MTU 12V2000G65, 16V 2000 G65-TB, 18V 2000 G65-TB, 12V 2000 G65-TB, 16V2000G65 Operating Instructions Manual

Operating Instructions

Diesel engine

12V2000G65, G65-TB
16V2000G65, G65-TB
18V2000G65, G65-TB
Application group 3A

MS15018/03E

Engine model kW/cyl. Application group

12V2000G65 42.9 kW/cyl. 3A, continuous operation, unrestricted

12V 2000 G65-TB 42.9 kW/cyl. 3A, continuous operation, unrestricted

16V2000G65 40.9 kW/cyl. 3A, continuous operation, unrestricted

16V 2000 G65-TB 40.9 kW/cyl. 3A, continuous operation, unrestricted

18V2000G65 40.0 kW/cyl. 3A, continuous operation, unrestricted

18V 2000 G65-TB 40.0 kW/cyl. 3A, continuous operation, unrestricted

Table 1: Applicability

© 2016 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 Correct use for all products 6

1.3 Personnel and organizational requirements 7

1.4 Safety regulations for startup and operation 8

1.5 Safety precautions when working on the
engine 10

1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 13

1.7 Standards for safety notices in the text 15

2 Transport

2.1 Transportation 16

2.2 Lifting requirements 17

3 General Information

3.1 Engine side and cylinder designations 18

3.2 Engine overview 19

3.3 Sensors and actuators – Overview 21

4 Technical Data

4.1 12/16/18V2000G65 engine data, fuel
optimized 23

4.2 12/16/18V2000G65-TB engine data, fuel
optimized 27

4.3 Firing order 31

4.4 Engine – Main dimensions 32

5 Operation

5.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 33

5.2 Putting the engine into operation after
scheduled out-of-service-period 34

5.3 Engine – Starting in manual mode (test run) 35

5.4 Safety system – Override 36

5.5 Operational monitoring 37

5.6 Engine – Stopping in manual mode (test
run) 38

5.7 Engine – Emergency stop 39

5.8 After stopping the engine – Engine remains
ready for operation 40

5.9 After stopping the engine – Putting the
engine out of operation 41

6 Maintenance

6.1 Maintenance task reference table [QL1] 42

7 Troubleshooting

7.1 Fault indication on SAM display – Genset
applications 43

7.2 Troubleshooting 67

8 Task Description

8.1 Engine 70

8.1.1 Engine – Barring manually 70

8.1.2 Engine – Barring with starting system 71

8.1.3 Engine – Test run 72

8.2 Cylinder Liner 73

8.2.1 Cylinder liner – Endoscopic examination 73

8.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 75

8.3 Crankcase Breather 77

8.3.1 Crankcase breather – Wire mesh cleaning 77

8.3.2 Crankcase breather – Oil separator
replacement, diaphragm check and
replacement 78

8.4 Valve Drive 80

8.4.1 Valve clearance – Check and adjustment 80

8.4.2 Cylinder head cover – Removal and
installation 83

8.5 Injection Pump / HP Pump 84

8.5.1 Injection pump – Replacement 84

8.5.2 Injection pump – Removal and installation 85

8.6 Injection Valve / Injector 88

8.6.1 Injector – Replacement 88

8.6.2 Injector – Removal and installation 89

8.7 Fuel System 94

8.7.1 Fuel injection line – Pressure pipe neck
replacement 94

8.7.2 Fuel – Draining 97

8.7.3 Fuel pressure relief valve – Removal and
installation 99

8.7.4 Fuel system – Venting 100

8.8 Fuel Filter 102

8.8.1 Fuel filter – Replacement 102

8.8.2 Fuel prefilter – Differential pressure gage
check and adjustment of gage 103

8.8.3 Fuel prefilter – Draining 104

8.8.4 Fuel prefilter – Flushing 106

8.8.5 Fuel prefilter – Cleaning 108

8.8.6 Fuel prefilter – Filter element replacement 109

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8.9 Charge-Air Cooling General, Left-Hand Side 111

8.9.1 Intercooler – Checking condensate drain for
coolant discharge and obstructions 111

8.10 Air Filter 112

8.10.1 Air filter – Replacement 112

8.10.2 Air filter – Removal and installation 113

8.11 Air Intake 114

8.11.1 Service indicator – Signal ring position check 114

8.12 Starting Equipment 115

8.12.1 Air starter – Manual operation 115

8.13 Lube Oil System, Lube Oil Circuit 116

8.13.1 Engine oil – Level check 116

8.13.2 Engine oil – Change 117

8.14 Oil Filtration / Cooling 118

8.14.1 Engine oil filter – Replacement 118

8.15 Coolant Circuit, General, High-Temperature
Circuit 119

8.15.1 Engine coolant – Level check 119

8.15.2 Engine coolant – Change 120

8.15.3 Engine coolant – Draining 121

8.15.4 Engine coolant – Filling 122

8.15.5 Coolant pump – Relief bore check 124

8.16 Low-Temperature Circuit 125

8.16.1 Charge-air coolant – Filling 125

8.16.2 Charge-air coolant – Draining 127

8.16.3 Charge-air coolant – Change 128

8.16.4 Charge-air coolant – Level check 129

8.17 Coolant System 130

8.17.1 Cooler – Checking cooler elements externally
for dirt 130

8.17.2 Cooler – Cleaning cooler elements 131

8.18 Battery-Charging Generator 132

8.18.1 Battery-charging generator drive – Drive-belt
check and adjustment 132

8.18.2 Battery-charging generator drive – Drive belt
replacement 134

8.19 Fan Drive 135

8.19.1 Fan drive – Drive-belt check and adjustment 135

8.19.2 Fan drive – Drive belt replacement 138

8.20 Wiring (General) for Engine/Gearbox/Unit 139

8.20.1 Engine cabling – Check 139

8.21 Accessories for (Electronic) Engine
Governor / Control System 140

8.21.1 Engine governor and connector – Cleaning 140

8.21.2 Engine governor plug connections – Check 141

8.21.3 Engine governor ECU 7 – Removal and
installation 142

9 Appendix A

9.1 Abbreviations 143

9.2 MTU Contact/Service Partners 146

10 Appendix B

10.1 Special Tools 147

10.2 Index 154

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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

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

On all MTU engines fitted with emission labels, these labels 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:

• The relevant emission labels must be affixed to the spare part.

• Do not transfer the emission labels from the replaced part to the spare part.

• Remove the emission labels from the replaced part and destroy them.

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1.2 Correct use for all products

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 preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva­tion 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

• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product

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

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

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

The product shall not be operated in explosive atmospheres unless the necessary approval has been grant­ed.

Any other use, particularly misuse, is considered as being contrary to the intended purpose. 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.

The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:

• For drive systems: http://www.mtu-online.com

• For power generation: http://www.mtuonsiteenergy.com

Modifications or 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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1.3 Personnel and organizational requirements

Organizational measures of the user/manufacturer

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

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

Personnel must receive instruction on product handling and 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, as­sembly, installation, and transport in writing.

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

Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip­tions of the individual activities.

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1.4 Safety regulations for startup and operation

Safety regulations for startup

Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.

Whenever the product is subsequently taken into operation ensure that:

• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.

• All maintenance and repair work has been completed.

• All loose parts have been removed from rotating machine components.

• All safety equipment is in place.

• No persons wearing pacemakers or any other technical body aids are present.

• The service room is adequately ventilated.

• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.

• The exhaust system is leak-tight and that the gases are vented to atmosphere.

• Protect battery terminals, generator terminals or cables against accidental contact.

• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).

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

Smoking is prohibited in the area of the product.

Safety regulations during operation

The operator must be familiar with the control and display elements.

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

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

Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.

The following steps must be taken if a malfunction of the system is detected or reported by the system:

• Inform supervisor(s) in charge.

• Analyze the message.

• Respond by taking any necessary emergency action, e.g. emergency stop.

Operation

Do not remain in the operating room when the product is running for any longer than absolutely necessary.

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

Do not inhale the exhaust gases of the product.

The following requirements must be fulfilled before the product is started:

• Wear ear protection.

• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.

Operation of electrical equipment

Parts of the electrical equipment are live, i.e. under voltage/high tension, during operation.

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Follow the applicable warning instructions pertaining to such devices.

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1.5 Safety precautions when working on the engine

Safety regulations prior to maintenance and repair work

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

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 cables or actuate the battery isolating switch, if fitted. 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.

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

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.

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

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 the engine, 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).

Ensure that the grounding system 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 cables or actuate the battery isolating switch.

• 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 cabling harnesses of the product. The
welding current may otherwise induce an interference voltage in the cabling 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 objects 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. Check cor­rect execution of the emergency stop function in particular.

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

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

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

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

Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem­perature of 20 °C.

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1.6 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 lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the
ground lead of the engine or to the ground terminal of the starter.

Always have a suitable extinguishing agent (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.

Auxiliary materials

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.

Lead

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

• Switch on extraction system.

• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale

lead vapors.

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

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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).

• Release residual pressure before removing or replacing pneumatic equipment in the supply line. To de­pressurize compressed-air lines, shut off the lines first, then release the residual pressure.

• 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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1.7 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.

Warning notices

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

2.1 Transportation

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Crossbeam

T80092210 1

DANGER

Suspended load.

Danger to life!

• Use appropriate lifting devices and appliances.

• Never stand beneath a suspended load.

Transportation

1. Use lifting eyes provided for transporting the engine (→ Page 17).

2. Only use suitable transportation and lifting equipment.

3. The engine must only be transported in installation position: Max. admissible diagonal pull 10°. (→ Page 17)°

4. Remove any loose parts on engine.

5. Always raise/lower engine slowly. The lifting ropes or chains must not rub against the engine or its compo­nents during the lifting procedure. Readjust lifting tackle as necessary.

6. For special packaging with aluminum foil: Attach engine to lifting eyes of bearing pedestal or transport with
means of transportation device suitable for the load (forklift truck).

7. Secure engine against tilting during transportation. Secure such as to preclude slipping and tipping when
driving up or down inclines and ramps.

Placement after transportation

1. Only set down engine on a firm, level surface.

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

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

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2.2 Lifting requirements

Lifting requirements

DANGER

Suspended load.

Danger to life!

• Use appropriate lifting devices and appliances.

• Never stand beneath a suspended load.

1 Lifting eye 2 Center of gravity

Take note of the engine center of gravity

See Installation/Arrangement drawings for details on engine center of gravity.

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3 General Information

3.1 Engine side and cylinder designations

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

ance with DIN ISO 1204
(KGS = 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).

18 | General Information |

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3.2 Engine overview

Engine with water-to-air charge-air cooling TB

1 Air filter
2 Oil separator
3 Intercooler
4 Engine governor
5 Fuel filter
6 Fan drive
7 Oil heat exchanger

8 Oil filter

9 Coolant pump
10 Fuel priming pump
11 Air outlet
12 Exhaust turbocharger
13 Exhaust elbow
14 Charge-air manifold

15 Cylinder head
16 Flywheel housing
17 Starter
18 Storage
19 Oil pan
20 Crankcase breather

Figure also applies similarly to 12V/16V/18V2000Gxy

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Engine with air-to-air charge-air cooling TD

1 Air filter
2 Oil separator
3 Air outlet
4 Engine governor
5 Fuel filter
6 Fan drive

7 Oil heat exchanger
8 Oil filter

9 Coolant pump
10 Fuel priming pump
11 Exhaust turbocharger
12 Oil pan

13 Exhaust elbow
14 Charge-air manifold
15 Cylinder head
16 Flywheel housing
17 Storage
18 Crankcase breather

Figure also applies similarly to 12V/16V/18V2000Gxy

Engine type designation

Explanation of engine type designation 12V/16V/18V2000Gxy

12/16/18 Number of cylinders

V Cylinder arrangement: V engine

2000 Series

G Application

x Application segment (2, 4, 6, 8)

y Design status (0, 1, 2,...)

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3.3 Sensors and actuators – Overview

Engines with water-cooled intercooler TB

Item Name Monitoring of

1 B7 Lube oil temperature

2 B5 Lube oil pressure

3 B9 Charge-air coolant temperature

4 B10 Charge-air pressure

5 B1 Camshaft speed

6 B13 Crankshaft speed

7 B6 Coolant temperature

8 B33 Fuel temperature

The coolant level sensor F33 is located in the coolant expansion tank at the cooler

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Engine with air-cooled intercooler TD

Item Name Monitoring of

1 B7 Lube oil temperature

2 B5 Lube oil pressure

3 B9 Charge-air coolant temperature

4 B10 Charge-air pressure

5 B1 Camshaft speed

6 B13 Crankshaft speed

7 B6 Coolant temperature

8 B33 Fuel temperature

The coolant level sensor F33 is located in the coolant expansion tank at the cooler

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4 Technical Data

4.1 12/16/18V2000G65 engine data, fuel optimized

Explanation

Abbr. Meaning

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

** Not sufficiently validated value (tolerance +/- 5%)

Reference condition

Description 12V2000

G65

16V2000

G65

18V2000

G65

Application group 3A 3A 3A

Intake air temperature °C 25 25 25

Barometric pressure mbar 1000 1000 1000

Site altitude above sea level M 100 100 100

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

Description 12V2000

G65

16V2000

G65

18V2000

G65

Rated engine speed A rpm 1500 1500 1500

Continuous power ISO 3046 (10% overload pos­sible) (power range DIN 6280, ISO 8528)

A kW 515 655 720

General conditions (for maximum power)

Description 12V2000

G65

16V2000

G65

18V2000

G65

Intake depression (new filter) A mbar 15 15 15

Intake depression, max. L mbar 50 50 50

Exhaust overpressure A mbar 30 30 30

Exhaust gas overpressure, max. L mbar 85 85 85

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Model related data (basic design)

Description 12V2000

G65

16V2000

G65

18V2000

G65

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

x x x

Uncooled exhaust lines x x x

Operating method: Four-stroke cycle, diesel,
single-action

x x x

Combustion method: direct fuel injection x x x

Cooling method: conditioned water x x x

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

Number of cylinders 12 16 18

Cylinder arrangement: V-angle degrees 90 90 90

Bore mm 130 130 130

Stroke mm 150 150 150

Displacement, cylinder Liter 1.99 1.99 1.99

Displacement, total Liter 23.88 31.84 35.82

Compression ratio 16 16 16

Cylinder heads: Individual cylinder heads x x x

Cylinder liners: wet, replaceable x x x

Number of inlet valves per cylinder 2 2 2

Number of exhaust valves, per cylinder 2 2 2

Standard housing connecting flange (engine
main PTO)

SAE 0 0 0

Flywheel interface DISC 18" 18" 18"

Air / exhaust gas

Description 12V2000

G65

16V2000

G65

18V2000

G65

Charge-air pressure before cylinder - DL R bar abs 2.5 2.5 2.4

Coolant system (HT circuit)

Description 12V2000

G65

16V2000

G65

18V2000

G65

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

A °C 95 95 95

Coolant temperature after engine, alarm R °C 97 97 97

Coolant temperature after engine, shutdown L °C 102 102 102

Coolant antifreeze content, max. L % 50 50 50

Pressure loss in off-engine cooling system, max. L bar 0.7 0.7 0.7

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Lube oil system

Description 12V2000

G65

16V2000

G65

18V2000

G65

Lube-oil operating temperature before engine,
from

R °C 88 88 88

Lube-oil operating temperature before engine,toR °C 98 98 98

Lube-oil temperature before engine, alarm R °C 100 100 100

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

Lube-oil operating pressure before engine, from R bar 6.2 5.5 6.0

Lube-oil operating pressure before engine, to R bar 7.5 6.5 8.0

Lube-oil operating pressure before engine,
warning

R bar 4.4 4.4 4.4

Lube-oil operating pressure before engine, shut­down

L bar 3.9 3.9 3.9

Fuel system

Description 12V2000

G65

16V2000

G65

18V2000

G65

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

L bar -0.3 -0.3 -0.3

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

L bar +0.5 +0.5 +0.5

General operating data

Description 12V2000

G65

16V2000

G65

18V2000

G65

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

R °C 0** 0** 0**

Coolant preheating: preheating temperature
(min.)

R °C 32 32 32

Firing speed, from R rpm 100 100 100

Firing speed. to R rpm 120 120 120

Oil and coolant capacity

Description 12V2000

G65

16V2000

G65

18V2000

G65

Engine coolant capacity, engine side (without
cooling equipment)

R Liter 90 110 120

Engine oil capacity, initial filling (standard oil
system)(Option: max. operating inclinations)

R Liter 77 102 130

Oil change capacity, max. (standard oil system) R Liter N N N

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

R Liter 74 99 114

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

L Liter 50 69 87

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

L Liter 67 92 110

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Weights / main dimensions

Description 12V2000

G65

16V2000

G65

18V2000

G65

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

R kg 2490 3100 3500

Acoustics

Description 12V2000

G65

16V2000

G65

18V2000

G65

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

R dB(A) 123 124 125

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

R dB(A) 115 119 119

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4.2 12/16/18V2000G65-TB engine data, fuel optimized

Explanation

Abbr. Meaning

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

** Not sufficiently validated value (tolerance +/- 5%)

Reference condition

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

Application group 3A 3A 3A

Intake air temperature °C 25 25 25

Charge air coolant temperature °C 55 55 55

Raw water inlet temperature °C - - -

Barometric pressure mbar 1000 1000 1000

Site altitude above sea level M 100 100 100

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

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

Rated engine speed A rpm 1500 1500 1500

Continuous power ISO 3046 (10% overload pos­sible) (power range DIN 6280, ISO 8528)

A kW 515 655 720

General conditions (for maximum power)

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

Intake depression (new filter) A mbar 15 15 15

Intake depression, max. L mbar 50 50 50

Exhaust overpressure A mbar 30 30 30

Exhaust gas overpressure, max. L mbar 85 85 85

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Model related data (basic design)

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

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

x x x

Uncooled exhaust lines x x x

Operating method: Four-stroke cycle, diesel,
single-action

x x x

Combustion method: direct fuel injection x x x

Cooling method: conditioned water x x x

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

Number of cylinders 12 16 18

Cylinder arrangement: V-angle degrees 90 90 90

Bore mm 130 130 130

Stroke mm 150 150 150

Displacement, cylinder Liter 1.99 1.99 1.99

Displacement, total Liter 23.88 31.84 35.82

Compression ratio 16 16 16

Cylinder heads: Individual cylinder heads x x x

Cylinder liners: wet, replaceable x x x

Number of inlet valves per cylinder 2 2 2

Number of exhaust valves, per cylinder 2 2 2

Standard housing connecting flange (engine
main PTO)

SAE 0 0 0

Flywheel interface DISC 18" 18" 18"

Air / exhaust gas

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

Charge-air pressure before cylinder - DL R bar abs 2.5 2.5 2.4

Coolant system (HT circuit)

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

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

A °C 95 95 95

Coolant temperature after engine, alarm R °C 97 97 97

Coolant temperature after engine, shutdown L °C 102 102 102

Coolant antifreeze content, max. L % 50 50 50

Pressure loss in off-engine cooling system, max. L bar 0.7 0.7 0.7

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Coolant system (LT circuit)

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

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

A °C 55 55 55

Coolant antifreeze content, max. L % 50 50 50

Pressure loss in off-engine cooling system, max. L bar 0.7 0.7 0.7

Lube oil system

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

Lube-oil operating temperature before engine,
from

R °C 88 88 88

Lube-oil operating temperature before engine,toR °C 98 98 98

Lube-oil temperature before engine, alarm R °C 100 100 100

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

Lube-oil operating pressure before engine, from R bar 6.2 5.5 6.0

Lube-oil operating pressure before engine, to R bar 7.5 6.5 8.0

Lube-oil operating pressure before engine,
warning

R bar 4.4 4.4 4.4

Lube-oil operating pressure before engine, shut­down

L bar 3.9 3.9 3.9

Fuel system

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

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

L bar -0.3 -0.3 -0.3

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

L bar +0.5 +0.5 +0.5

General operating data

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

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

R °C 0** 0** 0**

Coolant preheating: preheating temperature
(min.)

R °C 32 32 32

Firing speed, from R rpm 100 100 100

Firing speed. to R rpm 120 120 120

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Oil and Coolant Capacity

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

Engine coolant capacity, engine side (without
cooling equipment)

R Liter 110 130 140

Charge-air coolant, engine side R Liter 20 20 20

Engine oil capacity, initial filling (standard oil
system) (Option: max. operating inclinations)

R Liter 77 102 130

Oil change capacity, max. (standard oil system) R Liter N N N

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

R Liter 74 99 114

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

L Liter 50 69 87

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

L Liter 67 92 110

Weights / main dimensions

Description 12V2000

G65-TB

16V2000

G65-TB

18V2000

G65-TB

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

R kg 2570 3180 3580

Sound

Description 12 16 18

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

R dB(A) 123 124 125

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

R dB(A) 115 119 119

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4.3 Firing order

Firing order

Number of cylinders Firing order

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

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

18V A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8

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4.4 Engine – Main dimensions

Engine model Length (A) Width (B) Height (C)

12V2000Gx5 approx. 1882 mm approx. 1580 mm approx. 1570 mm

16V2000Gx5 approx. 2226 mm approx. 1580 mm approx. 1572 mm

18V2000Gx5 approx. 2398 mm approx. 1580 mm approx. 1603 mm

12V2000Gx5-TB approx. 1836 mm approx. 1580 mm approx. 1585 mm

16V2000Gx5-TB approx. 2180 mm approx. 1580 mm approx. 1585 mm

18V2000Gx5-TB approx. 2352 mm approx. 1580 mm approx. 1619 mm

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5 Operation

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

Preconditions

☑ Engine is stopped and starting disabled.

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

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

Item Action

Engine Depreserve (→ MTU Preservation and Represervation Specifications

A001070/..).

Lube oil system Check engine oil level (→ Page 116);

Fuel prefilter Fill with fuel (→ Page 106).

Fuel prefilter, pressure
gauge

Align adjustable pointer with position of pressure indicator (→ Page 103).

Fuel system Vent (→ Page 100).

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

(→ Page 120).
Change charge-air coolant (→ Page 128).

Coolant circuit Check engine coolant level (→ Page 119);

Check charge-air coolant level (→ Page 129).

Coolant circuit Heat engine coolant with coolant preheating unit.

Engine governor Check plug-in connections (→ Page 141).

Monitoring system Carry out lamp test (see manufacturer's documentation).

Engine/generator control
system

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

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

Preconditions

☑ Engine is stopped and starting disabled.

Putting the engine into operation

Item Task

Lube oil system Check oil level (→ Page 116);

Cooling system Check engine coolant level (→ Page 119);

Check charge-air coolant level (→ Page 129).

Cooling system Preheat coolant with preheating unit.

Fuel prefilter Drain (→ Page 104).

Monitoring equipment Carry out lamp test (see manufacturer's documentation).

Engine/generator control
system

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

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5.3 Engine – Starting in manual mode (test run)

Preconditions

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

☑ External start interlock is not active.

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.

Preparation

Item Action

Operating mode switch (if
fitted)

Change to manual mode.

Preheating pump (if fitted) Switch on.

Starting the engine

Item Action

Switchgear cabinet, control
panel etc. (depending on
manufacturer)

If coolant temperature is

• > 40 °C (with preheating system), or

• > 5 °C (without preheating system):
Press start button.

• Automatic starting sequence is performed;

• Engine speed display instrument indicates increasing speed;

• After the starting sequence is completed, engine is running at rated
speed.

Connecting the generator (if fitted) to network, engine warm-up procedure to
reach operating temperature

Item Action

Switchgear cabinet, control
panel etc. (depending on
manufacturer)

Close the generator circuit breaker.

Engine Apply full load only after engine has reached operating temperature (coolant

temperature approx. 75 °C).

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5.4 Safety system – Override

NOTICE

Safety functions and engine shutdown alarms will be disregarded.

Severe material damage!

• Initiate emergency start only in emergency situations.

NOTICE

Inadmissible operating status.

Severe damage to property!

• Use override function only in hazardous situations to ensure full capability in the event of engine
faults.

Preparation

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

Safety system – Override

Item Action

Switchgear cabinet, control
panel etc. (depending on
manufacturer)

Activate pushbutton for Override input of the ECU.

• Certain shutdown criteria and/or starting prerequisites are ignored.

Switchgear cabinet, control
panel etc. (depending on
manufacturer)

Actuate start button, for further starting sequence, refer to engine start
(→ Page 35).

Control and display panels During operation, check the displayed operational data (speed, temperature,

pressures).
Constantly monitor plant limit values.

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5.5 Operational monitoring

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 monitoring

Item Measure

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

Engine under load,
engine at nominal speed

Check engine/plant and all pipework visually for leaks, rectify any leaks with
the engine stopped;
Check for abnormal running noises and vibration.

Fuel prefilter Check reading on differential pressure gage to ensure that maximum admis-

sible value is not exceeded (→ Page 103).

Exhaust system Check exhaust color (→ Page 67).

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

(→ Page 111).

Air filter Check signal ring position of service indicator (→ Page 114).

Replace air filter (→ Page 112), if the signal ring is completely visible in the
red area of the service indicator observation window.

Coolant pump Check relief bore (→ Page 124).

Compressed-air system (if
installed)

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

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5.6 Engine – Stopping in manual mode (test run)

Preconditions

☑ Generator (if fitted) is not connected to network

☑ Engine in manual mode

NOTICE

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

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

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

Preparing a generator drive (only if generator circuit breaker is provided)

Item Action

Engine After the generator breaker (if provided) has been opened, allow the engine

to cool down by running it idle for approx. 5 minutes.

Preparing a pump drive (diesel-mechanical/diesel-electric)

Item Action

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

minutes. Observe the natural frequencies (plant-specific values) of the en­gine!

Stopping the engine

Item Action

Switchgear cabinet, control
panel etc. (depending on
manufacturer)

Press stop button.

• Automatic stopping sequence is performed;

• Engine at a standstill.

After stopping the engine

Item Action

Coolant circulation pump Operate pump for a sufficient period of time after the engine is stopped.

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5.7 Engine – Emergency stop

NOTICE

An emergency stop subjects the engine system to an extremely high load.

Risk of overheating, damage to components!

• Trigger an emergency stop only in emergency situations.

Emergency engine stop from LOP

Item Action

Emergency stop pushbutton Press pushbutton.

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

• Signaling (e.g. by horn, flashing lamp) is tripped.

After emergency engine stop from LOP

Item Action

Control cabinet, control pan­el etc. (depending on manu­facturer)

Press pushbutton for alarm acknowledgment.

• Audible and visual alarm signaling stops.

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5.8 After stopping the engine – Engine remains ready for
operation

After stopping the engine

Item Action

Engine/generator/pump
control

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

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

Preconditions

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

After stopping the engine

Item Action

Coolant circuit Drain engine coolant (→ Page 121);

Drain charge-air coolant (→ Page 127) if:

• freezing temperatures are to be expected and the engine is to remain out
of service for an extended period and if no antifreeze has been added to
the coolant;

• the engine room is not heated;

• the coolant is not kept at a suitable temperature;

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

• antifreeze concentration is 50 % and engine-room temperature is below

-40 °C.

Engine/generator/pump
control

Switch off.

Air intake and exhaust sys­tem

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

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6 Maintenance

6.1 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 116)

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

W0502 Check intercooler drain. (→ Page 111)

W0503 Check service indicator of air filter. (→ Page 114)

W0505 Check relief bores of coolant pump(s). (→ Page 124)

W0506 Check engine for abnormal running noises, exhaust color and

vibrations.

(→ Page 37)

W0507 Drain water and contaminants from fuel prefilter. (→ Page 104)

W0508 Check reading on differential pressure gage of fuel prefilter. (→ Page 103)

W0534 Carry out test run, minimum duration: until steady-state tem-

perature is reached, no less than 1/3 load (monthly).

(→ Page 72)

W1001 Replace fuel filter or fuel filter element. (→ Page 102)

W1002 Check valve clearance. (→ Page 80)

W1003 Check belt condition and tension, replace if necessary. (→ Page 132)

W1005 Replace air filter. (→ Page 112)

W1006 Replace injectors. (→ Page 88)

W1007 Replace fuel injection pump(s). (→ Page 85)

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

time limit (years) is reached, at the latest.

(→ Page 118)

W1010 Coolant cooler: Check exterior of cooler elements for dirt. (→ Page 130)

W1011 Perform endoscopic examination. (→ Page 73)

W1056 Replace fuel pressure maintaining valve. (→ Page 99)

W1178 Replace pressure pipe neck in cylinder head. (→ Page 94)

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7 Troubleshooting

7.1 Fault indication on SAM display – Genset applications

SAM fault messages

1 2-line LC display
2 Time indicator for alarms

3 Fault type
4 Node number

The structure of the display is as follows:

• First line
– Time indicator for alarms (e.g. #)
– Type of fault (e.g. SE03)
– Node number at which the fault occurred (e.g. nd11)

• Second line (option)
– Running text, providing more information about the fault currently displayed

Time indicator for alarms Meaning

# Alarm is no longer active, does not appear on next power-up.

A Alarm is active.

B Alarm was active during the last hour.

C Alarm was active during the last four hours.

D Alarm was active during the last four to twelve hours.

E Alarm was active more than twelve hours ago.

Proceed to the next alarm by pressing key (↓ ↑).

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Fault type – fault message text

SE no. Error message text

0 Sensor Temperatur Defect

1 Temperature failure

2 Sensor Voltage Defect

3 Voltage failure

4 CAN Bus- 1 Error/Bus Defec

5 CAN Bus- 1 Overrun

6 CAN Bus- 2 Error/Bus Defec

7 CAN Bus- 2 Overrun

8 Temperatur Compensation Error

9 I/O-Module Slot2 Defect

10 I/O-Module Slot3 Defect

11 I/O-Module Slot4 Defect

12 Serial Conection Lost

13 CAN Bus- 3 Error/Bus Defec

14 CAN Bus- 3 Overrun

15 S/A Bus Faulty

16 PAN 1 Defect

17 PAN 2 Defect

18 PAN 3 Defect

19 PAN 4 Defect

20 PAN 5 Defect

21 PAN 6 Defect

22 I/O-Module Slot1 Defect

23 I/O-Module Slot5 Defect

24 I/O-Module Slot6 Defect

25 I/O-Module Slot7 Defect

26 I/O-Module Slot8 Defect

27 Download Server Collision

28 not projected node

Engine governor messages

Recommended action in case of alarm

Yellow alarm:

The engine can still be operated providing that automatic engine shutdown to protect the engine has not
been configured or is not tripped. Contact Service immediately/start fault rectification.

Red alarm:

Caution, the engine is running at its limits. Shut down manually without further delay if the engine does not
shut itself down immediately after a red alarm is signaled.

Fault and alarm messages

The fault code numbers are generated by the engine governor and transmitted to the display below.

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The fault code (1) comprises three digits.

Fault messages can also be caused by faulty sensors/actuators. Contact Service to have sensors/actuators
checked and replaced as necessary if the troubleshooting measures listed in the table below prove unsuc­cessful.

IMPORTANT NOTE:

The information provided in the columns “Meaning” and “Action” applies to the standard default state of the
genset on delivery. Differing system responses requiring different action may result when settings are
changed by the OEM. The OEM is responsible for documenting any changes and defining appropriate coun­teraction.

The table below lists possible fault codes:

Fault
code no. Full designation Meaning Action

Setting parame­ter no.

003 HI T-Fuel Prewarning: Fuel tempera-

ture too high (limit value 1,
alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check tank temper­ature, contact Serv­ice if no fault detect­ed.

2.0122931

004 SS T-Fuel Main warning: Fuel tempera-

ture too high (limit value 2,
alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check tank temper­ature, contact Serv­ice if no fault detect­ed.

2.0122932

005 HI T-Charge Air Prewarning: Charge-air tem-

perature too high (limit value
1, alarm configuration pa­rameter, see PR 2.8008.100
for explanation).

Check cooler, check
intercooler, contact
Service if no fault
detected.

2.0121.931

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

006 SS T-Charge Air Main warning: Charge-air

temperature too high (limit
value 2, alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check cooler, check
intercooler, contact
Service if no fault
detected.

2.0121.932

009 HI T-Coolant Intercool-erPrewarning: Coolant temper-

ature in intercooler too high
(limit value 1, alarm configu­ration parameter, see PR

2.8008.100 for explanation).

Check cooler, con­tact Service if no
fault detected.

2.0124.931

010 SS T-Coolant Intercool-erMain warning: Coolant tem-

perature in intercooler too
high (limit value 2, alarm con­figuration parameter, see PR

2.8008.100 for explanation).

Check cooler, con­tact Service if no
fault detected.

2.0124.932

015 LO P-Lube Oil Prewarning: Lube-oil pres-

sure too low (limit value 1,
alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check oil level, con­tact Service if no
fault detected.

2.0100.921

016 SS P-Lube Oil Main warning: Lube-oil pres-

sure too low (limit value 2,
alarm configuration parame­ter, see PR 2.8008.100 for
explanation). Automatic en­gine shutdown.

Check oil level, con­tact Service.

2.0100.922

024 SS Coolant Level Coolant level too low (limit

value 2, alarm configuration
parameter, see PR

2.8008.100 for explanation).
Automatic engine shutdown.

Check coolant level
in expansion tank,
check for leakage
and seal any leaks
as necessary.

2.0152.912

030 SS Engine Overspeed Engine overspeed (limit value

2, alarm configuration pa­rameter, see PR 2.8008.100
for explanation). Automatic
engine shutdown.

Attempt to restart
engine.

2.2510.932

044 LO Coolant Level Inter-

cooler

Intercooler coolant level too
low (limit value 1, alarm con­figuration parameter, see PR

2.8008.100 for explanation).
Automatic engine shutdown.

Check coolant level
in expansion tank,
check for leakage
and seal any leaks
as necessary.

2.0153.921

051 HI T-Lube Oil Lube-oil temperature too

high (limit value 1, alarm con­figuration parameter, see PR

2.8008.100 for explanation).
Warning.

Check cooling sys­tem.

2.0125.931

052 SS T-Lube Oil Lube-oil temperature too

high (limit value 2, alarm con­figuration parameter, see PR

2.8008.100 for explanation).
Automatic engine shutdown.

Check cooling sys­tem, contact Service
if cooling system is
in order.

2.0125.932

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

065 LO P-Fuel Fuel inlet pressure too low

(limit value 1, alarm configu­ration parameter, see PR

2.8008.100 for explanation).
Warning.

Check filter, check
genset fuel supply.

2.0102.921

066 SS P-Fuel Fuel inlet pressure too low

(limit value 2, alarm configu­ration parameter, see PR

2.8008.100 for explanation).
Warning.

Check filter, check
genset fuel supply.

2.0102.922

067 HI T-Coolant Coolant temperature too high

(limit value 1, alarm configu­ration parameter, see PR

2.8008.100 for explanation).
Warning.

Check cooling sys­tem.

2.0120.931

068 SS T-Coolant Coolant temperature too high

(limit value 2, alarm configu­ration parameter, see PR

2.8008.100 for explanation).
Automatic engine shutdown.

Check cooling sys­tem. Contact Serv­ice if cooling system
is in order.

2.0120.932

081 AL Rail Leakage Pressure gradient in rail too

low on starting or too high on
stopping, HP system leaking
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

On stopping: Seal
off system, contact
Service; On starting:
Check engine for
leakage, if none
found, attempt re­starting as per oper­ating instructions
(air in system).

1.8004.046

082 HI P-Fuel (Common

Rail)

Rail pressure is greater than
set value (alarm configura­tion parameter, see PR

2.8008.100 for explanation).
Warning.

Check HP fuel con­trol block wiring, if
no fault detected,
contact Service.

2.0104.931

083 LO P-Fuel (Common

Rail)

Rail pressure is less than set
value (alarm configuration
parameter, see PR

2.8008.100 for explanation).
Warning.

Check HP fuel con­trol block wiring,
check HP system for
leakage, if no fault
detected, contact
Service.

2.0104.921

089 SS Engine Speed too

Low

Engine speed too low (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion). Engine stop.

Check for additional
messages.

2.2500.030

090 SS Idle Speed Not

Reached

Idling speed not reached
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation). Start terminat­ed.

Check for additional
messages.

2.1090.925

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

091 SS Release Speed Not

Reached

Runup speed not reached
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation). Start terminat­ed.

Check for additional
messages. Recharge
battery. Engine un­der load: Check fuel
supply; if no fault
detected, contact
Service.

2.1090.924

092 SS Starter Speed Not

Reached

Starter speed not reached
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation). Start terminat­ed. Starter does not turn or
turns slowly.

Check for additional
messages. Recharge
battery. Engine un­der load: Check fuel
supply; if no fault
detected, contact
Service.

2.1090.923

093 SS T-Preheat Preheating temperature too

low (limit value 2, alarm con­figuration parameter, see PR

2.8008.100 for explanation).

Engine start inter­lock is active as
coolant temperature
is too low for engine
start, preheating
necessary.

2.1090.922

094 LO T-Preheat Preheating temperature too

low (limit value 1, alarm con­figuration parameter, see PR

2.8008.100 for explanation).

Engine start inter­lock is active as
coolant temperature
is too low for engine
start, preheating
necessary.

2.1090.921

095 AL Prelubrication Fault Oil priming pressure not

reached (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.1090.920

102 AL Fuel Cons. Counter

Defect

Electronic fault: Consump­tion counter faulty (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace engine gov­ernor at next oppor­tunity.

1.8004.624

104 AL Eng Hours Counter

Defect

Electronic fault: Hour meter
faulty (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Replace engine gov­ernor at next oppor­tunity.

1.8004.623

118 LO ECU Power Supply

Voltage

Supply voltage too low (limit
value 1, alarm configuration
parameter, see PR

2.8008.100 for explanation).
Warning.

Check batteries and
charge as necessa­ry; check generator.

2.0140.921

119 LOLO ECU Power Sup-

ply Voltage

Supply voltage too low (limit
value 2, alarm configuration
parameter, see PR

2.8008.100 for explanation).
Warning.

Check batteries and
charge as necessa­ry; check generator.

2.0140.922

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

120 HI ECU Power Supply

Voltage

Supply voltage too high (limit
value 1, alarm configuration
parameter, see PR

2.8008.100 for explanation).
Warning.

Check batteries and
generator.

2.0140.931

121 HIHI ECU Power Sup-

ply Voltage

Supply voltage too high (limit
value 2, alarm configuration
parameter, see PR

2.8008.100 for explanation).
Warning.

Check batteries and
generator.

2.0140.932

122 HI T-ECU Electronics temperature too

high (limit value 1, alarm con­figuration parameter, see PR

2.8008.100 for explanation).
Warning.

Check engine room
ventilation.

2.0132.921

176 AL LifeData not availa-

ble

No (suitable) LifeData back­up system available, backup
system has no LifeData func­tion when timeout following
ECU reset expires or CAN
bus to backup system is dis­rupted (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.4000.004

177 AL LifeData restore in-

complete

This fault message is gener­ated when a CRC is faulty
(stated for each module) or
upload is incomplete during a
restore data upload process
(into ADEC) (alarm configura­tion parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.4000.006

180 AL CAN1 Node Lost Connection to a node on

CAN bus 1 has failed (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Test devices con­nected to CAN, test
wiring.

2.0500.680

181 AL CAN2 Node Lost Connection to a node on

CAN bus 2 has failed (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Check devices con­nected to CAN.

2.0500.681

182 AL CAN Wrong Param-

eters

Incorrect parameter values
entered in data record (alarm
configuration parameter, see
PR 2.8008.100).

2.0500.682

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

183 AL CAN No PU-Data The selected CAN mode initi-

alizes communication by
means of the PU data mod­ule. However, the required
PU data module is unavaila­ble or invalid (alarm configu­ration parameter, see PR

2.8008.100 for explanation).

Check devices con­nected to CAN.

2.0500.683

184 AL CAN PU-Data Flash

Error

Programming error on at­tempting to copy a received
PU data module into the
Flash module (alarm configu­ration parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.0500.684

186 AL CAN1 Bus Off CAN controller 1 is in "Bus

Off" state, automatic switch­ing to CAN2 results. Causes
are e.g. short circuit, massive
disruptions or baud rate in­compatibility (alarm configu­ration parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.0500.686

187 AL CAN1 Error Passive CAN controller 1 has indicat-

ed a warning. Causes are e.g.
missing associate nodes, mi­nor disruptions and tempora­ry bus overload (alarm con­figuration parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.0500.687

188 AL CAN2 Bus Off CAN controller 2 is in "Bus

Off" state, automatic switch­ing to CAN1 results. Causes
are e.g. short circuit, massive
disruptions or baud rate in­compatibility (alarm configu­ration parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.0500.688

189 AL CAN2 Error Passive CAN controller 2 has indicat-

ed a warning. Causes are e.g.
missing associate nodes, mi­nor disruptions and tempora­ry bus overload (alarm con­figuration parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.0500.689

201 SD T-Coolant SD alarm configuration, cool-

ant temperature sensor faul­ty, short circuit or wire break.

Check sensor and
wiring (B6), replace
as necessary.

1.8004.570

202 SD T-Fuel SD alarm configuration, fuel

temperature sensor faulty,
short circuit or wire break.

Check sensor and
wiring (B33), replace
as necessary.

1.8004.572

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

203 SD T-Charge Air SD alarm configuration,

charge-air temperature sen­sor faulty, short circuit or
wire break.

Check sensor and
wiring (B9), replace
as necessary.

1.8004.571

205 SD T-Coolant Intercool-erSD alarm configuration, cool-

ant temperature sensor of in­tercooler faulty, short circuit
or wire break.

Check sensor and
wiring (B26), replace
as necessary.

1.8004.574

208 SD P-Charge Air SD alarm configuration,

charge-air pressure sensor
faulty, short circuit or wire
break.

Check sensor and
wiring (B10), replace
as necessary.

1.8004.566

211 SD P-Lube Oil SD alarm configuration, lube-

oil pressure sensor faulty,
short circuit or wire break.

Check sensor and
wiring (B5), replace
as necessary.

1.8004.563

215 SD P-HD SD alarm configuration, rail

pressure sensor faulty, HP
controller in emergency
mode, short circuit or wire
break.

Check sensor and
wiring (B48), replace
as necessary.

1.8004.567

216 SD T-Lube Oil SD alarm configuration, lube-

oil temperature sensor faulty,
short circuit or wire break.

Check sensor and
wiring (B7), replace
as necessary.

1.8004.575

219 SD T-Intake Air SD alarm configuration, in-

take air temperature sensor
faulty, short circuit or wire
break.

Check sensor and
wiring (B3), replace
as necessary.

1.8004.573

220 SD Level Coolant Wa-

ter

SD alarm configuration, cool­ant level sensor faulty, short
circuit or wire break.

Check sensor and
wiring (F33), replace
as necessary. Fault
is rectified when
electronics are
switched back on

1.8004.584

223 SD Level Coolant Inter-

cooler

SD alarm configuration, cool­ant level sensor faulty, short
circuit or wire break.

Check sensor and
wiring (F57), replace
as necessary. Fault
is rectified when
electronics are
switched back on.

1.8004.583

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

229 AL Stop Camshaft Sen-

sor Defect

Engine stop due to camshaft
sensor fault (and a previous
crankshaft sensor fault in the
same operating cycle). Alarm
configuration parameter, see
PR 2.8008.100 for explana­tion.

Check connector
and wiring to sensor
B1, replace as nec­essary. Fault is rec­tified when engine is
restarted. If cam­shaft and crankshaft
sensor are both faul­ty, check connector
and wiring to sensor
B1 and B13. Re­start. Fault is recti­fied when engine is
restarted, contact
Service if this is not
the case.

1.8004.562

230 SD Crankshaft Speed SD alarm configuration,

crankshaft sensor faulty,
short circuit or wiring dam­age, engine remains opera­tional.

Check sensor and
wiring (B13), at­tempt restart, fault
may be rectified
when engine is re­started. Contact
Service if this is not
the case

1.8004.498

231 SD Camshaft Speed SD alarm configuration, cam-

shaft sensor faulty, short cir­cuit or wiring damage, engine
remains operational.

Check sensor and
wiring (B1), attempt
restart, fault may be
rectified when en­gine is restarted.
Contact Service if
this is not the case.

1.8004.499

240 SD P-Fuel SD alarm configuration, en-

gine remains operational,
fuel pressure sensor faulty,
short circuit or wiring dam­age.

Check sensor and
wiring (B34), replace
as necessary.

1.8004.565

245 SD ECU Power Supply

Voltage

SD alarm configuration, inter­nal engine governor fault.

Execute engine gov­ernor self-test, re­place engine gover­nor in case of fault.

2.8006.589

266 SD Speed Demand SD alarm configuration, ana-

log speed setting faulty,
short circuit or wiring dam­age.

Check speed setting
transmitter and wir­ing, replace as nec­essary. Fault is rec­tified when engine is
restarted.

2.8006.586

269 SD Loadp.Analog filt. SD alarm configuration, fil-

tered analog signal of load
pulse not available, short cir­cuit or wiring damage

Check wiring, re­place as necessary.
Fault is rectified
when engine is re­started.

2.8006.588

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

270 SD Frequency Input SD alarm configuration, fre-

quency input faulty, short cir­cuit or wiring damage.

Contact Service. 2.8006.590

301 AL Timing Cylinder A1 Time-of-flight measuring fault

injector cylinder A1: Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.500

302 AL Timing Cylinder A2 Time-of-flight measuring fault

injector cylinder A2 Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.501

303 AL Timing Cylinder A3 Time-of-flight measuring fault

injector cylinder A3: Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.502

304 AL Timing Cylinder A4 Time-of-flight measuring fault

injector cylinder A4 Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.503

305 AL Timing Cylinder A5 Time-of-flight measuring fault

injector cylinder A5 Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.504

306 AL Timing Cylinder A6 Time-of-flight measuring fault

injector cylinder A6 Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.505

307 AL Timing Cylinder A7 Time-of-flight measuring fault

injector cylinder A7 Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.506

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TIM-ID: 0000008508 - 003

Fault
code no. Full designation Meaning Action

Setting parame­ter no.

308 AL Timing Cylinder A8 Time-of-flight measuring fault

injector cylinder A8 Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.507

309 AL Timing Cylinder A9 Time-of-flight measuring fault

injector cylinder A9 Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.508

310 AL Timing Cylinder A10 Time-of-flight measuring fault

injector cylinder A10: Time­of-flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.509

311 AL Timing Cylinder B1 Time-of-flight measuring fault

injector cylinder B1: Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.510

312 AL Timing Cylinder B2 Time-of-flight measuring fault

injector cylinder B2: Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.511

313 AL Timing Cylinder B3 Time-of-flight measuring fault

injector cylinder B3: Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

18004.512

314 AL Timing Cylinder B4 Time-of-flight measuring fault

injector cylinder B4: Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.513

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

315 AL Timing Cylinder B5 Time-of-flight measuring fault

injector cylinder B5: Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.514

316 AL Timing Cylinder B6 Time-of-flight measuring fault

injector cylinder B6: Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.515

317 AL Timing Cylinder B7 Time-of-flight measuring fault

injector cylinder B7: Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.516

318 AL Timing Cylinder B8 Time-of-flight measuring fault

injector cylinder B8: Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.517

319 AL Timing Cylinder B9 Time-of-flight measuring fault

injector cylinder B9: Time-of­flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.518

320 AL Timing Cylinder B10 Time-of-flight measuring fault

injector cylinder B10: Time­of-flight value measured ex­tremely small or large (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Replace plug-in
pump if this occurs
frequently.

1.8004.519

321 AL Wiring Cylinder A1 Wiring fault in injector wiring

cylinder A1. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.520

MS15018/03E 2016-02 | Troubleshooting | 55

TIM-ID: 0000008508 - 003

Fault
code no. Full designation Meaning Action

Setting parame­ter no.

322 AL Wiring Cylinder A2 Wiring fault in injector wiring

cylinder A2. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.521

323 AL Wiring Cylinder A3 Wiring fault in injector wiring

cylinder A3. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.522

324 AL Wiring Cylinder A4 Wiring fault in injector wiring

cylinder A4. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.523

325 AL Wiring Cylinder A5 Wiring fault in injector wiring

cylinder A5. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.524

326 AL Wiring Cylinder A6 Wiring fault in injector wiring

cylinder A6. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.525

327 AL Wiring Cylinder A7 Wiring fault in injector wiring

cylinder A7. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.526

56 | Troubleshooting | MS15018/03E 2016-02

TIM-ID: 0000008508 - 003

Fault
code no. Full designation Meaning Action

Setting parame­ter no.

328 AL Wiring Cylinder A8 Wiring fault in injector wiring

cylinder A8. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.527

329 AL Wiring Cylinder A9 Wiring fault in injector wiring

cylinder A9. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.528

330 AL Wiring Cylinder A10 Wiring fault in injector wiring

cylinder A10. Result: Misfir­ing (alarm configuration pa­rameter, see PR 2.8008.100
for explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.529

331 AL Wiring Cylinder B1 Wiring fault in injector wiring

cylinder B1. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.530

332 AL Wiring Cylinder B2 Wiring fault in injector wiring

cylinder B2. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.531

333 AL Wiring Cylinder B3 Wiring fault in injector wiring

cylinder B3. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.532

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

334 AL Wiring Cylinder B4 Wiring fault in injector wiring

cylinder B4. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.533

335 AL Wiring Cylinder B5 Wiring fault in injector wiring

cylinder B5. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.534

336 AL Wiring Cylinder B6 Wiring fault in injector wiring

cylinder B6. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004535

337 AL Wiring Cylinder B7 Wiring fault in injector wiring

cylinder B7. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.536

338 AL Wiring Cylinder B8 Wiring fault in injector wiring

cylinder B8. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.537

339 AL Wiring Cylinder B9 Wiring fault in injector wiring

cylinder B9. Result: Misfiring
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004.538

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

340 AL Wiring Cylinder B10 Wiring fault in injector wiring

cylinder B10. Result: Misfir­ing (alarm configuration pa­rameter, see PR 2.8008.100
for explanation).

Check injector wir­ing, rectify injector
solenoid valve short
circuit (positive to
negative) (e.g. by
exchanging injec­tors). Fault rectifica­tion: When engine is
restarted.

1.8004539

341 AL Open Load CylinderA1Disruption fault in injector

wiring to cylinder A1. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.540

342 AL Open Load CylinderA2Disruption fault in injector

wiring cylinder A2. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.541

343 AL Open Load CylinderA3Disruption fault in injector

wiring cylinder A3. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.542

344 AL Open Load CylinderA4Disruption fault in injector

wiring cylinder A4. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.543

345 AL Open Load CylinderA5Disruption fault in injector

wiring cylinder A5. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.544

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

346 AL Open Load CylinderA6Disruption fault in injector

wiring cylinder A6. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.545

347 AL Open Load CylinderA7Disruption fault in injector

wiring cylinder A7. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.546

348 AL Open Load CylinderA8Disruption fault in injector

wiring cylinder A8. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.547

349 AL Open Load CylinderA9Disruption fault in injector

wiring cylinder A9. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.548

350 AL Open Load Cylinder

A10

Disruption fault in injector
wiring cylinder A10. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.549

351 AL Open Load CylinderB1Disruption fault in injector

wiring cylinder B1. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.550

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

352 AL Open Load CylinderB2Disruption fault in injector

wiring cylinder B2. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.551

353 AL Open Load CylinderB3Disruption fault in injector

wiring cylinder B3. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.552

354 AL Open Load CylinderB4Disruption fault in injector

wiring cylinder B4. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.553

355 AL Open Load CylinderB5Disruption fault in injector

wiring cylinder B5. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.554

356 AL Open Load CylinderB6Disruption fault in injector

wiring cylinder B6. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.555

357 AL Open Load CylinderB7Disruption fault in injector

wiring cylinder B7. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.556

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

358 AL Open Load CylinderB8Disruption fault in injector

wiring cylinder B8. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.557

359 AL Open Load CylinderB9Disruption fault in injector

wiring cylinder B9. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.558

360 AL Open Load Cylinder

B10

Disruption fault in injector
wiring cylinder B10. Result:
Misfiring (alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check injector wir­ing, exclude disrup­tion in solenoid
valve (e.g. by injec­tor replacement).
Fault rectification:
After each working
cycle.

1.8004.559

361 AL Power Stage Low Internal electronic fault (elec-

tronics may be defective). If
parameter 1.1020.021 (Pow­er Stage Failure: Stop En­gine) is set, engine is stop­ped here additionally (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

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

1.8004.496

362 AL Power Stage high Internal electronic fault (elec-

tronics may be defective). If
parameter 1.1020.021 (Pow­er Stage Failure: Stop En­gine) is set, engine is stop­ped here additionally (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

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

1.8004.497

363 AL Stop Power Stage Internal electronic fault (elec-

tronics may be defective). If
parameter 1.1020.021 (Pow­er Stage Failure: Stop En­gine) is set, engine is stop­ped here additionally (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

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

1.8004.560

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

365 AL Stop MV-Wiring

Ground

Injector wiring fault. Engine
stop configurable (alarm con­figuration parameter, see PR

2.8008.100 for explanation).
Possible causes: 1. Short cir­cuit of injector positive con­nection to ground of one or
more injectors. 2. Short cir­cuit of injector negative con­nection to ground of one or
more injectors.

Check wiring, re­place wiring harness
as necessary.

1.8004.561

381 AL Wiring TOP 1 Short circuit or wire break at

transistor output 1 plant side
(TOP 1, alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check wiring. 2.8006.638

382 AL Wiring TOP 2 Short circuit or wire break at

transistor output 2 plant side
(TOP 2, alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check wiring. 2.8006.639

383 AL Wiring TOP 3 Short circuit or wire break at

transistor output 3 plant side
(TOP 3, alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check wiring. 2.8006.640

384 AL Wiring TOP 4 Short circuit or wire break at

transistor output 4 plant side
(TOP 4, alarm configuration
parameter, see PR

2.8008.100 for explanation).

Check wiring. 2.8006.641

390 AL MCR exceeded DBR/MCR function: MCR

(maximum continuous rate)
exceeded. Engine power is
limited to admissible continu­ous power (alarm configura­tion parameter, see PR

2.8008.100 for explanation).

None. 1.1085.009

400 AL Open Load Digital

Input 1

Line disruption at digital in­put 1, wiring faulty or no re­sistance via switch, (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Check wiring. 2.8006.625

401 AL Open Load Digital

Input 2

Line disruption at digital in­put 2, wiring faulty or no re­sistance via switch, (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Check wiring. 2.8006.626

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

402 AL Open Load Digital

Input 3

Line disruption at digital in­put 3, wiring faulty or no re­sistance via switch, (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Check wiring. 2.8006627

403 AL Open Load Digital

Input 4

Line disruption at digital in­put 4, wiring faulty or no re­sistance via switch, (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Check wiring. 2.8006.628

404 AL Open Load Digital

Input 5

Line disruption at digital in­put 5, wiring faulty or no re­sistance via switch, (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Check wiring. 2.8006.629

405 AL Open Load Digital

Input 6

Line disruption at digital in­put 6, wiring faulty or no re­sistance via switch, (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Check wiring. 2.8006.630

406 AL Open Load Digital

Input 7

Line disruption at digital in­put 7, wiring faulty or no re­sistance via switch, (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Check wiring. 2.8006.631

407 AL Open Load Digital

Input 8

Line disruption at digital in­put 8, wiring faulty or no re­sistance via switch, (alarm
configuration parameter, see
PR 2.8008.100 for explana­tion).

Check wiring. 2.8006.632

408 AL Open Load Emerg.

Stop Input ESI

Line disruption at input for
emergency stop, wiring faulty
or no resistance via switch

Check wiring. 2.8006.633

410 LO U-PDU Injector voltage too low (limit

value 1, alarm configuration
parameter, see PR

2.8008.100 for explanation).

Execute engine gov­ernor self-test, re­place engine gover­nor in case of fault.

2.0141.921

411 LOLO U-PDU Injector voltage too low (limit

value 2, alarm configuration
parameter, see PR

2.8008.100 for explanation).

Execute engine gov­ernor self-test, re­place engine gover­nor in case of fault.

2.0141.922

412 HI U-PDU Injector voltage too high (lim-

it value 1, alarm configura­tion parameter, see PR

2.8008.100 for explanation).

Execute engine gov­ernor self-test, re­place engine gover­nor in case of fault.

2.0141.931

64 | Troubleshooting | MS15018/03E 2016-02

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

413 HIHI U-PDU Injector voltage too high (lim-

it value 2, alarm configura­tion parameter, see PR

2.8008.100 for explanation).

Execute engine gov­ernor self-test, re­place engine gover­nor in case of fault.

2.0141.932

444 SD U-PDU SD alarm configuration, sen-

sor fault at injector output
stage. Engine governor inter­nal fault. Engine governor re­placement.

Replace engine gov­ernor.

1.8004.578

450 SD Idle/End-Torque In-

put [%]

SD alarm configuration, input
signal for initial/final torque
faulty, short circuit or wiring
damage

Check signal trans­mitter and wiring,
replace as necessa­ry. Fault is rectified
when engine is re­started.

2.8006.592

454 SS Power Reduction

Active

Power reduction activated,
engine operating outside
standard limits. The following
variables may also combine
to lead to this message: In­take depression, exhaust
back pressure, charge-air
coolant temperature, intake
air temperature. Alarm con­figuration parameter, see PR

2.8008.100 for explanation.

None. 2.7000.011

463 SD AUX 2 SD alarm configuration, ana-

log input signal for Aux 2
faulty, short circuit or wiring
damage.

Check signal trans­mitter and wiring,
replace as necessa­ry.

1.8004.591

464 SD P-AUX 1 SD alarm configuration, ana-

log input signal for pressure
Aux 1 faulty, short circuit or
wiring damage.

Check pressure
transmitter and wir­ing, replace as nec­essary.

1.8004.589

468 SD T-AUX 1 Analog input for temperature

Aux 1 faulty, short circuit or
wiring damage

Check signal trans­mitter and wiring,
replace as necessa­ry.

1.8004.579

469 SD AUX 1 SD alarm configuration, ana-

log input signal for Aux 1
faulty, short circuit or wiring
damage.

Check signal trans­mitter and wiring,
replace as necessa­ry.

1.8004.590

470 SD T-ECU Engine governor defective. Replace engine gov-

ernor at next oppor­tunity.

1.8004.587

471 SD Coil Current SD alarm configuration, HP

fuel control block activation,
short circuit or wiring dam­age.

Check sensor and
wiring, replace as
necessary. Fault is
rectified when en­gine is restarted.

1.8004.592

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Fault
code no. Full designation Meaning Action

Setting parame­ter no.

472 AL Stop SD Engine stop as shutdown

channels have "sensor fault"
(alarm configuration parame­ter, see PR 2.8008.100 for
explanation).

Contact Service. 2.8006.593

474 AL Wiring FO Line break or short circuit at

channel FO (alarm configura­tion parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.8006.655

475 AL CR Trigger Engine

Stop

Tripped by crash recorder
triggering due to engine shut­down.

Replace engine gov­ernor at next oppor­tunity.

1.8010.009

476 AL Crash Rec. Init. Er-

ror

Initialization error of crash re­corder.

Contact Service. 1.8010.007

478 AL Comb. Alarm Yel

(Plant)

YELLOW combined alarm
from plant (alarm configura­tion parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.8006.001

479 AL Comb. Alarm Red

(Plant)

RED combined alarm from
plant (alarm configuration pa­rameter, see PR 2.8008.100
for explanation).

Contact Service. 2.8006.002

480 AL Ext. Engine Protec-

tion

External engine protection
function active (alarm config­uration parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.0291.921

555 AL Call MTU Field Serv-

ice

Power reduction caused by
maintenance function (main­tenance concept, alarm con­figuration parameter, see PR

2.8008.100 for explanation).

Contact Service. 2.0555.001

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7.2 Troubleshooting

Engine does not turn when starter is actuated

Cause Corrective action

Battery flat or faulty. u Charge or replace battery (see manufacturer's documentation).

Cable connections on battery are
faulty.

u Check if cable connections are properly secured (see

manufacturer's documentation).

Engine wiring or starter faulty. u Check if cable connections are properly secured, contact Service.

Engine wiring is faulty. u Check (→ Page 139).

Loose plug connections at
engine/generator control system.

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

Loose plug connection are loose
at engine governor.

u Check plug connections (→ Page 141).

Engine blocked (cannot be rotated
by hand).

u Contact Service.

Engine turns but does not fire

Cause Corrective action

Poor rotation by starter: Battery
flat or faulty.

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

Engine wiring is faulty. u Check (→ Page 139).

Air in fuel system u Vent fuel system (→ Page 100).

Engine governor is faulty. u Contact Service.

Engine fires unevenly

Cause Corrective action

Injector is faulty. u Replace (→ Page 88).

Injection pump is faulty. u Replace (→ Page 85).

Engine wiring is faulty. u Check (→ Page 139).

Air in fuel system u Vent fuel system (→ Page 100).

Engine governor is faulty. u Contact Service.

Engine does not reach rated speed

Cause Corrective action

Fuel prefilter clogged. u Replace filter element (→ Page 109).

Easy-change fuel filter clogged. u Replace (→ Page 102).

Air filter clogged. u Check signal ring position of contamination indicator (→ Page 114).

Injector is faulty. u Replace (→ Page 88).

Injection pump is faulty. u Replace (→ Page 85).

Engine wiring is faulty. u Check (→ Page 139).

Overload. u Contact Service.

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Engine speed not steady

Cause Corrective action

Injector is faulty. u Replace (→ Page 88).

Injection pump is faulty. u Replace (→ Page 84).

Speed sensor is faulty. u Contact Service.

Air in fuel system u Vent fuel system (→ Page 100).

Engine governor is faulty. u Contact Service.

Charge-air temperature too high.

Cause Corrective action

Incorrect engine coolant
concentration.

u Check (MTU test kit).

Charge-air cooler is contaminated. u Contact Service.

Air inlet temperature in engine
room is too high.

u Check fans and air supply / ventilation ducts.

Charge-air pressure too low

Cause Corrective action

Air filter clogged. u Check signal ring position of contamination indicator (→ Page 114).

Charge-air cooler is contaminated. u Contact Service.

Exhaust turbocharger is faulty. u Contact Service.

Coolant leaks at intercooler

Cause Corrective action

Major coolant discharge at
charge-air cooler. Charge-air
cooler leaky.

u Contact Service.

Black exhaust gas

Cause Corrective action

Air filter clogged. u Check signal ring position of contamination indicator (→ Page 114).

Injector is faulty. u Replace (→ Page 88).

Injection pump is faulty. u Replace (→ Page 84).

Overload. u Contact Service.

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Blue exhaust gas

Cause Corrective action

Too much engine oil in the engine u Drain engine oil (→ Page 117).

Oil separator of crankcase
breather contaminated.

u Replace (→ Page 78).

Exhaust turbocharger is faulty. u Contact Service.

Cylinder head is faulty. u Contact Service.

Piston rings are faulty. u Contact Service.

Cylinder liner is faulty. u Contact Service.

White exhaust gas

Cause Corrective action

Engine is not at operating
temperature.

u Run engine to reach operating temperature.

Water in fuel u Check fuel system at fuel prefilter.

Drain water from fuel prefilter (→ Page 104).

Charge-air cooler leaky. u Contact Service.

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8 Task Description

8.1 Engine

8.1.1 Engine – Barring manually

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Barring device for 12V engines

F6558556 1

Barring device for 16V, 18V engines

F6558557 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.

Engine – Barring manually

1. Remove access cover from flywheel housing.

2. Install barring device (arrow) on flywheel
housing.

3. 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 com-

pression resistance, contact Service.

4. For barring device removal, follow reverse se­quence of working steps.

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8.1.2 Engine – Barring with starting system

Preconditions

☑ External pushbutton 'Bar engine without starting' is provided.

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.

Engine – Barring with starting system

1. Press pushbutton 'Bar engine without starting' and keep depressed.

2. Let the crankshaft rotate until oil pressure is indicated, but not longer than 10 seconds.

3. Repeat procedure after approx. 20 seconds if necessary.

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8.1.3 Engine – Test run

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.

Engine – Test run

1. Start engine (→ Page 35).

2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.

3. Carry out operational checks (→ Page 37).

4. Stop engine (→ Page 38).

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8.2 Cylinder Liner

8.2.1 Cylinder liner – Endoscopic examination

Preconditions

☑ Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Rigid endoscope

Y20097353 1

Preparatory steps

1. Remove cylinder head cover (→ Page 83).

2. Remove injector (→ Page 89).

Positioning crankshaft at BDC

1. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC.

2. Insert endoscope into cylinder liner through injector seat.

Cylinder liner – Endoscopic examination

Findings Task

• Thin carbon coating around circumference of carbon scraper ring

• Slight localized additive deposits at top edge

• Localized smooth areas at bottom edge

• Carbon deposits around circumference between top piston ring and
bottom edge of carbon scraper ring

• First signs of marks left by top piston ring

• Bright mark around circumference

• Faultless, even honing pattern

• First signs of marks left by lower cooling bores

• Running pattern seems darker

No action required.

• Darker areas of even or varying color intensity

• Beginning and end of the discoloration are not sharply defined and do
not cover the entire stroke area

• Dark areas in the upper section of the cooling bore, remaining circum­ference cannot be faulted

• Piston rings faultless

Further endoscopic examina­tion required as part of mainte­nance work.

• On the entire circumference not only bright discoloration (not critical
for operation) clearly visible darker stripes that begin at the top piston
ring

• Heat discoloration in the direction of stroke and honing pattern dam­age

• Heat discoloration of piston rings

Cylinder liner must be replaced,
contact Service.

1. Compile endoscopy report using the table.

2. Use technical terms for description of the liner surface (→ Page 75).

3. Depending on findings:

• Do not take any action or

• Carry out further endoscopic examination as part of maintenance work or

• Contact Service; cylinder liner must be replaced.

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Final steps

1. Install injector (→ Page 89).

2. Install cylinder head cover (→ Page 83).

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8.2.2 Instructions and comments on endoscopic and visual examination of cylinder
liners

Terms used for endoscopic examination

Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina­tion report.

Findings Explanations/Action

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

particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.

Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area

and cross through the hone pattern in the direction of stroke.
Findings not critical.

Scored area These areas consist of scores of different length and depth next to one another. In

most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Findings not critical.

Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern

is still visible. Smoothened areas appear brighter and more brilliant than the sur­rounding running surface.
Findings not critical.

Bright area Bright areas are on the running surface and show local removal of the honing pat-

tern. Grooves from honing process are not visible any more.

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-

ture differences around the liner. It appears rather darker within the honed struc­ture in contrast to the bright metallic running surface. The honing pattern is undis­turbed. Discolorations extend in stroke direction and may be interrupted.
Findings not critical.

Corrosion fields /
spots

Corrosion fields / spots result from water (condensed water) with the valves in the
overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.

Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-

oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.

Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run

over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be­coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re­placed.

Seizure marks, scuff­ing

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

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Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough inves­tigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnec­essary disassembly work, it is recommended that another inspection be carried out after further operation of
the engine.

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8.3 Crankcase Breather

8.3.1 Crankcase breather – Wire mesh cleaning

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Cleaner

Diesel fuel

Petroleum jelly

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.

NOTICE

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

Damage to components is possible!

• Observe manufacturer's instructions.

Crankcase breather – Wire
mesh cleaning

1. Remove hose.

2. Loosen clamp (5).

3. Remove oil separator cover (7).

4. Remove individual parts from cover (7).

5. Wash filter element (wire mesh) (3) with die­sel fuel.

6. Blow out filter element (wire mesh) (3) with
compressed air.

7. Clean remaining components with cleaner.

8. Remove cleaner.

9. Coat sealing ring (6) with petroleum jelly and
insert in groove in cover (7).

10. Insert both retainers (2, 4) and filter element
(wire mesh) (3) into the cover (7), ensuring
correct installation sequence.

11. Install cover (7) with clamp (5) on cylinder
head cover (1).

12. Install hose, ensuring that it is not subjected
to tension.

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8.3.2 Crankcase breather – Oil separator replacement, diaphragm check and
replacement

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 adapter

F30027340 1

Engine oil

Filter element

(→ Spare Parts Catalog)

Diaphragms

(→ Spare Parts Catalog)

Gasket

(→ Spare Parts Catalog)

WARNING

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

Risk of injury and poisoning!

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

• Avoid contact with skin.

• Do not inhale oil vapor.

Replacing oil separator filter el­ement

1. Remove cover (2) with O-ring (3).

2. Remove filter element (1) from housing (4).

3. Insert new filter element in housing (4).

4. Install cover (2) with new O-ring.

5. Use torque wrench to tighten the screws of cover (2) to the specified torque.

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 10 Nm −2 Nm

6. Replace further oil separator elements in the same way.

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Checking diaphragm

1. Remove cover (4).

2. Remove spring (5), gasket (2) and dia­phragm (3).

3. Check diaphragm (3) for damage, fit new dia­phragm if used one is damaged.

4. Install diaphragm (3) on housing (1).

5. Install new gasket (2) and spring (5) together
with cover (4).

6. Use torque wrench to tighten the screws of cover (4) to the specified torque.

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 10 Nm −2 Nm

7. Check diaphragm in other oil separators in the same manner.

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8.4 Valve Drive

8.4.1 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 gage

Y4342013 1

Torque wrench, 20–100 Nm

F30026582 1

Ratchet adapter

F30027340 1

Engine oil

Preparatory steps

1. Remove cylinder head cover (→ Page 83).

2. Install barring tool (→ Page 70).

3. Bar crankshaft with barring tool in engine di­rection of rotation until TDC pointer and TDC
mark on the flywheel are aligned.

Checking valve clearance at two crankshaft positions

1. Check TDC position of piston in cylinder A1:

• The piston is at firing TDC when the rocker arms at cylinder A1 are unloaded.

• The piston is at overlap TDC when the rocker arms at cylinder A1 are loaded.

2. Check valve clearance with cold engine:

• Inlet = 0.4 mm;

• Exhaust = 0.6 mm.

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3. Check clearance of all valves at two crankshaft positions (firing TDC and overlap TDC at cylinder A1) in ac­cordance with the table:

Position Cylinder 1 2 3 4 5 6 7 8 9 10

12V

Firing TDC at cylinder A1 Side A I X I – – X I – – X – –

Side B – X I X I – – X – – I –

Overlap TDC at cylinder A1 Side A – – – X I – – X I – I X

Side B I – – – – X I – I X – X

16V

Firing TDC at cylinder A1 Side A I X – X – X I – – X I – – – – –

Side B I – – X – – I – I X I – I X – X

Overlap TDC at cylinder A1 Side A – – I – I – – X I – – X I X I X

Side B – X I – I X – X – – – X – – I –

18V

Firing TDC at cylinder A1 Side A I X I – I X I – – X I – – X – – – –

Side B – X – X – – – X – – I X I – I X I –

Overlap TDC at cylinder A1 Side A – – – X – – – X I – – X I – I X I X

Side B I – I – I X I – I X – – – X – – – X

I

Inlet: Inlet valve adjustment admissible

X

Exhaust: Exhaust valve adjustment admissible

–

Valve adjustment not admissible

Table 2: Valve clearance settings

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

5. Adjust valve clearance if the deviation from the desired value exceeds 0.1 mm.

Adjusting valve clearance

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

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

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

4. Tighten locknut (1) to specified torque using a torque wrench while holding adjusting screw (2) firmly with a
screwdriver.

Name Size Type Lubricant Value/Standard

Locknut M12 x 1 Tightening torque (Engine oil) 50 Nm

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

Result: Adjust valve clearance if this is not the case.

Final steps

1. Remove barring tool (→ Page 70).

2. Install cylinder head cover (→ Page 83).

3. Install cap.

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8.4.2 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 adapter

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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8.5 Injection Pump / HP Pump

8.5.1 Injection pump – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Injection pump

(→ Spare Parts Catalog)

Injection pump – Replacement

u Remove injection pump and install new one (→ Page 85).

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8.5.2 Injection pump – Removal and installation

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

Crowfoot wrench, 19 mm

F30027424 1

Crowfoot box wrench, 22 mm

F30027425 1

Torque wrench, 0.5–5 Nm

0015384230 1

Assembly compound (Kluthe Hakuform 30-15)

X00067260 1

Engine oil

Sealing ring

(→ Spare Parts Catalog)

Sealing ring

(→ 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!

• Before cranking the engine with starter system, make sure that there are no persons in 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.

Preparatory steps

1. Close fuel supply line upstream of fuel filter.

2. Drain fuel (→ Page 97).

3. Remove engine governor as necessary (→ Page 142).

4. Remove charge-air manifolds and remove gaskets (only on engines with air-to-air charge-air cooling).

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Removing injection pump

1. Mark installation position of injection pump.

2. Disconnect cabling (1) from injection pump.

3. Disconnect fuel line (2).

4. Unscrew securing screws of injection pump
by approx. 6 mm.

Result: The preloaded compression spring presses

the injection pump out of the crankcase. If
not:

• Turn crankshaft with barring tool

(→ Page 70).
Pump cam of camshaft presses the injec­tion pump out of the crankcase. If not:

• Carefully press out injection pump at the

recess in the injection pump head.

5. Remove injection pump securing screws.

6. Remove injection pump.

7. Remove sealing rings from injection pump.

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

Installing injection pump

1. Remove all blanking plugs and covers.

2. Clean mating face of injection pump and roll­er.

Note: Sealing ring (1) Ø47 mm

3. Coat sealing ring (1) with assembly com­pound and fit onto injection pump.

Note: Sealing ring (2) Ø45 mm

4. Coat sealing ring (2) with assembly com­pound and fit onto injection pump.

5. Coat roller (arrowed) with engine oil.

6. Clean sealing face and fuel bores in crank­case.

7. Using barring tool (→ Page 70), set pump cam
on camshaft to base circle.

8. Install injection pump, observing marked in­stallation position.

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9. Install injection pump securing screws and tighten to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard

Screw M10 Tightening torque (Engine oil) 60 Nm +12 Nm

10. Coat the mating face between union nut and fuel line, ball seal and thread on both ends of the fuel line (3)
with engine oil.

11. Install fuel line (3).

Note: Observe the lettering on the union nuts (2) and 4).

12. Tighten union nuts (2) and (4) marked with “35 +3 Nm” (see arrow) to specified torque using a torque
wrench.

Name Size Type Lubricant Value/Standard

Union nut M14 Tightening torque (Engine oil) 35 Nm +3 Nm

13. Tighten union nuts (2) and (4) marked with “30 +3 Nm” (see arrow) to specified torque using a torque
wrench.

Name Size Type Lubricant Value/Standard

Union nut M14 Tightening torque (Engine oil) 30 Nm +3 Nm

14. Install injection pump cabling (1).

15. Tighten screws to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 1.5 Nm ±0.2 Nm

Final steps

1. Remove barring tool (→ Page 70).

2. Clean mating faces on cylinder head and charge-air manifold.

3. Check gaskets for damage and replace as necessary.

4. Coat gaskets with assembly compound and place onto cylinder head.

5. Install charge-air pipes.

6. Install engine governor (→ Page 142).

7. Open fuel supply line.

8. Vent fuel system (→ Page 100).

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8.6 Injection Valve / Injector

8.6.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Injector

(→ Spare Parts Catalog)

Replacing injector

u Remove injector and install new injector (→ Page 89).

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8.6.2 Injector – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Barring tool

F6557929 1

Puller

3555890163/00 1

Fuel suction device

F30378207 1

Torque wrench, 20–100 Nm

F30026582 1

Ratchet adapter

F30027340 1

Adapter

F30006234 1

Open-end socket wrench, 19 mm

F30025897 1

Crowfoot wrench, 19 mm

F30027424 1

Crowfoot box wrench, 22 mm

F30027425 1

Double-head box wrench

F30011450 1

Assembly compound (Kluthe Hakuform 30-15)

X00067260 1

Engine oil

Sealing ring

(→ Spare Parts Catalog)

Sealing ring

(→ Spare Parts Catalog)

Sealing

(→ 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. Close fuel supply line before fuel filter.

2. Drain fuel (→ Page 97).

3. Remove engine governor as necessary (→ Page 142).

4. Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).

5. Remove cylinder head cover (→ Page 83).

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Removing injector

1. Disconnect leak-off fuel line from cylinder
head.

2. Disconnect fuel line (1).

3. Remove thrust screw (2).

4. Pull off pressure pipe neck (3).

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

6. Remove sealing ring from pressure pipe
neck (3).

7. Remove screw (1).

8. Take off clamp (2).

9. Screw puller into injector.

10. Remove injector with puller.

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11. Remove sealing rings (1) and (2) of injec­tor (3) with a self-made hook.

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

13. Remove sealing cap from cylinder head with
screwdriver.

14. Remove sealing ring.

Installing injector

1. Remove all covers before installation.

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

3. Coat sealing ring with grease and insert in
groove of sealing cap.

4. Insert sealing cap in bore.

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5. Use engine barring device to turn engine sev­eral times to blow out remaining fuel.

6. Fit sealing ring (2) with assembly compound
on to injector (3).

7. Coat sealing ring (1) with assembly com­pound to secure it on injector (3).

8. Press injector (3) into cylinder head by hand.

Result: • The pin is at 11-o'clock position to the

transversal axis of the engine.

9. Install clamp (2) with screw (3) in correct po­sition.

Result: • The pin (1) on the injector is engaged in

the groove of the clamp (2).

• Forked clamp end (2) is engaged in the

cover recess.

10. Tighten screw (3) of the clamp by hand.

Result: Injector can still be turned.

11. Blow out fuel line (2) and pressure pipe
neck (5) with compressed air.

12. Coat sealing ring with assembly compound
and fit onto pressure pipe neck (5).

13. Coat the taper of the pressure pipe neck (5)
with engine oil.

14. Insert pressure pipe neck (5) into cylinder
head until the sealing ring is in contact with
cylinder head.

15. Fully press in pressure pipe neck (5) by hand.

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16. Tighten thrust screw (4) with torque wrench to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Thrust screw M22 x 1.5 Tightening torque (Engine oil) 45 Nm ±2.5 Nm

17. Loosen thrust screw (4) and tighten it again with torque wrench to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Thrust screw M22 x 1.5 Tightening torque (Engine oil) 45 Nm ±2.5 Nm

18. Use torque wrench to tighten screw for clamp at injector to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Screw M10 Tightening torque (Engine oil) 50 Nm

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

20. Connect fuel line (2) to injection pump and pressure pipe neck (5).

21. Tighten union nut (1) on injection pump hand-tight.

22. Tighten union nut (3) on pressure pipe neck (5) hand-tight.

Note: Observe the lettering on the union nuts (1) and 3).

23. Tighten union nuts (1) and (3) marked with “35 +3 Nm” (see arrows) to specified torque using a torque
wrench.

Name Size Type Lubricant Value/Standard

Union nut M14 Tightening torque (Engine oil) 35 Nm +3 Nm

24. Tighten union nuts (1) and (3) marked with “30 +3 Nm” (see arrows) to specified torque using a torque
wrench.

Name Size Type Lubricant Value/Standard

Union nut M14 Tightening torque (Engine oil) 30 Nm +3 Nm

25. Connect leak-off fuel line to cylinder head.

Final steps

1. Install cylinder head cover (→ Page 83).

2. Clean mating faces on cylinder head and charge-air manifold.

3. Check gaskets for damage and replace them, if required.

4. Coat gaskets with assembly compound and place onto cylinder head.

5. Install charge-air pipes.

6. Install engine governor (→ Page 142).

7. Open fuel supply line.

8. Vent fuel system (→ Page 100).

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8.7 Fuel System

8.7.1 Fuel injection line – 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

Open-end socket wrench, 19 mm

F30025897 1

Crowfoot wrench, 19 mm

F30027424 1

Crowfoot box wrench, 22 mm

F30027425 1

Double-head box wrench

F30011450 1

Assembly compound (Kluthe Hakuform 30-15)

X00067260 1

Engine oil

Pressure pipe tube

(→ Spare Parts Catalog)

Sealing

(→ 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. Close fuel supply line upstream of fuel filter.

2. Drain fuel (→ Page 97).

3. Remove engine governor as necessary (→ Page 142).

4. Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).

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Replacing pressure pipe neck

1. Disconnect fuel line (2).

2. Blow out fuel line (2) with compressed air.

3. Remove thrust screw (4).

4. Withdraw pressure pipe neck (5).

5. Coat sealing ring with grease and fit on new
pressure pipe neck (5).

6. Coat the tape of the pressure pipe neck (5)
with engine oil.

7. Insert pressure pipe neck (5) into cylinder
head until the sealing ring is in contact with
cylinder head.

8. Fully press in pressure pipe neck (5) by hand.

9. Tighten thrust screw (4) with torque wrench to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Thrust screw M22 x 1.5 Tightening torque (Engine oil) 45 Nm ±2.5 Nm

10. Loosen thrust screw (4) and tighten it again with torque wrench to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Thrust screw M22 x 1.5 Tightening torque (Engine oil) 45 Nm ±2.5 Nm

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

12. Connect fuel line (2) to injection pump and pressure pipe neck (5).

13. Tighten union nut (1) on injection pump hand-tight.

14. Tighten union nut (3) on pressure pipe neck (5) hand-tight.

Note: Observe the tightening torque according to the lettering on the union nuts (1) and 3).

15. Tighten union nuts (1) marked with "35 +3 Nm" (see arrows) with torque wrench to the specified tightening
torque.

Name Size Type Lubricant Value/Standard

Union nut M14 Tightening torque (Engine oil) 35 Nm +3 Nm

16. Tighten union nuts (1) marked with "30 +3 Nm" (see arrows) with torque wrench to the specified tightening
torque.

Name Size Type Lubricant Value/Standard

Union nut M14 Tightening torque (Engine oil) 30 Nm +3 Nm

17. Tighten union nuts (3) marked with "35 +3 Nm" (see arrows) with torque wrench to the specified tightening
torque.

Name Size Type Lubricant Value/Standard

Union nut M14 Tightening torque (Engine oil) 35 Nm +3 Nm

18. Tighten union nuts (3) marked with "30 +3 Nm" (see arrows) with torque wrench to the specified tightening
torque.

Name Size Type Lubricant Value/Standard

Union nut M14 Tightening torque (Engine oil) 30 Nm +3 Nm

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Final steps

1. Clean mating faces on cylinder head and charge-air manifold.

2. Check gaskets for damage and replace them, if required.

3. Coat gaskets with grease and place onto cylinder head.

4. Install charge-air pipes.

5. Install engine governor (→ Page 142).

6. Open fuel supply line.

7. Vent fuel system (→ Page 100).

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8.7.2 Fuel – Draining

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 8–40 Nm

F30043446 1

Plug-in open-end wrench, 17 mm

F30028341 1

Engine oil

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.

Draining fuel

1. Loosen nut (arrowed) on banjo union.

2. Disconnect fuel line on non-return valve (ar­rowed).

3. Remove non-return valve and collect emerg­ing fuel in a suitable container.

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4. When fuel no longer emerges, install non-return valve and tighten to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard

Non-return valve Tightening torque (Engine oil) 10 Nm +1 Nm

5. Install fuel line.

6. Tighten nut on banjo union.

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8.7.3 Fuel pressure relief valve – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Pressure relief valve

(→ Spare Parts Catalog)

Sealing ring

(→ Spare Parts Catalog)

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.

Removing and installing pres­sure relief valve

1. Close fuel supply.

2. Remove fuel line (6).

3. Remove banjo screws (1) and (4).

4. Remove sealing rings (2) and (5).

5. Remove screws (9) with washer (8).

6. Remove screws (7) and take off holder.

7. Install new pressure relief valve (3) with new
sealing rings (2) and (5) in reverse order.

8. Open fuel inlet.

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8.7.4 Fuel system – Venting

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Engine oil

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.

Venting fuel system

1. Unlock fuel priming pump, unscrew handle.

2. Loosen nut (arrowed) on banjo union.

3. Operate the pump with the handle until bub­ble-free fuel emerges.

4. Tighten nut on banjo union.

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