – Tension check 128

6.14.3 Drive belt – Tension adjustment 130

6.14.4 Drive belt – Replacement 132

6.15 Battery-Charging Generator 133

6.15.1 Battery-charging generator drive – Drive belt
replacement 133

6.16 Engine Governor 134

6.16.1 Engine governor – Overview 134

6.16.2 Engine governor – Removal 135

6.16.3 Engine governor – Installation 136

6.16.4 Engine governor plug connections – Check 137

6.17 Wiring (General) for Engine/Gearbox/Unit 138

6.17.1 Engine cabling – Check 138

6.17.2 Lambda, NOx and humidity sensors –
Overview 139

6.17.3 Lambda sensor – Replacement 140

6.17.4 NOx sensor – Replacement 142

6.17.5 Humidity sensor – Replacement 144

6.18 Accessories for (Electronic) Engine
Governor / Control System 146

6.18.1 Resetting CDC parameter and entering IIG
with DiaSys® 146

6.18.2 Engine governor and connector – Cleaning 147

6.18.3 Engine governor plug connections – Check 148

7 Appendix A

7.1 Abbreviations 149

7.2 MTU contact persons/service partners 151

8 Appendix B

8.1 Special Tools 152

8.2 Index 161

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1 Safety

1.1 Important provisions for all products

Nameplate

The product is identified by nameplate, model designation or serial number and must match with the infor­mation on the title page of this manual.

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

All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi­cations.

General information

This product may pose a risk of injury or damage in the following cases:

• Incorrect use

• Operation, maintenance and repair by unqualified personnel

• Modifications or conversions

• Noncompliance with the safety instructions and warning notices

Correct use

The product is intended for use in accordance with its contractually-defined purpose as described in the rele­vant technical documents only.

Intended use entails operation:

• Within the permissible operating parameters in accordance with the (→ Technical data)

• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)

• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con­tact/Service partner)

• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in­cluding engine control/parameters)

• In compliance with all safety regulations and in adherence with all warning notices in this manual

• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the use­ful life of the product

• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques

• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re­pair

• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul

The product may only be operated in explosive atmospheres if it was certified for such operating conditions.

Any other use, in particular malpractice, shall be considered non-intended. Such improper use increases the
risk of injury and damage when working with the product. The manufacturer shall not be held liable for any
damage resulting from improper, non-intended use.

Modifications or conversions

Unauthorized 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 author­ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor­ized changes or modifications.

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Emission regulations and emission labels

Responsibility for compliance with emission regulations

Modification or removal of any mechanical/electronic components or the installation of additional compo­nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex­changed or repaired if the components used for this purpose are approved by the manufacturer.

Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu­lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product.

Replacing components with emission labels

Emission labels are attached to all MTU engines. These must remain on the engine throughout its operational
life.

Engines used exclusively in land-based, military applications other than by US government agencies are ex­cepted from this proviso.

Please note the following when replacing components with emission labels:

• Appropriate emission labels must be affixed on spare parts.

• Emission labels may not be transferred from old components to new ones.

• Emission labels on old components must be removed and destroyed.

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1.2 Personnel and organizational requirements

Organizational measures of the user/manufacturer

This manual must be issued to all personnel involved in operation, maintenance, repair, or transportation.

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

Personnel must receive instruction on product handling and maintenance based on this manual with a spe­cial emphasis on safety requirements and warnings.

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

Personnel requirements

All work on the product shall be carried out by trained and qualified personnel only:

• Training at the Training Center of the manufacturer

• Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering

The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, and
transport.

Personnel must not be under the influence of alcohol, drugs, or strong medication.

Working clothes and personal protective equipment

When working, always wear the necessary personal protective equipment (for example safety shoes, ear pro­tectors, protective gloves, goggles, breathing protection). Observe the information on personal protective
equipment in the respective activity description.

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1.3 Transport

Transport

Also valid for 12V engines

Only use the lifting eyes provided to lift the engine.

Only use transport and lifting devices approved by MTU.

Take the engine's center of gravity into account.

The engine must only be transported in installation position, max. permissible diagonal pull 10°.

If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bearing
pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).

Install the crankshaft locking device and the locking screws for the engine mounts prior to engine transporta­tion.

Secure the engine against tilting during transport. In particular when going down inclines or ramps, the en­gine must be secured against moving and tilting.

Setting the engine down after transport

Only set down engine on a firm, level surface.

Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.

Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-case
basis .

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1.4 Safety precautions when working on the engine

Safety regulations prior to maintenance and repair work

Have maintenance or repair work carried out by qualified and authorized personnel only.

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

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

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

Never carry out maintenance and repair work with the product in operation, unless:

• It is expressly permitted to do so following a written procedure.

• The product is running in the low load range and only for as long as absolutely necessary.

Lock-out the product to preclude undesired starting, e.g.

• Start interlock

• Key switch

• With hydraulic starting system: shut off supply line.

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

Disconnect the battery. Lock out circuit breakers.

Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start­ers are fitted.

Disconnect the control equipment from the product.

If special tools are specified, these special tools or other suitable tools must be used.

Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
They may only be installed after painting the engine or must be covered before painting work is carried out.

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 during maintenance and repair work

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug with a
rag to prevent fluids escaping under pressure.

Take care when draining hot fluids and lubricants (risk of burning).

Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem­bly.

Carry out work only on assemblies or plants which are properly secured.

Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down . Use the specified lifting equipment for all components.

Never use the product as a climbing aid.

When working high on the equipment, always use suitable ladders and work platforms. Never work on en­gines or components that are held in place by lifting equipment.

Keep fuel injection lines and connections clean.

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

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

Fit new seals when re-installing lines.

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

Ensure that all retainers and dampers are installed correctly.

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

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

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

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

Pay particular attention to cleanliness at all times.

Remove any condensate from components which were chilled before assembly. If necessary, coat the com­ponents with a suitable corrosion inhibitor.

Safety regulations following maintenance and repair work

Before barring, make sure that nobody is standing in the danger zone of the product.

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

Check that all safety equipment has been installed and that all tools and loose parts have been removed
(especially the barring gear).

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

Make sure the grounding device is properly connected.

Welding work

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

Before starting welding work:

• Switch off the power supply master switch.

• Disconnect the battery.

• Separate the electrical ground of electronic equipment from the ground of the unit.

No other maintenance or repair work must be carried out in the vicinity of the product while welding is going
on. Risk of explosion or fire due to oil vapors and highly flammable process materials.

Do not use product as ground terminal.

Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The
welding current may otherwise induce an interference voltage in the wiring harnesses which could conceiva­bly damage the electrical system.

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

Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the
specified jigs and fixtures for hydraulic removal/installation procedures.

Observe the max. permissible force-on pressure specified for the jig/fixture.

Do not attempt to bend or exert force on H.P. lines.

Before starting work, pay attention to the following:

• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.

• During the installation procedure, screw on device with pushed-in plunger.

• During the removal procedure, screw on device with retracted plunger.

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

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During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the
component being pressed.

Working with batteries

Observe the safety instructions of the battery manufacturer when working with 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 tools on the battery.

Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to in­jury through the sudden discharge of acid or bursting of the battery body.

Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work or
switching off any part of the electronic system required to do so.

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

Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be damaged
during operation by:

• Contact with sharp edges

• Chafing on components

• Contact with hot surfaces.

Do not secure cables on lines carrying fluids.

Do not use cable straps to secure cables.

Always use connector pliers to tighten union nuts on connectors.

Subject the device as well as the product to a functional testing on completion of all repair work. In particu­lar, check the function of the emergency stop feature.

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:

• Moisture-proof

• Shock-proof

• Wrapped in antistatic foil if necessary.

Work with laser devices

Laser work must only be performed by authorized and trained personnel. When working with laser equip­ment, always observe the safety instructions in the manufacturer's Operating Instructions.

When working with laser equipment, always wear special laser-protection goggles (hazard due to heavily fo­cused radiation).

Laser devices must be equipped, in accordance with their class and usage, with protective devices for ensur­ing safe operation.

Measuring deviations on components

At a reference temperature of 20 °C, workpieces, components and measuring instrument are within the
specified tolerances.

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1.5 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials

Fire prevention

Flames, naked light and smoking are prohibited.

When working with combustible indirect materials, e.g. cleaning agent, ensure area is well ventilated. The
resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.

Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore always
keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on the product.
Do not store combustible materials near the product.

Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a
nonflammable fluid.

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

Always have a suitable extinguishant (fire extinguisher) on hand and familiarize yourself fully with its han­dling.

Noise

Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan­ger are drowned.

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

Environmental protection and disposal

Dispose of used fluids, lubricants and filters in accordance with local regulations.

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

Fluids and lubricants, auxiliary materials

The Fluids and Lubricants Specifications 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 website on the “Technical
Info” or “Parts and Service” tabs at http://www.mtu-online.com.

Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as well
as other chemical substances, observe the information contained in the safety data sheet for the product.
The safety data sheet may be obtained from the relevant manufacturer or from MTU.

Take special care when using hot, chilled or caustic materials.

Used oil

Used oil contains combustion residues that are harmful to health.

Wear protective gloves!

Wash relevant areas after contact with used oil.

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Lead

• Adopt suitable measures to avoid the formation of lead dust.

• Switch on extraction system.

• When working with lead or pastes containing lead, avoid direct contact to the skin and do not inhale lead
vapors.

• Wash relevant areas after contact with lead or lead-containing substances.

Compressed air

Observe special safety precautions when working with compressed air:

• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con­tainers, risks causing an explosion.

• Wear goggles when blowing dirt off workpieces or blowing away swarf.

• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.

• Pay special attention to the pressure in the compressed air system or pressure vessel.

• Assemblies or products 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).

• First shut off compressed air lines before compressed air device is disconnected from the supply line, or
before device or tool is to be replaced.

• Carry out leak test in accordance with the specifications.

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.

• There must be no naked flames in the vicinity.

• No smoking.

• Observe fire-prevention regulations.

• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen

• 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 working area is well ventilated.

• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

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

• Observe the relevant safety data sheet for all materials.

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth­ing.

• Do not inhale vapors.

• If urea solution is swallowed, rinse out mouth and drink plenty of water.

• Remove any wet clothing immediately.

• After contact skin, wash body areas with plenty of water.

• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.

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1.6 Standards for safety notices in the text

DANGER

In the event of immediate danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

WARNING

In the event of a situation involving potential danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

CAUTION

In the event of a situation involving potential danger.

Consequences: Minor or moderate injuries!

• Remedial action.

NOTICE

In the event of a situation involving potentially adverse effects on the product.

Consequences: Material damage!

• Remedial action.

• Additional product information.

Safety notices

1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera­tion, maintenance, repair or transportation.

2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person­al injury shall be considered to include a warning of potential damage.

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2 Product Summary

2.1 Engine – Overview

12/16 V 2000 C66/S96

This overview also applies to 16 V 2000 C66 and 16 V 2000 S96 engines.

1 Exhaust turbocharger
2 Air intake/air supply
3 EGR cooler
4 Intercooler
5 Monitoring, control and reg-

ulation equipment, general
electr. equipment

6 Lube oil system / lube oil

circuit

7 Power supply
8 Cooling air system

9 Coolant system
10 Mounting / support
11 Fuel system (low pressure)
12 Fuel system (high pressure)

13 Valve gear
14 Cylinder head
15 Exhaust system
16 PTO systems, driving end

and free end (coupling)

17 Starting equipment

Engine model designation

Key to the engine model designation

12/16 Number of cylinders

V Cylinder arrangement: V engine

2000 Series

C/S Application: C, charge-air cooling in internal circuit, with

piston cooling
Application S: Exhaust turbocharging with supercharger

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Key to the engine model designation

6/9 Application segment (0, 1, 2,...,9)

6 Design index (0, 1, 2,...,9)

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2.2 Engine side and cylinder designations

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

ance with DIN ISO 1204
(KGS = Kupplungsgegen­seite)

3 Right engine side (B-side)

4 Engine driving end in ac-

cordance with
DIN ISO 1204 (KS = Kup­plungsseite)

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 left­hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of
each bank are numbered consecutively, starting with x=1 at driving end (4).

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

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2.3 Engine – Main dimensions

Item Engine model / Dimension

Engine model / Dimension

12 V 2000 C66/S96 16 V 2000 C66/S96

Length (A) approx. 2028 mm approx. 2378 mm

Width (B) approx. 1276.5 mm approx. 1287 mm

Height (C) approx. 1429 mm approx. 1442 mm

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2.4 Firing order

Firing order for 12 / 16 V 2000 C66/S96 engines

Number of cylin­ders

Firing order

12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1

16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7

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2.5 Technical Data

2.5.1 12/16V 2000 C66 engine data

Explanation:

DL Ref. value: Continuous power

BL Ref. value: Fuel stop power

A Design value
G Guaranteed value
R Guideline value

L Limit value, up to which the engine can be operated, without change (e.g. of power setting)

N Not yet defined value

- Not applicable

X Applicable

Engine model 12V2000

C66

16V2000

C66

Application group 5B 5B

Intake air temperature °C 25 25

Charge-air coolant temperature °C 45 45

Barometric pressure mbar 1000 1000

Site altitude above sea level m 100 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)

Number of cylinders 12

16

Rated engine speed A rpm 2100 2100

Effective power (w/o fan) (Fuel stop power ISO 3046) A kW 783 970

GENERAL CONDITIONS (for maximum power)

Number of cylinders 12

16

Intake depression (new filter) A mbar 15 15

Intake depression, max. L mbar 50 50

Exhaust overpressure A mbar 30 30

Exhaust gas overpressure, max. L mbar 100 75

Fuel temperature at engine inlet connection R °C 37 37

Fuel temperature at engine inlet connection, max (w/o power re­duction)

L °C 65 65

CONSUMPTION

Number of cylinders 12

16

Lube oil consumption after 100 h runtime (B = hourly fuel con­sumption)

R % of B 0.35 0.35

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MODEL RELATED DATA (basic design)

Number of cylinders 12

16

Number of cylinders 12 16

Cylinder arrangement: V angle Degrees

(°)

90 90

Bore mm 135 135

Stroke mm 156 156

Cylinder displacement Liters 2.233 2.233

Total displacement Liters 26.80 35.73

Inlet valves per cylinder 2 2

Exhaust valves per cylinder 2 2

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 12

16

Charge-air pressure before cylinder R bar abs 3.80 3.80

Exhaust temperature after turbocharger R °C 375 390

COOLANT SYSTEM (HT circuit)

Number of cylinders 12

16

Coolant temperature (at engine connection: outlet to cooling
equipment)

A °C 100 100

Coolant temperature after engine, warning R °C 106 105

Coolant temperature after engine, shutdown L °C 108 107

Coolant antifreeze content, max. L % 50 50

Coolant pump: inlet pressure, max. L bar 1.3 1.3

Thermostat: Starts to open R °C 79 79

Thermostat: Fully open R °C 92 92

COOLING SYSTEM (LT circuit)

Number of cylinders 12

16

Coolant antifreeze content, max. L % 50 50

Charge-air temperature after charge-air cooler, max. L °C 95 95

Thermostat: Starts to open R °C 38 38

Thermostat: Fully open R °C 51 51

LUBE OIL SYSTEM

Number of cylinders 12

16

Lube oil operating temperature before engine, from R °C 80 80

Lube oil operating temperature before engine, to R °C 103 104

Lube oil temperature before engine, alarm R °C 103 105

Lube oil temperature before engine, shutdown L °C 105 107

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Number of cylinders 12

16

Lube oil operating pressure before engine, warning R bar 6.4 7.0

Lube oil operating pressure before engine, shutdown L bar 5,9 6.5

FUEL SYSTEM

Number of cylinders 12

16

Fuel pressure at engine inlet connection, min. (when engine is
starting)

L bar -0.5 -0.5

Fuel pressure at engine inlet connection, min. (when engine is run­ning),

L bar -0.5 -0.5

Fuel pressure at engine inlet connection, max. (when engine is
starting)

L bar 0.5 0.5

GENERAL OPERATING DATA

Number of cylinders 12

16

Coolant preheating: preheating temperature (min.) L °C 32 32

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders 12

16

Longitudinal inclination, continuous max. driving end down (Op­tion: max. operating inclinations)

L Degrees

(°)

15 10

Longitudinal inclination, continuous max. driving end up (Option:
max. operating inclinations)

L Degrees

(°)

15 10

Transverse inclination, continuous max. (option: max. operating in­clinations)

L Degrees

(°)

15 10

CAPACITIES

Number of cylinders 12

16

Engine coolant capacity, engine side (without cooling equipment) R Liters 63 83

Charge-air coolant, engine side R Liters 25 37

Total engine oil capacity at initial filling (standard oil system) (Op­tion: max. operating inclinations)

R Liters 103 158,5

Oil pan capacity at dipstick mark “min.” (standard oil system) (Op­tion: max. operating inclinations)

L Liters 73 107

Oil pan capacity at dipstick mark “max.” (standard oil system) (Op­tion: max. operating inclinations)

L Liters 81 120

ACOUSTICS

Number of cylinders 12

16

Exhaust noise, unsilenced - BL (free-field sound pressure level Lp,
1 m distance, ISO 6798, +3 dB(A) tolerance)

R dB(A) 103 109

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

R dB(A) 116 122

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Number of cylinders 12

16

Engine surface noise with attenuated intake noise (filter) - BL
(free-field sound pressure level Lp, 1 m distance, ISO 6798,
+2 dB(A) tolerance)

R dB(A) 103 104

Engine surface noise with attenuated intake noise (filter) - BL
(sound power level LW, ISO 6798+2 dB(A) tolerance)

R dB(A) 121 122

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2.5.2 Engine data 12V2000C66R

Explanation:

DL Ref. value: Continuous power

BL Ref. value: Fuel stop power

A Design value
G Guaranteed value
R Guideline value

L Limit value, up to which the engine can be operated, without change (e.g. of power settings).

N Not yet defined value

- Not applicable

X Applicable

Engine model

12V2000C
66R

Application group 5B

Intake air temperature °C 25

Charge-air coolant temperature °C 45

Barometric pressure mbar 1000

Site altitude above sea level m 100

Power-related data (power ratings are net brake power as per ISO 3046)

Number of cylinders

12V2000C
66R

Rated engine speed A rpm 1800

Fuel stop power ISO 3046 A kW 783

General conditions (for maximum power)

Number of cylinders

12V2000C
66R

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 39

Exhaust overpressure A mbar 30

Exhaust gas overpressure, max. L mbar 80

Model-related data (basic design)

Number of cylinders

12V2000C
66R

Engine with exhaust turbocharging (ETC) and charge-air cooling (CAC) X

Uncooled exhaust lines X

Cylinder arrangement: V-angle Degrees (°) 90

Bore mm 135

Stroke mm 156

Displacement, cylinder Liters 2.233

Displacement, total Liters 26.80

Compression ratio 16.5

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Number of cylinders

12V2000C
66R

Number of inlet valves per cylinder 2

Number of exhaust valves per cylinder 2

Standard housing connecting flange (engine main PTO) SAE 0

Coolant system (HT circuit)

Number of cylinders

12V2000C
66R

Coolant temperature (at engine connection: outlet to cooling equipment) A °C 100

Coolant temperature after engine, alarm L °C 106

Coolant temperature after engine, shutdown L °C 108

Coolant antifreeze content, max. L % 50

Pressure loss in off-engine cooling system, max. L bar 0.8

Coolant system (LT circuit)

Number of cylinders

12V2000C
66R

Coolant temperature before intercooler (at engine connection:inlet from
cooling equipment)

A °C 45

Coolant antifreeze content, max. L % 50

Pressure loss in off-engine cooling system, max. L bar 0.8

Lube-oil system

Number of cylinders

12V2000C
66R

Lube-oil operating temperature before engine, from R °C 80

Lube-oil operating temperature before engine, to R °C 103

Lube-oil temperature before engine, alarm L °C 103

Lube-oil temperature before engine, shutdown L °C 105

Lube-oil operating pressure before engine, from R bar 7.6

Lube-oil operating pressure before engine, to R bar 8.5

Fuel system

Number of cylinders

12V2000C
66R

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.5

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 0.5

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General operating data

Number of cylinders

12V2000C
66R

Cold start capability: air temperature (w/o start aid, w/o preheating) ­(case A)

R °C 0

Firing speed, from R rpm 100

Firing speed. to R rpm 120

Inclinations, standard oil system (reference: waterline)

Number of cylinders

12V2000C
66R

Longitudinal inclination, continuous max. driving end down (option: max.
operating inclinations)

L Degrees (°) 15

Longitudinal inclination, continuous max. driving end up (option: max. op­erating inclinations)

L Degrees (°) 15

Transverse inclination continuous max. (option: max. operating inclina­tions)

L Degrees (°) 15

Capacities

Number of cylinders

12V2000C
66R

Engine coolant capacity, engine side (without cooling equipment) R Liters 63

Charge-air coolant, engine side R Liters 25

Total engine oil capacity, initial filling (standard oil system) (option: max.
operating inclinations)

R Liters 99

Oil change quantity max. (standard oil system) (option: max. operating in­clinations)

R Liters 87

Oil pan capacity dipstick mark min. (standard oil system) (option: max. op­erating inclinations)

L Liters 73

Oil pan capacity dipstick mark max. (standard oil system) (option: max. op­erating inclinations)

L Liters 81

Weights / Main dimensions

Number of cylinders

12V2000C
66R

Engine weight, dry (basic engine configuration acc. to scope of supply
specification)

R kg 2950

Acoustics

Number of cylinders

12V2000C
66R

Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m dis­tance, ISO 6798, +3dB(A) tolerance)

R dB(A) 103

Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798+3 db(A)
tolerance)

R dB(A) 116

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Number of cylinders

12V2000C
66R

Engine surface noise with attenuated intake noise (filter) - BL (free-field
sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance)

R dB(A) 103

Engine surface noise with attenuated intake noise (filter) - BL (sound power
level LW, ISO 6798+2dB(A) tolerance)

R dB(A) 121

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2.5.3 Engine data 12/16V2000S56

Explanation:

DL Ref. value: Continuous power

BL Ref. value: Fuel stop power

A Design value
G Guaranteed value
R Guideline value

L Limit value, up to which the engine can be operated, without change (e.g. of power settings).

N Not yet defined value

- Not applicable

X Applicable

Engine model 12V2000

S56

16V2000

S56

Application group 4B 4B

Intake air temperature °C 25 25

Charge-air coolant temperature °C 45 45

Barometric pressure mbar 1000 1000

Site altitude above sea level m 100 100

Power-related data (power ratings are net brake power as per ISO 3046)

Number of cylinders 12

16

Rated engine speed A rpm 2100 2100

Fuel stop power ISO 3046 A kW 783 970

General conditions (for maximum power)

Number of cylinders 12

16

Intake depression (new filter) A mbar 15 15

Intake depression, max. L mbar 50 35

Exhaust overpressure A mbar 30 30

Exhaust gas overpressure, max. L mbar 100 75

Model-related data (basic design)

Number of cylinders 12

16

Engine with exhaust turbocharging (ETC) and charge-air cooling
(CAC)

X X

Uncooled exhaust lines X X

Cylinder arrangement: V-angle Degrees

(°)

90 90

Bore mm 135 135

Stroke mm 156 156

Displacement, cylinder Liters 2.233 2.233

Displacement, total Liters 26.80 35.73

Compression ratio 16.5 16.5

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Number of cylinders 12

16

Number of inlet valves per cylinder 2 2

Number of exhaust valves per cylinder 2 2

Standard housing connecting flange (engine main PTO) SAE 0 0

Coolant system (HT circuit)

Number of cylinders 12

16

Coolant temperature (at engine connection: outlet to cooling
equipment)

A °C 100 100

Coolant temperature after engine, alarm R °C 106 105

Coolant temperature after engine, shutdown L °C 108 107

Coolant antifreeze content, max. L % 50 50

Pressure loss in off-engine cooling system, max. L bar 1.0 1.0

Coolant system (LT circuit)

Number of cylinders 12

16

Coolant temperature before intercooler (at engine connection:inlet
from cooling equipment)

A °C 45 45

Coolant antifreeze content, max. L % 50 50

Pressure loss in off-engine cooling system, max. L bar 1.0 1.0

Lube-oil system

Number of cylinders 12

16

Lube-oil operating temperature before engine, from R °C 80 80

Lube-oil operating temperature before engine, to R °C 103 104

Lube-oil temperature before engine, alarm L °C 103 105

Lube-oil temperature before engine, shutdown L °C 105 107

Lube-oil operating pressure before engine, from R bar 7.6 7.8

Lube-oil operating pressure before engine, to R bar 9.0 9.6

Fuel system

Number of cylinders 12

16

Fuel pressure at engine inlet connection, min. (when engine is
starting)

L bar -0.5 -0.5

Fuel pressure at engine inlet connection, max. (when engine is
starting)

L bar 0.5 0.5

General operating data

Number of cylinders 12

16

Cold start capability: air temperature (w/o start aid, w/o preheat­ing) - (case A)

R °C 0 0

Firing speed, from R rpm 100 100

Firing speed, to R rpm 120 120

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Inclinations, standard oil system (reference: waterline)

Number of cylinders 12

16

Longitudinal inclination, continuous max. driving end down (op­tion: max. operating inclinations)

L Degrees

(°)

15 10

Longitudinal inclination, continuous max. driving end up (option:
max. operating inclinations)

L Degrees

(°)

15 10

Transverse inclination continuous max. (option: max. operating in­clinations)

L Degrees

(°)

15 10

Capacities

Number of cylinders 12

16

Engine coolant capacity, engine side (without cooling equipment) R Liters 63 83

Charge-air coolant, engine side R Liters 25 37

Total engine oil capacity, initial filling (standard oil system) (option:
max. operating inclinations)

R Liters 99 154

Oil change quantity max. (standard oil system) (option: max. oper­ating inclinations)

R Liters 87 130

Oil pan capacity dipstick mark min. (standard oil system) (option:
max. operating inclinations)

L Liters 73 109

Oil pan capacity dipstick mark max. (standard oil system) (option:
max. operating inclinations)

L Liters 81 120

Weights / Main dimensions

Number of cylinders 12

16

Engine weight, dry (basic engine configuration acc. to scope of
supply specification)

R kg 2950 3350

Acoustics

Number of cylinders 12

16

Exhaust noise, unsilenced - BL (free-field sound pressure level Lp,
1m distance, ISO 6798, +3dB(A) tolerance)

R dB(A) 103 109

Exhaust noise, unsilenced - BL (sound power level LW, ISO
6798+3 db(A) tolerance)

R dB(A) 116 122

Engine surface noise with attenuated intake noise (filter) - BL
(free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A)
tolerance)

R dB(A) 103 104

Engine surface noise with attenuated intake noise (filter) - BL
(sound power level LW, ISO 6798+2dB(A) tolerance)

R dB(A) 121 122

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2.5.4 12/16V 2000 S96 engine data

Explanation:

DL Ref. value: Continuous power

BL Ref. value: Fuel stop power

A Design value
G Guaranteed value
R Guideline value

L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value

- Not applicable

X Applicable

Engine model 12V

2000S96

16V

2000S96

Application group 4D 4D

Intake air temperature °C 25 25

Charge-air coolant temperature °C 45 45

Barometric pressure mbar 1000 1000

Site altitude above sea level m 100 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)

Number of cylinders 12

16

Rated engine speed A rpm 2100 2100

Fuel stop power ISO 3046 A kW 858 1163

GENERAL CONDITIONS (for maximum power)

Number of cylinders 12

16

Intake depression (new filter) A mbar 15 15

Intake depression, max. L mbar 50 50

Exhaust overpressure A mbar 30 30

Exhaust overpressure, max. L mbar 100 100

MODEL RELATED DATA (basic design)

Number of cylinders 12

16

Engine with exhaust turbocharging (ETC) and charge-air cooling
(CAC)

X X

Uncooled exhaust lines X X

Number of cylinders 12 16

Cylinder arrangement: V angle Degrees

(°)

90 90

Bore mm 135 135

Stroke mm 156 156

Cylinder displacement Liters 2.233 2.233

Total displacement Liters 26.80 35.73

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Number of cylinders 12

16

Compression ratio 16.5 16.5

Inlet valves per cylinder 2 2

Exhaust valves per cylinder 2 2

Standard housing connecting flange (engine main PTO) SAE 0 0

COOLANT SYSTEM (HT circuit)

Number of cylinders 12

16

Coolant temperature (at engine connection: outlet to cooling
equipment)

A °C 100 100

Coolant temperature after engine, warning R °C 101

Coolant temperature after engine, shutdown L °C 104

Coolant antifreeze content, max. L % 50 50

Pressure loss in off-engine cooling system, max. L bar 1.0 1.0

COOLING SYSTEM (LT circuit)

Number of cylinders 12

16

Coolant temperature before intercooler (at engine connection: in­let from cooling system)

A °C 45 45

Coolant antifreeze content, max. L % 50 50

Pressure loss in off-engine cooling system, max. L bar 1.0 1.0

LUBE OIL SYSTEM

Number of cylinders 12

16

Lube oil operating temperature before engine, from R °C 95

Lube oil operating temperature before engine, to R °C

Lube oil temperature before engine, alarm R °C 103

Lube oil temperature before engine, shutdown L °C 106

Lube oil operating pressure before engine, from R bar

Lube oil operating pressure before engine, to R bar 8.6

FUEL SYSTEM

Number of cylinders 12

16

Fuel pressure at engine inlet connection, min. (when engine is
starting)

L bar -0.5 -0.5

Fuel pressure at engine inlet connection, max. (when engine is
starting)

L bar 0.5 0.5

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GENERAL OPERATING DATA

Number of cylinders 12

16

Cold start capability: air temperature (w/o start aid, w/o preheat­ing) - (case A)

R °C 0 0

Firing speed, from R rpm 100 100

Firing speed, to R rpm 120 120

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders 12

16

Longitudinal inclination, continuous max. driving end down (Op­tion: max. operating inclinations)

L Degrees

(°)

10 10

Longitudinal inclination, continuous max. driving end up (Option:
max. operating inclinations)

L Degrees

(°)

10 10

Transverse inclination, continuous max. (option: max. operating in­clinations)

L Degrees

(°)

10 10

CAPACITIES

Number of cylinders 12

16

Engine coolant capacity, engine side (without cooling equipment) R Liters

Charge-air coolant, engine side R Liters

Total engine oil capacity at initial filling (standard oil system) (Op­tion: max. operating inclinations)

R Liters 111

Oil change quantity, max. (standard oil system) (Option: max. op­erating inclinations)

R Liters 94 125

Oil pan capacity at dipstick mark “min.” (standard oil system) (Op­tion: max. operating inclinations)

L Liters (86)

Oil pan capacity at dipstick mark “max.” (standard oil system) (Op­tion: max. operating inclinations)

L Liters (94)

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 12

16

Engine weight, dry (basic engine configuration acc. to scope of de­livery specification)

R kg 3005 3350

ACOUSTICS

Number of cylinders 12

16

Exhaust noise, unsilenced - BL (free-field sound pressure level Lp,
1m distance, ISO 6798, +3dB(A) tolerance)

R dB(A) 107 108

Exhaust noise, unsilenced - BL (sound power level LW, ISO
6798+3 db(A) tolerance)

R dB(A) 120 121

Engine surface noise with attenuated intake noise (filter) - BL
(free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A)
tolerance)

R dB(A) 103 104

Engine surface noise with attenuated intake noise (filter) - BL
(sound power level LW, ISO 6798+2dB(A) tolerance)

R dB(A) 121 122

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3 Operation

3.1 Putting the engine into operation after extended out-of-service
periods (>3 months)

Preconditions

☑ Engine is stopped and starting disabled.

☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Putting into operation after long out-of-service periods (>3 months)

Item Action

Engine Depreserve (→ Preservation and Represervation Specifications (A001070/

…)).

Lube oil system Check engine oil level (→ Page 102).

Fuel system Connect appropriate equipment to fuel supply line to fill the system.

Fuel system Vent (→ Page 89).

Coolant circuit If engine is out of service for more than one year, change engine coolant

(→ Page 113). Change charge-air coolant (→ Page 122).

Coolant circuit Check engine coolant level (→ Page 112); Check charge-air coolant level

(→ Page 121).

Coolant circuit Preheat engine coolant with coolant preheating unit (if fitted).

Engine governor Check plug-in connections (→ Page 137).

Engine control sstem Switch on.

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3.2 Putting the engine into operation after scheduled out-of­service-period

Preconditions

☑ Engine is stopped and starting disabled.

Putting into operation

Item Action

Lube oil system Check engine oil level (→ Page 102).

Coolant circuit Check engine coolant level (→ Page 112), check charge-air coolant level

(→ Page 121).

Coolant circuit Preheat engine coolant with coolant preheating unit, if fitted.

Fuel prefilter (if fitted) Drain water and contaminants, see manufacturer's documentation.

Engine control system Switch on.

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3.3 Starting the engine

Preconditions

☑ Engine with no load.

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.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Starting the engine

Item Measure

Engine Start the engine (→ documentation of the vehicle manufacturer/plant manu-

facturer).

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3.4 Operational checks

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Operational checks

Item

Action

Control and display panels Check readings of operational data (speed, temperature, pressures).

Engine oil Check engine oil level (→ Page 102).

Engine operation Check engine visually for leaks and general condition;

Check engine for abnormal running noises, exhaust color and vibrations.

Air filter Check service indicator at air filter (if fitted), see manufacturer's docu-

mentation.

Exhaust system Check exhaust color (→ Page 43).

Fuel prefilter (if fitted) Check reading at differential pressure gauge of fuel prefilter, see manufac-

turer's documentation.

Intercooler Check condensate drain(s) for water discharge and obstruction.

Engine coolant pump Check relief bore (→ Page 117).

Charge-air coolant pump Check relief bore (→ Page 126).

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3.5 Engine shutdown

Preconditions

☑ Engine is not connected to load.

CAUTION

Shutting down from full-load operation may cause hot water to escape from the expansion tank.

Risk of scalding!

• Allow engine to cool down.

• Wear protective clothing, protective gloves, and safety goggles / safety mask.

NOTICE

Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress­es.

Overheating of and, therefore, damage to components is possible!

• Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant
levels are indicated.

Preparation

Item Action

Engine Allow the engine to cool down by running it at idle speed for approx. 5 mi-

nutes.

Stopping the engine

Item Action

Engine Stopping (→ Documentation of the vehicle/plant manufacturer).

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3.6 Emergency engine stop

CAUTION

Shutting down from full-load operation may cause hot water to escape from the expansion tank.

Risk of scalding!

• Allow engine to cool down.

• Wear protective clothing, protective gloves, and safety goggles / safety mask.

NOTICE

An emergency stop causes extreme stress to the engine plant.

Risk of overheating, damage to components!

• Initiate emergency stop only in emergency situations.

Emergency engine stop

Item Action

Emergency stop pushbutton Press EMERGENCY STOP pushbutton.

• Engine is stopped by disconnecting the power supply to the ECU;

• Emergency air-shutoff flaps close (if applicable);

• Signalization (e.g. by horn, beacon) is activated.

After emergency engine stop

Item Action

Switchgear cabinet, opera­tor station etc. (depending
on manufacturer)

Press pushbutton for alarm acknowledgment.

• Audible and visual signalization stops.

Engine Manually open emergency air-shutoff flaps (if applicable).

• Switch on ECU power supply

• Engine is ready for starting.

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3.7 After stopping the engine – Putting the engine out of
operation

Preconditions

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

NOTICE

Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at
temperatures below 0 °C.

Risk of sensor damage!

• Remove pressure sensors and shake off residual water.

After stopping the engine

Item Measure

Coolant circuit Drain engine coolant (→ Page 114) and

Drain charge-air coolant (→ Page 125) if

• freezing temperatures are expected, the engine is to remain out of service
for an extended period, but engine coolant has no antifreeze additive.

• the engine room is not heated.

• the coolant is not kept at a suitable temperature.

• the antifreeze concentration is insufficient for the engine-room tempera­ture.

• the antifreeze concentration is 50% and the engine room temperature is
below -40 °C.

Engine control system Switch off (see manufacturer's documentation).

Air intake and exhaust sys­tem

If the equipment is to remain out of service for more than one week, seal the
engine's air and exhaust sides. Otherwise, components carrying air or ex­haust gas are at risk of corrosion.
If the equipment is to remain out of service for more than one month, pre­serve the engine (→ MTU Preservation and Represervation Specifications
A001070/..).

40 | Operation | MS150094/02E 2015-05

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3.8 Plant – Cleaning

Preconditions

☑ Engine is stopped and starting disabled.

☑ No operating voltage is applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

High-pressure cleaning unit

- 1

Cleaner (Hakupur 50/136)

X00056700 1

WARNING

Compressed air gun ejects a jet of pressurized air.

Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!

• Never direct air jet at people.

• Always wear safety goggles/face mask and ear defenders.

WARNING

Water jet from high-pressure cleaning unit.

Risk of eye injury, risk of scalding!

• Do not direct water jet at persons.

• Wear protective clothing, protective gloves, and goggles/safety mask.

NOTICE

Cleaning agents should not be left to take effect for too long.

Damage to components is possible!

• Observe manufacturer's instructions.

NOTICE

Blowing down product with compressed air.

Entry of dirt and damage to components is possible!

• Do not aim compressed air gun directly at seals or electronic components such as connectors or
ECUs.

Plant – Cleaning

1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec­tion).

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 flat-mouth nozzle only.

Note: Never direct compressed air directly at electronic components.

5. Carry out external cleaning as follows:

a) Seal all openings in a suitable way.

b) Remove coarse dirt.

c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.

d) Use the high-pressure jet to remove the loosened dirt.

e) Dry engine with compressed air.

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4 Maintenance

4.1 Maintenance task reference table [QL1]

The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte­nance Schedule is a stand-alone publication.

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

Task Maintenance tasks

W0500 Check engine oil level. (→ Page 102)

W0501 Visually inspect engine for leaks and general condition. (→ Page 37)

W0502 Check intercooler drain(s). (→ Page 37)

W0503 Check service indicator of air filter. (→ Page 37)

W0505 Check relief bores of coolant pump(s). (→ Page 37)

W0506 Check engine for abnormal running noises, exhaust color and

vibrations.

(→ Page 37)

W0507 Drain water and contaminants from fuel prefilter. (→ Page 37)

W0508 Check reading on differential pressure gauge of fuel prefilter. (→ Page 37)

W1001 Replace fuel filter or fuel filter element (→ Page 91)

W1003 Check belt condition and tension, replace if necessary (→ Page 127)

W1005 Replace air filter. (→ Page 98)

W1006 Replace fuel injectors. (→ Page 81)

W1008 Replace engine oil filter when changing engine oil, or when the

interval (years) is reached, at the latest.

(→ Page 104)

W1009 Check layer thickness of the oil residue, clean out and replace

filter sleeve, at each oil change, at the latest.

(→ Page 105)

W1178 Replace pressure pipe neck in cylinder head. (→ Page 87)

W1207 Check valve clearance, adjust if necessary. ATTENTION! First

adjustment after 1,000 operating hours on a new engine and
after 1,000 operating hours following each overhaul of the cyl­inder heads.

(→ Page 77)

W1244 Check function of rod electrode. -

W1245 Check alarm function of differential pressure gauge. -

W1246 Check pump capacity. -

W1523 Check operation of flaps and actuators. (→ Page 101)

W1525 Replace sensor. (→ Page 142)

W1526 Replace sensor. (→ Page 140)

W1547 Replace oil mist separator. (→ Page 76)

W1636 Reset drift compensation (CDC) parameters and enter injector

codes (IIG).

(→ Page 146)

Table 1: Maintenance task reference table [QL1]

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5 Troubleshooting

5.1 Troubleshooting

Engine does not turn when starter is actuated

Component Cause Action

Battery Low or faulty Charge or replace (see manufacturer's

documentation).

Cable connections faulty Check if cable connections are properly

secured (see manufacturer's documen­tation).

Starter Engine cabling or starter faulty Check cable connections for secure

seating ; contact Service.

Engine wiring Faulty Check (→ Page 138).

Engine governor Plug-in connections possibly loose Check plug-in connections (→ Page 137).

Engine Running gear blocked (engine cannot be

barred manually)

Contact Service.

Engine turns but does not fire

Component Cause Action

Starter Poor rotation by starter: Battery low or

faulty

Charge or replace battery (see manufac­turer's documentation).

Engine wiring Faulty Check (→ Page 137).

Fuel system Air in fuel system, if fault occurs after

filling the system.

Vent fuel system (→ Page 89).

Engine governor Faulty Contact Service.

Engine fires unevenly

Component Cause Action

Fuel injection equip­ment

Injector faulty Replace (→ Page 81).

Engine wiring Faulty Check (→ Page 138).

Fuel system Air in fuel system, if fault occurs after

filling the system.

Vent fuel system (→ Page 89).

Engine governor Faulty Contact Service.

Engine does not reach rated speed

Component Cause Action

Fuel supply Fuel prefilter (if fitted) clogged. Clean filter element (see manufacturer's

documentation).

Fuel filter clogged Replace (→ Page 91).

Air supply Air filter clogged Replace air filter (→ Page 98).

Fuel injection equip­ment

Injector faulty Replace (→ Page 81).

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Component Cause Action

Engine wiring Faulty Check (→ Page 138).

Engine Overloaded Contact Service.

Engine speed not steady

Component Cause Action

Fuel injection equip­ment

Injector faulty Replace (→ Page 81).

Speed sensor Faulty Contact Service.

Fuel system Air in fuel system, if fault occurs after

filling the system.

Vent fuel system (→ Page 89).

Engine governor Faulty Contact Service.

Charge-air temperature too high

Component Cause Action

Engine coolant Engine coolant treatment incorrect Check (MTU test kit).

Intercooler Contaminated Contact Service.

Engine room Air-intake temperature too high Check fan;

check air inlet/outlet ducts.

Charge-air pressure too low

Component Cause Action

Air supply Air filter clogged Replace air filter (see manufacturer's

documentation).

Intercooler Contaminated Contact Service.

Exhaust turbocharger Faulty Contact Service.

Coolant leaks at intercooler

Component Cause Action

Intercooler Leaking, major coolant discharge Contact Service.

Black exhaust gas

Component Cause Action

Air supply Air filter clogged Replace air filter (see manufacturer's

documentation).

Fuel injection equip­ment

Injector faulty Replace (→ Page 81).

Engine Overloaded Contact Service.

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Blue exhaust gas

Component Cause Action

Engine oil Too much oil in engine Drain engine oil (→ Page 103).

Oil mist fine separator of crankcase
breather clogged

Replace (→ Page 76).

Exhaust turbocharger
Cylinder head
Piston rings
Cylinder liner

Faulty Contact Service.

White exhaust gas

Component Cause Action

Engine Not at operating temperature Run engine to reach operating tempera-

ture.

Fuel system Water in fuel Check fuel system at fuel prefilter

Drain fuel prefilter (→ Page 93).

Intercooler Leaking Contact Service.

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5.2 Engine Control Unit – ECU9 fault messages

5 – HI T-Charge Air

Yellow alarm; warning

Cause Corrective action

Charge-air temperature too high
(Level 1).

1. Check coolant cooler and intercooler.

2. Contact Service if no malfunction can be detected.

6 – SS T-Charge Air

Yellow alarm; emergency stop

Cause Corrective action

Charge-air temperature too high
(Level 2).

1. Check coolant cooler and intercooler.

2. Contact Service if no malfunction can be detected.

9 – HI T-Coolant Intercooler

Yellow alarm; warning

Cause Corrective action

Coolant temperature in
intercooler too high (Level 1).

1. Check coolant cooler for leaks, contamination and operation.

2. Contact Service if no malfunction can be detected.

10 – SS T-Coolant Intercooler

Red alarm; emergency stop

Cause Corrective action

Coolant temperature in
intercooler too high (Level 2).

1. Check coolant cooler for leaks, contamination and operation.

2. Contact Service if no malfunction can be detected.

15 – LO P-Lube Oil

Yellow alarm; warning

Cause Corrective action

Lube oil pressure too low (Level

1).

1. Check oil level, top up as necessary (→ Page 102).

2. Contact Service if no malfunction can be detected.

16 – SS P-Lube Oil

Red alarm; emergency stop

Cause Corrective action

Lube oil pressure too low (Level

2).

1. Check oil level, top up as necessary (→ Page 102).

2. Contact Service if no malfunction can be detected.

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23 – LO Coolant Level

Red alarm; emergency stop

Cause Corrective action

Coolant level too low. 1. Check coolant circuit for leaks. Check coolant level in expansion

tank, top up as necessary.

2. Contact Service if no malfunction can be detected.

25 – HI P-Diff. Lube Oil

Yellow alarm; warning

Cause Corrective action

Differential oil pressure at oil filter
too high (Level 1).

u Check oil filter, replace as necessary.

26 – SS P-Diff. Lube Oil

Yellow alarm; warning

Cause Corrective action

Differential oil pressure at oil filter
too high (Level 2).

u Check oil filter, replace as necessary.

27 – HI Leak Fuel Level

Yellow alarm; warning

Cause Corrective action

Leak-fuel level too high. u Contact Service.

30 – SS Engine Overspeed

Red alarm; emergency stop

Cause Corrective action

Engine speed too high. u Restart engine.

33 – HI P-Diff-Fuel

Yellow alarm; warning

Cause Corrective action

Differential pressure at fuel filter
too high (Level 1).

u Check fuel filter, replace as necessary.

34 – SS P-Diff-Fuel

Yellow alarm; warning

Cause Corrective action

Differential pressure at fuel filter
too high (Level 2).

u Check fuel filter, replace as necessary.

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44 – LO Coolant Level Intercooler

Red alarm; emergency stop

Cause Corrective action

Intercooler coolant level too low. 1. Check coolant circuit for leaks.

2. Check coolant level in expansion tank, top up as necessary.

3. Contact Service if no malfunction can be detected.

51 – HI T-Lube Oil

Yellow alarm; warning

Cause Corrective action

Lube oil temperature too high
(Level 1).

1. Check cooling system.

2. Contact Service if no malfunction can be detected.

52 – SS T-Lube Oil

Red alarm; emergency stop

Cause Corrective action

Lube oil temperature too high
(Level 2).

1. Check cooling system.

2. Contact Service if no malfunction can be detected.

53 – HI T-Intake Air

Yellow alarm; warning

Cause Corrective action

Intake air temperature too high
(Level 1).

u -

54 – HIHI T-Intake Air

Yellow alarm; warning

Cause Corrective action

Intake air temperature too high
(Level 2).

u -

59 – SS T-Coolant L3

Red alarm; emergency stop

Cause Corrective action

Coolant temperature too high
(Level 3).

1. Check cooling system.

2. Contact Service.

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65 – LO P-Fuel

Yellow alarm; warning

Cause Corrective action

Fuel inlet pressure too low (Level

1).

1. Check fuel lines for leakage.

2. Drain fuel prefilter (→ Page 93).

3. Replace filter element of fuel prefilter (→ Page 96).

4. Replace fuel filter and, if required, intermediate fuel filter
(→ Page 91).

66 – SS P-Fuel

Red alarm; emergency stop

Cause Corrective action

Fuel inlet pressure too low (Level

2).

1. Check fuel lines for leakage.

2. Drain fuel prefilter (→ Page 93).

3. Replace filter element of fuel prefilter (→ Page 96).

4. Replace fuel filter and, if required, intermediate fuel filter
(→ Page 91).

67 – HI T-Coolant

Yellow alarm; warning

Cause Corrective action

Coolant temperature too high
(Level 1).

1. Check cooling system.

2. Contact Service if no malfunction can be detected.

68 – SS T-Coolant

Red alarm; emergency stop (3 min. delay)

Cause Corrective action

Coolant temperature too high
(Level 2).

1. Check cooling system.

2. Contact Service if no malfunction can be detected.

81 – AL Rail Leakage

Yellow alarm; warning

Cause Corrective action

Rail pressure gradient too low for
start or too high for stop => HP
fuel system leaky, air in system

1. On engine stopping: Seal off system, contact Service

2. On engine starting: Check engine for leakage, if none found,
attempt restarting as per operating instructions (air in system).

82 – HI P-Fuel (Common Rail)

Yellow alarm; warning

Cause Corrective action

Rail pressure > Set value => HP
fuel control block jamming or
wiring faulty

1. Check wiring of HP fuel control block.

2. Contact Service if no fault can be detected.

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83 – LO P-Fuel (Common Rail)

Yellow alarm; warning

Cause Corrective action

Rail pressure < set value; HP fuel
control block faulty or leakage in
HP fuel system.

1. Check wiring of HP fuel control block.

2. Check high-pressure system for leaks.

3. Contact Service if no fault can be detected.

89 – SS Engine Speed too Low

Yellow alarm; warning

Cause Corrective action

Engine speed too low. 1. Restart engine (→ Page 36).

2. Observe additional messages.

90 – SS Idle Speed Not Reached

Yellow alarm; warning

Cause Corrective action

Idling speed not reached, start
aborted

1. Restart engine (→ Page 36).

2. Observe additional messages.

91 – SS Release Speed Not Reached

Yellow alarm; warning

Cause Corrective action

Run-up speed not reached, start
aborted

1. Restart engine (→ Page 36).

2. Observe additional messages.

92 – SS Starter Speed Mot Reached

Yellow alarm; warning

Cause Corrective action

Starter speed not reached;
termination of starting sequence;
starter does not turn or turns
slowly.

1. Check battery.

2. Check wiring and voltage supply.

3. Check fuel supply.

4. Restart engine (→ Page 36).

5. Observe additional messages.

93 – SS T-Preheat

Red alarm; engine start interlock

Cause Corrective action

Preheating temperature too low
(Level 2); coolant temperature too
low for engine start.

1. Extend preheating period.

2. Check preheater.

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94 – LO T-Preheat

Yellow alarm; warning

Cause Corrective action

Preheating temperature too low
(Level 1); coolant temperature too
low for engine start.

1. Extend preheating period.

2. Check preheater.

95 – AL Prelubrication Fault

Yellow alarm; warning

Cause Corrective action

Oil priming fault u Contact Service.

102 – AL Fuel Cons. Meter Defect

Yellow alarm; warning

Cause Corrective action

Consumption meter faulty. u Replace Engine Control Unit at next opportunity.

104 – AL Eng Hours Counter Defect

Yellow alarm; warning

Cause Corrective action

Hour meter faulty. u Replace Engine Control Unit at next opportunity.

118 – LO ECU Supply Voltage

Yellow alarm; warning

Cause Corrective action

Supply voltage too low (Level 1). u Check batteries, charge as necessary; check alternator.

119 – LOLO ECU Power Supply Voltage

Yellow alarm; warning

Cause Corrective action

Supply voltage too low (Level 2). u Check batteries, charge as necessary; check alternator.

120 – HI ECU Supply Voltage

Yellow alarm; warning

Cause Corrective action

Supply voltage too high (Level 1). u Check batteries, charge as necessary; check alternator.

121 – HIHI ECU Power Supply Voltage

Yellow alarm; warning

Cause Corrective action

Supply voltage too high (Level 2). u Check batteries, charge as necessary; check alternator.

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122 – HI T-ECU

Yellow alarm; warning

Cause Corrective action

Temperature of the electronics
too high.

u Check engine room ventilation.

141 – AL Power too high

Yellow alarm; warning

Cause Corrective action

The average power rate over the
last 24 hours of engine operation
has exceeded the set maximum
value.

u -

180 – AL CAN1 Node Lost

Yellow alarm; warning

Cause Corrective action

Connection to a node on CAN bus
1 failed.

1. Check devices connected to CAN.

2. Check wiring (termination resistor installed?).

181 – AL CAN2 Node Lost

Yellow alarm; warning

Cause Corrective action

Connection to a node on CAN bus
2 failed.

1. Check devices connected to CAN.

2. Check wiring (termination resistor installed?).

182 – AL CAN Wrong Parameters

Yellow alarm; warning

Cause Corrective action

Incorrect parameter values
entered in data record.

u Contact Service.

183 – AL CAN No PU Data

Yellow alarm; warning

Cause Corrective action

The selected CAN mode initializes
communication by means of the
PU data module. However, the
required PU data module is not
available or not valid.

1. Check devices connected to CAN.

2. Contact Service.

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184 – AL CAN PU Data Flash Error

Yellow alarm; warning

Cause Corrective action

A programming error occurred
when attempting to copy a
received PU data module into the
Flash module.

u Contact Service.

186 – AL CAN1 Bus Off

Yellow alarm; warning

Cause Corrective action

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 Passive

Yellow alarm; warning

Cause Corrective action

CAN controller 1 has signaled a
warning.

1. Check CAN bus for short circuit, rectify short circuit as necessary.

2. Check shielding, improve shielding as necessary.

3. Contact Service.

188 – AL CAN2 Bus Off

Yellow alarm; warning

Cause Corrective action

CAN controller 2 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.

189 – AL CAN2 Error Passive

Yellow alarm; warning

Cause Corrective action

CAN controller 2 has signaled a
warning.

1. Check CAN bus for short circuit, rectify short circuit as necessary.

2. Check shielding, improve shielding as necessary.

3. Contact Service.

201 – SD T-Coolant

Yellow alarm; warning

Cause Corrective action

Coolant temperature sensor
faulty.

u Check sensor B6 and wiring, replace as necessary (→ Page 138).

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203 – SD T-Charge Air

Yellow alarm; warning

Cause Corrective action

Charge air temperature sensor
faulty.

u Check sensor B9 and wiring, replace as necessary (→ Page 138).

205 – SD T-Coolant Intercooler

Yellow alarm; warning

Cause Corrective action

Coolant pressure sensor of
intercooler faulty.

u Check sensor B26 and wiring, replace as necessary (→ Page 138).

208 – SD P-Charge Air

Yellow alarm; warning

Cause Corrective action

Charge air pressure sensor faulty. u Check sensor B10 and wiring, replace as necessary (→ Page 138).

211 – SD P-Lube Oil

Yellow alarm; warning

Cause Corrective action

Lube-oil pressure sensor faulty. u Check sensor B5.1 and wiring, replace as necessary (→ Page 138).

215 – SD P-HD

Yellow alarm; warning

Cause Corrective action

Rail pressure sensor faulty; High
pressure regulator emergency
operation mode.

u Check sensor B48.1 and wiring, replace as necessary

(→ Page 138).

216 – SD T-Lube Oil

Yellow alarm; warning

Cause Corrective action

Lube-oil temperature sensor
faulty.

u Check sensor B7 and wiring, replace as necessary (→ Page 138).

219 – SD T-Intake Air

Yellow alarm; warning

Cause Corrective action

Intake air temperature sensor
faulty.

u Check sensor B3 and wiring, replace as necessary (→ Page 138).

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220 – SD Level Coolant Water

Yellow alarm; warning

Cause Corrective action

Coolant level sensor faulty. 1. Check sensor F33 and wiring, replace as necessary (→ Page 138).

2. Fault is rectified when electronics are switched back on.

221 – SD P-Diff Lube Oil

Yellow alarm; warning

Cause Corrective action

Lube oil differential pressure
sensor faulty.

u Check sensor B5.1 and B5.3 and wiring, replace as necessary

(→ Page 138).

222 – SD Leak Fuel Level

Yellow alarm; warning

Cause Corrective action

Leak-off fuel level sensor faulty. u Check sensor F46 and wiring, replace as necessary (→ Page 138).

223 – SD Level Coolant Intercooler

Yellow alarm; warning

Cause Corrective action

Coolant level sensor for
intercooler defective.

1. Check sensor F57 and wiring, replace as necessary (→ Page 138).

2. Fault is rectified when electronics are switched back on.

227 – SD P-Oil before Filter

Yellow alarm; warning

Cause Corrective action

Sensor for lube-oil pressure
before filter faulty.

u Check sensor B5.3 and wiring, replace as necessary (→ Page 138).

228 – SD P-Fuel before Filter

Yellow alarm; warning

Cause Corrective action

Fuel pressure sensor (before main
filter) faulty.

u Check sensor B34.2 and wiring, replace as necessary

(→ Page 138).

229 – AL Stop Camshaft Sensor Defect

Red alarm; emergency stop

Cause Corrective action

Engine stop due to camshaft
sensor fault and a previous
crankshaft sensor fault in the
same operating cycle.

1. Check sensor and wiring to connectors B1 and B13, replace as
necessary (→ Page 138).

2. Acknowledge alarm.

3. Restart engine (→ Page 36).

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230 – SD Crankshaft Speed

Yellow alarm; warning

Cause Corrective action

Crankshaft sensor faulty. 1. Check sensor B13 and wiring, replace as necessary (→ Page 138).

2. Fault is rectified when engine is restarted, contact Service if this is
not the case.

231 – SD Camshaft Speed

Yellow alarm; warning

Cause Corrective action

Camshaft sensor faulty. 1. Check sensor B1 and wiring, replace as necessary (→ Page 138).

2. Fault is rectified when engine is restarted, contact Service if this is
not the case.

239 – SD P-Diff Fuel

Yellow alarm; warning

Cause Corrective action

Fuel pressure sensors faulty. u Check sensor B34.2, sensor 34.3 and wiring, replace as necessary

(→ Page 138).

240 – SD P-Fuel

Yellow alarm; warning

Cause Corrective action

Fuel pressure sensor before
intermediate filter faulty.

u Check sensor B34.3 and wiring, replace as necessary

(→ Page 138).

245 – SD ECU Supply Voltage

Yellow alarm; warning

Cause Corrective action

Internal ECU fault. u Replace Engine Control Unit.

266 – SD Speed Setting

Yellow alarm; warning

Cause Corrective action

Analog speed setting faulty. 1. Check speed setting transmitter and wiring, replace as necessary

(→ Page 138).

2. Fault is rectified when engine is restarted.

269 – SD Loadp. Analog fil.

Yellow alarm; warning

Cause Corrective action

The filtered analog signal from the
load pulse is not present.

1. Check wiring, replace as necessary.

2. Fault is rectified when engine is restarted.

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270 – SD Frequency Input

Yellow alarm; warning

Cause Corrective action

Frequency input faulty. 1. Check speed setting transmitter and wiring, replace as necessary

(→ Page 138).

2. Fault is rectified when engine is restarted.

321 – AL Wiring Cylinder A1

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder A1
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

322 – AL Wiring Cylinder A2

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder A2
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

323 – AL Wiring Cylinder A3

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder A3
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

324 – AL Wiring Cylinder A4

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder A4
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

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325 – AL Wiring Cylinder A5

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder A5
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

326 – AL Wiring Cylinder A6

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder A6
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

327 – AL Wiring Cylinder A7

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder A7
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

328 – AL Wiring Cylinder A8

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder A8
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

329 – AL Wiring Cylinder A9

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder A9
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

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331 – AL Wiring Cylinder B1

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder B1
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

332 – AL Wiring Cylinder B2

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder B2
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

333 – AL Wiring Cylinder B3

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder B3
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

334 – AL Wiring Cylinder B4

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder B4
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

335 – AL Wiring Cylinder B5

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder B5
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

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336 – AL Wiring Cylinder B6

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder B6
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

337 – AL Wiring Cylinder B7

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder B7
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

338 – AL Wiring Cylinder B8

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder B8
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

339 – AL Wiring Cylinder B9

Yellow alarm; warning

Cause Corrective action

Short circuit in cylinder B9
injector wiring. Result: Misfiring.

1. Check injector wiring.

2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

341 – AL Open Load Cylinder A1

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder A1
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

342 – AL Open Load Cylinder A2

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder A2
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

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343 – AL Open Load Cylinder A3

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder A3
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

344 – AL Open Load Cylinder A4

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder A4
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

345 – AL Open Load Cylinder A5

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder A5
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

346 – AL Open Load Cylinder A6

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder A6
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

347 – AL Open Load Cylinder A7

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder A7
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

348 – AL Open Load Cylinder A8

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder A8
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

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349 – AL Open Load Cylinder A9

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder A9
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

351 – AL Open Load Cylinder B1

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder B1
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

352 – AL Open Load Cylinder B2

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder B2
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

353 – AL Open Load Cylinder B3

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder B3
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

354 – AL Open Load Cylinder B4

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder B4
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

355 – AL Open Load Cylinder B5

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder B5
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

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356 – AL Open Load Cylinder B6

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder B6
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

357 – AL Open Load Cylinder B7

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder B7
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

358 – AL Open Load Cylinder B8

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder B8
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

359 – AL Open Load Cylinder B9

Yellow alarm; warning

Cause Corrective action

Open circuit in cylinder B9
injector wiring. Result: Misfiring.

1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector replacement).

2. Fault is rectified after each working cycle.

361 – AL Injector Power Stage Low

Yellow alarm; warning

Cause Corrective action

Internal electronic fault,
electronics possibly faulty.

1. Start Engine Control Unit self-test.

2. Replace ECU in case of fault; if self-test diagnoses “Electronics OK”
check for additional fault messages (e.g. wiring fault).

362 – AL Injector Power Stage High

Yellow alarm; warning

Cause Corrective action

Internal electronic fault,
electronics possibly faulty.

1. Start Engine Control Unit self-test.

2. Replace ECU in case of fault; if self-test diagnoses “Electronics OK”
check for additional fault messages (e.g. wiring fault).

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363 – AL Stop Injector Power Stage

Red alarm; Self-restoring

Cause Corrective action

Internal electronic fault,
electronics possibly faulty.

1. Start Engine Control Unit self-test.

2. Replace ECU in case of fault; if self-test diagnoses “Electronics OK”
check for additional fault messages (e.g. wiring fault).

365 – AL Stop SV-Wiring Ground

Red alarm; Self-restoring

Cause Corrective action

Injector wiring fault. u Check wiring, replace wiring harness as necessary.

381 – AL Wiring TOP 1

Yellow alarm; warning

Cause Corrective action

Short circuit or wire break on
transistor output 1 plant-side
(TOP 1).

u Check wiring (→ Page 138).

382 – AL Wiring TOP 2

Yellow alarm; warning

Cause Corrective action

Short circuit or wire break on
transistor output 2 plant-side
(TOP 2).

u Check wiring (→ Page 138).

383 – AL Wiring TOP 3

Yellow alarm; warning

Cause Corrective action

Short circuit or wire break on
transistor output 3 plant-side
(TOP 3).

u Check wiring (→ Page 138).

384 – AL Wiring TOP 4

Yellow alarm; warning

Cause Corrective action

Short circuit or wire break on
transistor output 4 plant-side
(TOP 4).

u Check wiring (→ Page 138).

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390 – AL MCR exceeded

Yellow alarm; warning

Cause Corrective action

DBR/MCR function: MCR
(continuous maximum rate) was
exceeded.

u -

400 – AL Open Load Digital Input 1

Yellow alarm; warning

Cause Corrective action

Line disruption at digital input 1. u Check wiring (→ Page 138).

401 – AL Open Load Digital Input 2

Yellow alarm; warning

Cause Corrective action

Line disruption at digital input 2. u Check wiring (→ Page 138).

402 – AL Open Load Digital Input 3

Yellow alarm; warning

Cause Corrective action

Line disruption at digital input 3. u Check wiring (→ Page 138).

403 – AL Open Load Digital Input 4

Yellow alarm; warning

Cause Corrective action

Line disruption at digital input 4. u Check wiring (→ Page 138).

404 – AL Open Load Digital Input 5

Yellow alarm; warning

Cause Corrective action

Line disruption at digital input 5. u Check wiring (→ Page 138).

405 – AL Open Load Digital Input 6

Yellow alarm; warning

Cause Corrective action

Line disruption at digital input 6. u Check wiring (→ Page 138).

406 – AL Open Load Digital Input 7

Yellow alarm; warning

Cause Corrective action

Line disruption at digital input 7. u Check wiring (→ Page 138).

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407 – AL Open Load Digital Input 8

Yellow alarm; warning

Cause Corrective action

Line disruption at digital input 8. u Check wiring (→ Page 138).

408 – AL Open Load Emerg. Stop Input ESI

Yellow alarm; warning

Cause Corrective action

Open circuit at input for
emergency stop.

u Check wiring (→ Page 138).

410 – LO U-PDU

Yellow alarm; warning

Cause Corrective action

Injector voltage too low (Level 1). u Perform Engine Control Unit self-test, replace as necessary.

411 – LOLO U-PDU

Yellow alarm; warning

Cause Corrective action

Injector voltage too low (Level 2). u Perform Engine Control Unit self-test, replace as necessary.

412 – HI U-PDU

Yellow alarm; warning

Cause Corrective action

Injector voltage too high (Level 1). u Perform Engine Control Unit self-test, replace as necessary.

413 – HIHI U-PDU

Yellow alarm; warning

Cause Corrective action

Injector voltage too high (Level 2). u Perform Engine Control Unit self-test, replace as necessary.

414 – HI Level Water Fuel Prefilter

Yellow alarm; warning

Cause Corrective action

Water level in fuel prefilter too
high.

u Empty fuel prefilter.

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415 – LO P-Coolant Intercooler

Yellow alarm; warning

Cause Corrective action

Coolant pressure in intercooler
too low (Level 1).

1. Check coolant level in expansion tank, top up as necessary.

2. Check coolant circuit for leaks.

3. Check coolant pump.

416 – SS P-Coolant Intercooler

Yellow alarm; warning

Cause Corrective action

Coolant pressure in intercooler
too low (Level 2).

1. Check coolant level in expansion tank, top up as necessary.

2. Check coolant circuit for leaks.

3. Check coolant pump.

417 – SD Level Water Fuel Prefilter

Yellow alarm; warning

Cause Corrective action

Water level sensor of fuel prefilter
faulty, short circuit or wire break.

u Check sensor F70 and wiring, replace as necessary .

438 – LO P-Fuel 2 (Common Rail)

Yellow alarm; warning

Cause Corrective action

Rail pressure below specified
value.
HP fuel control block faulty or
leakage in HP fuel system.

u Contact Service.

439 – HI P-Fuel 2 (Common Rail)

Yellow alarm; warning

Cause Corrective action

Rail pressure above specified
value.
HP fuel control block jamming or
wiring faulty.

1. Check wiring of HP fuel control block.

2. Contact Service if no malfunction can be detected.

441 – AL System 2 Leaky

Yellow alarm; warning

Cause Corrective action

Pressure gradient in rail is too low
during starting or too high during
stopping.

1. On engine stopping: Seal off system, contact Service.

2. On engine starting: Check engine for leakage, if none found,
attempt restarting as per operating instructions (air in system).

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444 – SD U-PDU

Yellow alarm; warning

Cause Corrective action

Sensor of injector output stage
faulty.

u Replace Engine Control Unit.

445 – SD P-Ambient Air

Yellow alarm; warning

Cause Corrective action

Ambient air pressure sensor
faulty.

u Replace Engine Control Unit (sensor is in the ECU).

446 – SD P-HD2

Yellow alarm; warning

Cause Corrective action

Rail pressure sensor faulty, high­pressure regulator emergency
mode;

u Check sensor B48.2 and wiring, replace as necessary

(→ Page 138).

450 – SD Idle/End-Torque Input [%]

Yellow alarm; warning

Cause Corrective action

Input signal for initial/final torque
faulty.

1. Check signal transmitter and wiring, replace as necessary.

2. Restart engine (→ Page 36).

454 – SS Power Reduction Active

Yellow alarm; warning

Cause Corrective action

Power reduction activated. u Observe any other messages.

470 – SD T-ECU

Yellow alarm; warning

Cause Corrective action

Temperature sensor for Engine
Control Unit faulty.

u Replace Engine Control Unit at next opportunity.

471 – SD HP fuel control block

Yellow alarm; warning

Cause Corrective action

Actuation of HP fuel control block
faulty.

1. Check HP fuel control block and wiring, replace as necessary
(→ Page 138).

2. Fault is rectified when engine is restarted.

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472 – AL Stop SD

Red alarm; emergency stop

Cause Corrective action

Shutdown channels sensor fault. u Contact Service.

474 – AL Wiring FO

Yellow alarm; warning

Cause Corrective action

Wire break or short circuit at FO
channel.

u Contact Service.

476 – AL Crash Rec. Init. Error

Yellow alarm; warning

Cause Corrective action

Initialization error of crash
recorder.

u Contact Service.

478 – AL Comb. Alarm Yel (Plant)

Yellow alarm; warning

Cause Corrective action

Combined alarm initiated by plant
(yellow).

u Observe any other fault messages.

479 – AL Comb. Alarm Red (Plant)

Yellow alarm; warning

Cause Corrective action

Combined alarm initiated by plant
(red).

u Observe any other fault messages.

480 – AL Ext. Engine Protection

Yellow alarm; warning

Cause Corrective action

External engine protection
function active.

u Contact Service.

514 – Write Error Flash

Yellow alarm; warning

Cause Corrective action

Value was not accepted into flash. u Contact Service.

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536 – AL Wiring PWM_CM1

Yellow alarm; warning

Cause Corrective action

Wire break or short circuit on
channel PWM_CM1.

u Check wiring to connected device or check connected device

(actuator/sensor), replace as necessary.

549 – AL Power Cut-Off detected

Entered in fault memory only.

Cause Corrective action

The operating voltage of the
Engine Control Unit was switched
of with the engine running. This
may lead to overpressure in the
HP fuel system, which might
cause damage to the engine.

u Instruct the operator only to disconnect the power supply when the

engine has stopped.

551 – SS Engine Overspeed Camshaft

Red alarm, emergency stop

Cause Corrective action

Engine overspeed, camshaft. u Restart engine (→ Page 36).

558 – AL Wiring PWM_CM2

Yellow alarm; warning

Cause Corrective action

Wire break or short circuit on
channel PWM_CM2.

u Check wiring to connected device or check connected device

(actuator/sensor), replace as necessary.

582 – AL Emergency Stop Failure

Entered in fault memory only.

Cause Corrective action

Emergency stop command was
not executed.

u Contact Service.

596 – AL Cons. Parameter Record

Yellow alarm; warning

Cause Corrective action

Standard production data record
available. The data record stored
is for testing.

u Contact Service.

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602 – AL CAN Engine Start Lock

Yellow alarm; warning

Cause Corrective action

Start interlock initiated by plant. 1. Check plant configuration.

2. Restart engine (→ Page 36).

610 – AL Wiring HP Control Block 1

Yellow alarm; warning

Cause Corrective action

Wire break or short circuit at PWM
channel HP fuel control block.

u Check wiring or HP fuel control block, replace as necessary .

611 – AL Wiring HP Control Block 2

Yellow alarm; warning

Cause Corrective action

Fuel prefilter differential pressure
too high.

u Check wiring or HP fuel control block, replace as necessary.

615 – AL EIL Protection

Yellow alarm; emergency stop (15 min. delay)

Cause Corrective action

Alarm for Protection module as
reaction to faulty or manipulated
EIL.

u Replace EIL.

616 – AL EIL Error

Yellow alarm; warning

Cause Corrective action

Alarm with faulty or manipulated
EIL.

u Replace EIL.

762 – AL Smart Connect Lost

Yellow alarm; warning

Cause Corrective action

Smart Connect device has failed
on CAN bus.

u Check wiring or Smart Connect, replace as necessary.

832 – AL EIL Engine Number Differs

Yellow alarm; warning

Cause Corrective action

Alarm when fault numbers differ
between ECU and EIL.

u Contact Service.

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836 – AL Nominal Speed Setting Fail

Yellow alarm; warning

Cause Corrective action

Active analog speed setting faulty. u Check wiring (CAN MD).

851 – AL Extern Start and HD too high

Entered in fault memory only

Cause Corrective action

An external start is pending and
high pressure is too high.

u Contact Service.

852 – AL Max. Blankshot Time Expired

Yellow alarm; warning

Cause Corrective action

High pressure could not be
released in the max. blankshot
time.

u Contact Service.

947 – AL Wrong LSI Channel Config

Yellow alarm; warning

Cause Corrective action

Data fault on allocating LSI
channels.

u Contact Service.

973 – AL Checksum IIG

Yellow alarm; warning

Cause Corrective action

Checksum calculation or word
limit check for one of the injectors
is not correct.

u Contact Service.

1130 – AL Short Circuit Analog Output 1

Yellow alarm; warning

Cause Corrective action

The value output at analog output
1 deviates excessively from the
value read back.

u Check wiring.

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1131 – AL Short Circuit Analog Output 2

Yellow alarm; warning

Cause Corrective action

The value output at analog output
2 deviates excessively from the
value read back.

u Check wiring.

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6 Task Description

6.1 Engine

6.1.1 Engine – Barring manually

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Engine barring gear

F6783914 1

Ratchet with extension

F30006212 1

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Before barring the engine, make sure that there are no persons in the engine's danger zone.

• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Barring engine manually

1. Fit ratchet with barring gear on barring gear connection at the vibration damper on engine free end.

2. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there
should be no resistance.

Result: If the resistance exceeds the normal compression resistance, contact Service.

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6.1.2 Engine – Barring with starting system

DANGER

Unguarded rotating and moving engine components.

Risk of serious injury – danger to life!

• Before barring or starting the engine, ensure that nobody is in the danger zone.

• After working on the engine, check that all protective devices have been reinstalled and all tools re­moved from the engine.

Engine – Barring with starting system

1. Bar engine, preventing it from firing, see documentation of vehicle/plant manufacturer.

2. Do not actuate starter for more than 10 seconds.

3. Repeat this procedure after approx. 20 seconds if required.

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6.2 Crankcase Breather

6.2.1 Crankcase breather – Oil mist fine separator replacement

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Engine oil

Oil mist fine separator

(→ Spare Parts Catalog)

O-ring

(→ Spare Parts Catalog)

WARNING

Hot oil.
Oil can contain combustion residues which are harmful to health.

Risk of injury and poisoning!

• Wear protective clothing, gloves, and goggles / safety mask.

• Avoid contact with skin.

• Do not inhale oil vapor.

Replacing oil mist fine separator

1. Remove screws (1) and take off together with
holder (2).

2. Replace oil mist fine separator (3).

3. Replace O-ring (4) if necessary.

4. Replace further oil mist fine separators in the
same way.

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6.3 Valve Drive

6.3.1 Valve clearance – Check and adjustment

Preconditions

☑ Engine is stopped and starting disabled.

☑ Engine coolant temperature is max. 40 °C.

☑ Valves are closed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Feeler gauge

Y4345893 1

Barring device

F6783914 1

Ratchet with extension

F30006212 1

Double-head box wrench

F30002800 1

Ring socket, 19 mm

F30038493 1

Torque wrench, 20–100 Nm

F30026582 1

Ratchet

F30027340 1

WARNING

Valve gear is moving.

Risk of crushing!

• Keep hands clear of the danger zone when barring the engine.

Preparatory steps

u Remove cylinder head cover (→ Page 80).

Positioning A1 piston at TDC

1. Install barring device.

2. Losen plug screw (1) and remove.

3. Using ratchet and barring device, rotate
crankshaft in engine direction of rotation un­til the bore (2) on the flywheel is visible in the
center of the exposed opening.

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Checking valve clearance at two crankshaft positions

1. Check TDC position of piston in cylinder A1:

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

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

2. Check valve clearance with cold engine:

• Inlet (E) = 0.3 mm;

• Exhaust (A) = 0.4 mm.

3. Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC) according to the table
below.

12 V 2000

Position Cylinder 1 2 3 4 5 6 7 8

Firing TDC in cylinder A1 Bank A E A E - - A E - - A - -

Bank B E - - - - A E - E A - A

Overlap TDC in cylinder A1 Bank A - - - A E - - A E - E A

Bank B - A E A E - - A - - E -

“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

16 V 2000

Position Cylinder 1 2 3 4 5 6 7 8

Firing TDC in cylinder A1 Bank A E A - A E A E - - A E - - - - -

Bank B E - - A - - - - E A E - E A - A

Overlap TDC in cylinder A1 Bank A - - E - - - - A E - - A E A E A

Bank B - A E - E A E A - - - A - - E -

“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

4. Use feeler gauge to determine the distance between valve bridge and rocker arm.

5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

Valve clearance adjustment

1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.

2. Insert feeler gauge between valve bridge and
rocker arm.

3. Readjust adjusting screw (2) so that the feel­er gauge just passes through the gap.

4. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2)
with Allen key to prevent it from turning.

Name Size Type Lubricant Value/Standard

Locknut Tightening torque 50 Nm +5 Nm

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5. Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the
gap.

Result: If not, adjust valve clearance again.

Final steps

1. Install plug screw and tighten.

2. Remove barring device.

3. Install cylinder head cover (→ Page 80).

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6.3.2 Cylinder head cover – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 8–40 Nm

F30043446 1

Ratchet

F30027340 1

Gasket

(→ Spare Parts Catalog)

Preparatory steps

1. On cylinder head covers with crankcase breather: Loosen clamps.

2. Slide rubber sleeves onto the pipe.

Cylinder head cover – Removal
and installation

1. Remove cylinder head cover (2) with gas­ket (1) from cylinder head.

2. Clean installation surface.

3. Check condition of gasket (1) in cylinder
head cover (1).

4. Replace damaged gasket(s) (1).

5. Install cylinder head cover (2) with screws (4)
and washers (3).

Final steps

1. Slide rubber sleeves onto the relevant fitting.

2. Tighten all clamps.

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6.4 Injector

6.4.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Injector

(→ Spare Parts Catalog)

Injector – Replacement

u Remove injector and install new one (→ Page 82).

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6.4.2 Injector – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Installation device

F6790085 1

Puller

F6790636 1

Fuel suction device

F30378207 1

Torque wrench, 1–5 Nm

F30452774 1

Torque wrench, 20–100 Nm

F30026582 1

Ratchet

F30027340 1

Adapter

F30006234 1

Adapter

F30452771 1

Socket wrench, 19 mm

F30453236 1

Crowfoot wrench, 19 mm

F30027424 1

Crowfoot wrench, 22 mm

F30027425 1

Double-head box wrench

F30011450 1

Socket wrench, 24 mm

F30453238 1

Assembly compound (Hakuform 30–15)

X00067260 1

Engine oil

Sealing ring

(→ Spare Parts Catalog)

WARNING

Fuels 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.

WARNING

Compressed air gun ejects a jet of pressurized air.

Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!

• Never direct air jet at people.

• Always wear safety goggles/face mask and ear defenders.

Preparatory steps

1. Shut off fuel supply line.

2. Drain fuel (→ Page 90).

3. Remove cylinder head cover (→ Page 80).

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Removing injector

1. Remove fuel line (1).

2. Unscrew union nut (2).

3. Pull off pressure pipe neck (3).

4. Extract fuel from the exposed bores using the
suction device.

5. Loosen terminals (arrow) on injector and pull
off terminal lugs.

6. Remove gasket.

7. Remove screw (3).

Note: Screw (3) must be used only once.

8. Take off hold-down clamp (2).

9. Carefully remove injector (1) with puller.

10. After removal, seal all openings with suitable
covers.

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Installing injector

1. Remove all covers before installation.

2. Clean sealing surface on cylinder head and
protective sleeve.

3. Apply grease to sealing ring on injector (1).

Note: Always use the installation device or the hold-

down clamp to press injector (1) into cylinder
head.

4. Align square on injector (1) with seat in hold­down clamp (2) and insert injector manually
into cylinder head.

5. Place hold-down clamp (2) in position by
hand, ensuring the position is correct

Assembly without installation device

1. Install new screw (3) and tighten screw (3) to carefully press injector (1) into cylinder head.

Name Size Type Lubricant Value/Standard

Screw M8 Preload torque 2 Nm +2 Nm

2. Loosen screw (3) again and relieve hold-down clamp.

Assembly with installation device

1. Place installation device onto hold-down clamp and carefully press injector (1) into cylinder head.

2. Fit clamp (2) in correct position, install screw (3) and tighten hand-tight.

Installing pressure pipe neck

1. Blow out fuel line (1) and pressure pipe
neck (3) with compressed air.

2. Coat sealing ring with grease.

3. Coat sealing cone of pressure pipe neck (3)
with engine oil.

4. Slide pressure pipe neck (3) into cylinder
head until it rests against the sealing ring.

5. Press in pressure pipe neck (3) completely by
hand.

6. Align HP connection of injector to pressure
pipe neck (3).

7. Apply engine oil to thread and mating face of union nut (2) and use torque wrench to tighten it to the speci­fied tightening torque.

Name Size Type Lubricant Value/Standard

Union nut Preload torque (Engine oil) 15 Nm +5 Nm

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8. Use torque wrench to tighten screw (3) for hold-down clamp (2) to specified tightening torque.

Name Size Type Lubricant Value/Standard

Screw M8 Tightening torque (Engine oil) 40 Nm +4 Nm

9. Using a torque wrench, tighten union nut (2) on pressure pipe neck (3) to specified torque.

Name Size Type Lubricant Value/Standard

Union nut Tightening torque 45 Nm +5 Nm

Installing fuel line

1. Apply engine oil to thread and mating face of union nut of fuel line (1).

Note: Position fuel line, ensuring that it is free of tension.

2. Position fuel line (1) so that the end with the marked union faces the rail and the end with the unmarked
union nut faces the pressure pipe neck (2) and tighten it hand-tight.

3. Tighten union nut of fuel line (1) on rail to specified tightening torque using a torque wrench.

Name Size Type Lubricant Value/Standard

Union nut Tightening torque (Engine oil) 45 Nm +5 Nm

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4. Tighten union nut of fuel line (1) on pressure pipe neck (2) to specified tightening torque using a torque
wrench.

Name Size Type Lubricant Value/Standard

Union nut Tightening torque (Engine oil) 37 Nm +3 Nm

Fitting gasket and connecting
injector

1. Place gasket in correct position onto cylinder
head.

2. Slide terminal lugs under terminals (arrow) on injector and use torque wrench to tighten to the specified
tightening torque.

Name Size Type Lubricant Value/Standard

Nut M4 Tightening torque (Engine oil) 1.5 Nm ±0.25 Nm

Final steps

1. Install cylinder head cover (→ Page 80).

2. Open fuel supply line.

3. Vent fuel system (→ Page 89).

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6.5 Fuel System

6.5.1 HP fuel line and pressure pipe neck – Replacement

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 20–100 Nm

F30026582 1

Ratchet adapter

F30027340 1

Adapter

F30006234 1

Plug-in open-end wrench, 19 mm

F30025897 1

Crowfoot box wrench, 19 mm

F30027424 1

Crowfoot box wrench, 22 mm

F30027425 1

Double-head box wrench

F30011450 1

Assembly compound (Hakuform 30–15)

X00067260 1

Pressure pipe neck

(→ Spare Parts Catalog)

HP fuel line

(→ Spare Parts Catalog)

WARNING

Fuels 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.

Preparatory steps

1. Close fuel inlet line.

2. Drain fuel (→ Page 90).

HP fuel line and pressure pipe
neck – Replacement

1. Remove leak fuel line from cylinder head.

2. Remove HP fuel line (2).

3. Remove thrust screw (4).

4. Withdraw pressure pipe neck (5).

5. Coat sealing ring of new pressure pipe neck
with grease.

6. Coat sealing cone of pressure pipe neck with
engine oil.

7. Insert pressure pipe neck into cylinder head
until it is in contact with the sealing ring.

8. Fully press in pressure pipe neck by hand.

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9. Use torque wrench to tighten thrust screw (4) to specified tightening torque.

Name Size Type Lubricant Value/Standard

Screw Tightening torque 40 Nm ±5 Nm

10. Coat mating face between union nut and HP fuel line, ball seal and thread on both ends of the new HP fuel
line (2) with engine oil.

11. Install new HP fuel line (2).

12. Observe marking on union nut (1).

13. Use torque wrench to tighten union nut (1) with marking (see arrow) to specified tightening torque.

Name Size Type Lubricant Value/Standard

Nut with marking Tightening torque 35 Nm +3 Nm

14. Use torque wrench to tighten union nut (1) without marking to specified tightening torque.

Name Size Type Lubricant Value/Standard

Nut without mark­ing

Tightening torque 30 Nm +5 Nm

15. Observe marking on union nut (3).

16. Use torque wrench to tighten union nut (3) with marking (see arrow) to specified tightening torque.

Name Size Type Lubricant Value/Standard

Nut with marking Tightening torque 35 Nm +3 Nm

17. Use torque wrench to tighten union nut (3) without marking to specified tightening torque.

Name Size Type Lubricant Value/Standard

Nut without mark­ing

Tightening torque 25 Nm +5 Nm

18. Install leak fuel line on cylinder head.

Final steps

1. Open fuel supply line.

2. Vent fuel system (→ Page 89).

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6.5.2 Fuel system – Venting

Preconditions

☑ Engine is not connected to load.

Fuel system – Venting

Note: The fuel system can only be vented with the engine running.

1. Start engine (→ Page 36).

2. Operate the engine until it runs smoothly.

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6.5.3 Fuel – Draining

Preconditions

☑ Engine is stopped and starting disabled.

WARNING

Fuels 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.

WARNING

Liquid 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 eyes
and 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.

Fuel – Draining

1. Provide a suitable container in which to collect the fuel.

2. Remove fuel filter (→ Page 91).

3. Catch fuel as it runs out.

4. Install fuel filter (→ Page 91).

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6.6 Fuel Filter

6.6.1 Fuel filter – Replacement

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Filter wrench

F30379104 1

Diesel fuel

Easy-change filter

(→ Spare Parts Catalog)

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Fuel filter – Replacement

1. Remove easy-change filter using the filter
wrench.

2. Clean sealing surface on filter head.

3. Check sealing ring of the new easy-change fil­ter and moisten it with fuel.

4. Fill the new easy-change filter with clean fuel.

5. Screw on easy-change filter and tighten
hand-tight.

6. Replace further fuel filters in the same way.

7. Vent fuel system (→ Page 89).

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6.6.2 Fuel prefilter – Differential pressure check and adjustment of gauge

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Differential pressure gauge ad­justment

1. When installing the new filter element: align
adjustable pointer (2) with pressure-indicat­ing pointer (3) of pressure gauge (1).

2. Verify that differential pressure is within the
limit.

Fuel prefilter – Checking differential pressure

1. With the engine running at full load or rated power, read off pressure at gauge (1).

2. If differential pressure as indicated between position of adjustable pointer (2) and pressure indicator of pres­sure gauge (3) is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 94).

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6.6.3 Fuel prefilter – Draining

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Diesel fuel

Gasket

(→ Spare Parts Catalog)

WARNING

Fuels 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.

Fuel prefilter – Draining

1. Cut out the filter to be drained.
1 Left filter cut in
2 Right filter cut in

2. Open vent plug (5) of filter to be drained.

3. Unlock drain valve (6) by pressing toggle and

open.

4. Drain water and contaminants from the filter

until pure fuel escapes.

5. Close drain valve (6).

6. Remove screws securing cover and take off

cover (2).

7. Fill filter housing with clean fuel.

8. Place new gasket in cover (2).

9. Fit cover with gasket and secure it with

screws.

10. Cut in the cut-out filter again.

11. When fuel escapes from system, close vent
plug (5).

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6.6.4 Fuel prefilter – Flushing

Preconditions

☑ Engine is stopped and starting disabled (only in the case of single fuel prefilter).

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Fuel

Sealing

(→ Spare Parts Catalog)

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

Fuels 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.

WARNING

Liquid 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 eyes
and 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.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

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Fuel prefilter – Flushing

Note: Only in the case of double fuel prefilter:

1. Cut out contaminated filter.
1 Left filter cut in
2 Right filter cut in

2. Open vent plug (5) of filter to be flushed.

3. Unlock drain cock (6) by pressing toggle,

open it and drain fuel.

Result: Fuel flows from filtered side back to the unfil-

tered side, flushing the filter deposits down­wards out of the filter.

4. Close vent plug (5) and drain cock (6).

Fuel prefilter – Filling with fuel

1. Remove screws securing cover and take off cover (2).

2. Fill filter housing with clean fuel.

3. Place new gasket in cover (2).

4. Fit cover with gasket and secure it with screws.

5. Check differential pressure (→ Page 92).

Result: If flushing did not improve differential pressure, replace fuel prefilter element (→ Page 96).

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6.6.5 Fuel prefilter – Filter element replacement

Preconditions

☑ Engine is stopped and starting disabled (only in the case of single fuel prefilter).

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Fuel

Filter element

(→ Spare Parts Catalog)

Gasket

(→ Spare Parts Catalog)

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

Fuels 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.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Replacing filter element

Note: Only in the case of double fuel prefilter:

1. Cut out contaminated filter.
1 Left filter cut in
2 Right filter cut in

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2. Open vent plug (5) of contaminated filter.

3. Unlock drain valve (6) by pressing toggle and
open.

4. Drain water and contaminants from the filter.

5. Close drain valve (6).

6. Remove screws securing cover and take off
cover (2).

7. Remove spring housing (4) and filter ele­ment (3).

8. Insert new filter element (3) and spring hous­ing (4).

9. Fill filter housing with clean fuel.

10. Place new gasket in cover (2).

11. Fit cover with gasket and secure it with
screws.

Note: Only in the case of double fuel prefilter:

12. Cut in the cut-out filter.

13. Close vent plug (5) when fuel escapes.

14. Set adjustable pointer of differential pressure
gauge (→ Page 92).

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6.7 Air Filter

6.7.1 Air filter – Replacement

Preconditions

☑ Engine is stopped and starting disabled.

Note: Component is genset manufacturer's or vehicle manufacturer's scope of supply.

Air filter – Replacement

u Perform tasks according to manufacturer's specifications.

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6.8 Air Intake

6.8.1 Service indicator – Check

See manufacturer's documentation.

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6.9 Exhaust Gas Recirculation

6.9.1 Exhaust gas recirculation flaps – Overview

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