MTU 12 V 2000 P12, 16 V 2000 P12 Operating Instructions Manual

Operating Instructions

Diesel engine
12 V 2000 P12
16 V 2000 P12

MS150025/02E

Printed in Germany

© 2012 Copyright MTU Friedrichshafen GmbH

This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.

This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.

Subject to alterations and amendments.

Table of Contents

1 Safety

1.1 Important provisions for all MTU engines or
systems 5

1.2 Personnel and organizational requirements 6

1.3 Transport 7

1.4 Safety regulations for maintenance and
repair work 8

1.5 Fire prevention and environmental
protection, auxiliary materials, fluids and
lubricants 11

1.6 Standards for safety messages in the text 13

1.7 ATEX precautions (if applicable) 14

2 General Information

2.1 Engine side and cylinder designations 15

2.2 Engine layout 16

2.3 Use 18

2.4 ECS-5 – Use of devices 25

2.5 MDEC – Functions 28

2.6 Peripheral Interface Modules (PIMs) 33

2.7 Printed circuit board SCB 3 35

3 Technical Data

3.1 12/16 V 2000 P12 engine data 38

3.2 Firing order 41

3.3 Engine – Main dimensions 42

3.4 SAM 43

3.5 SCB 3 – Technical data 47

4 Operation

4.1 LOP – Controls 48

4.2 Putting the engine into operation after
extended out-of-service-periods (>3
months) 50

4.3 Putting the engine into operation after
scheduled out-of-service-period 51

4.4 Start engine in manual mode (testing
mode) 52

4.5 Safety system – Override 53

4.6 Operational checks 54

4.7 Stop engine in manual mode (testing
mode) 55

4.8 Emergency stop 56

4.9 After stopping the engine – Engine remains
ready for operation 57

4.10 After stopping the engine – putting the
engine out of service 58

4.11 Plant cleaning 59

5 Maintenance

5.1 Maintenance task reference table [QL1] 60

6 Troubleshooting

6.1 Troubleshooting 61

6.2 Fault indication on printed circuit board
SAM 64

6.3 ECU alarms 73

7 Task Description

7.1 Engine 84

7.1.1 Engine – Barring manually 84

7.1.2 Engine – Barring with starting system 85

7.1.3 Engine – Test run 86

7.2 Cylinder Liner 87

7.2.1 Cylinder liner – Endoscopic examination 87

7.2.2 Instructions and comments on endoscopic
and visual examination of cylinder liners 89

7.3 Crankcase Breather 91

7.3.1 Crankcase breather – Wire mesh cleaning 91

7.3.2 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 93

7.4 Valve Drive 95

7.4.1 Valve clearance – Check and adjustment 95

7.4.2 Cylinder head cover – Removal and
installation 97

7.5 Injection Pump / HP Pump 98

7.5.1 Injection pump – Replacement 98

7.5.2 Injection pump – Removal and installation 99

7.6 Injection Valve / Injector 102

7.6.1 Injector – Replacement 102

7.6.2 Injector – Removal and installation 103

7.7 Fuel System 106

7.7.1 Fuel pressure relief valve – Replacement 106

7.7.2 Fuel – Draining 108

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7.7.3 Fuel system – Venting 109

7.8 Fuel Filter 110

7.8.1 Fuel filter – Replacement 110

7.8.2 Fuel prefilter cleaning 112

7.8.3 Fuel prefilter – Differential pressure gauge
check and adjustment 113

7.8.4 Fuel prefilter – Draining 114

7.8.5 Fuel prefilter – Flushing 115

7.8.6 Fuel prefilter – Filter element replacement 117

7.9 Charge-Air Cooling General, Left-Hand
Side 119

7.9.1 Intercooler – Checking condensate drains for
coolant discharge and obstructions 119

7.10 Air Filter 120

7.10.1 Air filter – Replacement 120

7.11 Air Intake 121

7.11.1 Service indicator – Signal ring position check 121

7.12 Starting Equipment 122

7.12.1 Starter – Condition check 122

7.13 Lube Oil System, Lube Oil Circuit 123

7.13.1 Engine oil – Level check 123

7.13.2 Engine oil – Change 124

7.14 Oil Filtration / Cooling 125

7.14.1 Engine oil filter – Replacement 125

7.15 Coolant Circuit, General, High­Temperature Circuit 127

7.15.1 Drain and venting points 127

7.15.2 Engine coolant – Level check 131

7.15.3 Engine coolant – Change 132

7.15.4 Engine coolant – Draining 133

7.15.5 Engine coolant – Filling 134

7.15.6 Coolant pump – Relief bore check 136

7.16 Low-Temperature Circuit 137

7.16.1 Charge-air coolant – Filling 137

7.16.2 Charge-air coolant – Draining 139

7.16.3 Charge-air coolant – Change 140

7.16.4 Charge-air coolant – Level check 141

7.17 Belt Drive 142

7.17.1 Drive belt – Condition check 142

7.18 Engine Mounting / Support 143

7.18.1 Engine mounts – Resilient elements check 143

7.19 Wiring (General) for Engine/Gearbox/Unit 144

7.19.1 Engine wiring – Check 144

7.20 Accessories for (Electronic) Engine
Governor / Control System 145

7.20.1 Engine governor and connectors – Cleaning 145

7.20.2 Engine monitoring unit and connectors –
Cleaning 146

7.20.3 Checking engine control unit plug connections 147

7.20.4 Engine monitoring unit – Plug connection
check 148

7.20.5 Engine control unit – Removal and installation 149

7.21 Emergency Instrumentation (Local
Operating Panel) 151

7.21.1 LOP – Visual inspection 151

7.21.2 LOP – Test procedures 154

8 Engine Governor Assignment and Circuitry

8.1 Engine Governor 156

8.1.1 Engine governor channel circuitry 156

8.1.2 MDEC governor assignment 165

8.2 Connector Assignment 167

8.2.1 Connector pin assignment 167

9 Appendix A

9.1 Abbreviations 176

9.2 MTU contact persons/service partners 179

10 Appendix B

10.1 Special Tools 180

10.2 Index 186

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1 Safety

1.1 Important provisions for all MTU engines or systems

Nameplate

Engine identification is provided by the engine serial number on the nameplate.

The nameplate is located on the engine.

General information

This engine or plant may present a risk of injury or damage in the following cases:

• Incorrect use

• Operation, maintenance and repair by unqualified personnel

• Modifications or conversions

• Noncompliance with the safety instructions

Correct use

The engine or plant is intended solely for use in accordance with contractual agreements and the pur‐
pose envisaged for it on delivery.

This means that the equipment must be operated:

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

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

• With spare parts approved by MTU in accordance with the associated (→ Spare Parts Catalog)

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

• In compliance with all safety instructions and in adherence to all warning notices in these Operating
Instructions

• In compliance with the maintenance and repair instructions contained in these Operating Instructions,
in particular with regard to the specified tightening torques

• Appointing only qualified personnel to carry out work related to initial startup, operation, maintenance
and repair

• Contracting only workshops authorized by MTU to carry out repair and overhaul

Any other use is considered improper use and increases the risk of personnel injury or material damage
in engine/plant operation.MTU will accept no liability for such damage.

Modifications or conversions

Unauthorized modifications to the engine or plant represent a safety risk.

MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.

Spare parts

Only genuine MTU spare parts must be used to replace components or assemblies.

MTU will accept no liability or warranty claims for any damage caused by the use of other spare parts.

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1.2 Personnel and organizational requirements

Organizational measures of the operator

This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.

Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair
and transport personnel at all times.

Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on
explaining safety-relevant instructions.

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

For the identification and layout of the spare parts during maintenance or repair work, take photos or use
the spare parts catalog.

Personnel requirements

All work on the engine or plant shall be carried out by trained and qualified personnel only:

• Training at the MTU Training Center

• Qualified personnel specialized in mechanical and plant engineering

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

Working clothes and protective equipment

Wear proper protective clothing for all work.

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1.3 Transport

Transport

Lift the engine only with the lifting eyes provided.

Use only the transport and lifting equipment approved by MTU.

Take note of the engine center of gravity.

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

In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans‐
port pallet or transport with equipment for heavy loads (forklift truck).

Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and
engine mounts.

Secure the engine against tilting during transportation. The engine must be especially secured against
slipping or tilting when going up or down inclines and ramps.

Setting the engine down after transport

Place the engine only on an even, firm surface.

Ensure appropriate consistency and load-bearing capacity of the ground or support surface.

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

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1.4 Safety regulations for maintenance and repair work

Safety regulations prior to maintenance and repair work

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

Allow the engine or plant to cool down to less than 50°C before starting maintenance work (risk of explo‐
sion of oil vapors, fluids and lubricants, risk of burning).

Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use
suitable containers of adequate capacity to catch fluids and lubricants.

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

Never carry out maintenance and repair work with the engine running.

Carry out function checks on a running engine only if expressly permitted to do so.

Secure the engine or plant against accidental starting.

Disconnect the battery. Lock 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 engine or plant.

The following additional instructions apply to starters with beryllium copper pinion:

• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.

Safety regulations during maintenance and repair work

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

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

Use only proper and, if applicable, calibrated tools. Observe the specified tightening torques during as‐
sembly/disassembly.

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

Never use lines for climbing.

Keep fuel injection lines and connections clean.

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

Take care not to damage lines, in particular fuel lines, during maintenance and repair work.

Ensure that all retainers and dampers are installed correctly.

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

Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.

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

When working high on the equipment, always use suitable ladders and work platforms. Make sure com‐
ponents are placed on stable surfaces.

Observe special cleanness when conducting maintenance and repair work on the engine or plant. After
completion of maintenance and repair work, make sure that no loose objects are in/on the assembly or
plant (e.g. cloths and cable ties)

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Safety regulations after completion of maintenance and repair work

Before barring the engine, make sure that nobody is standing in the danger zone of the engine or plant.

Check that all guards have been reinstalled and that all tools and loose parts have been removed after
working on the engine or plant (in particular, the barring tool).

Welding work

Never carry out welding work on the assembly or plant, or attached units. Cover the engine or plant when
welding in its vicinity.

Before starting welding work:

• Switch off the power supply master switch.

• Disconnect the battery.

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

No other maintenance or repair work must be carried out in the vicinity of the engine or plant while weld‐
ing is going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.

Do not use the engine or plant as ground terminal.

Do not route the welding lead over or near the wiring harnesses of the engine or plant. The welding cur‐
rent may otherwise induce an interference voltage in the wiring harnesses which could conceivably dam‐
age the electrical system.

Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.

Hydraulic installation and removal

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

Observe the max. permissible push-on pressure specified for the equipment.

Do not attempt to bend or apply force to lines.

Before starting work, pay attention to the following:

• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).

• For hydraulic installation, screw on the tool with the piston retracted.

• For hydraulic removal, screw on the tool with the piston extended.

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

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

Working on electrical 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 reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.

Do not secure cables on lines carrying fluids.

Do not use cable binders to secure cables.

Always use connector pliers to tighten connectors.

Subject the device or system to a function check on completion of all repair work. In particular, check the
function of the engine emergency stop feature.

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Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.

Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.

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

For conducting light-beam procedures and measurement work, only the following laser devices must be
used:

• Laser devices of classes 1, 2 or 3A.

• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.

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

Fire prevention

Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires –
therefore always keep the engine or plant in a clean condition. Do not leave cloths soaked with fluids and
lubricants on the engine or plant. Do not store combustible materials near the engine or plant.

Do not weld pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid.

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

Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their
use.

Noise

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

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

Environmental protection and disposal

Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐
lent components. Noncompliance with these guidelines will lead to forfeiture of the operating permit is‐
sued by the emission monitoring authorities. MTU does not accept any liability for violations of the emis‐
sion regulations. The Maintenance Schedules of MTU must be observed over the entire life cycle of the
engine or plant.

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

Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are
subjected to proper recycling procedures.

Auxiliary materials, fluids and lubricants

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using
them, make sure you have the latest version. The latest version is also available at: http://www.mtu-on‐
line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.

Auxiliary materials, fluids and lubricants might be hazardous goods or toxic substances.When using flu‐
ids, lubricants and other chemical substances, follow the safety instructions that apply to the product.
Take special care when using hot, chilled or caustic materials. When using flammable materials, avoid
contact with ignition sources and do not smoke.

Used oil

Used oil contains harmful combustion residues.

Rub barrier cream into hands.

Wash hands after contact with used oil.

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Lead

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

• Switch on extraction system.

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

• Wash hands after contact with lead or lead-containing substances.

Compressed air

Observe special safety precautions when working with compressed air:

• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.

• Wear goggles when blowing off components or blowing away chips.

• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.

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

• Assemblies or plants to be connected must either be designed for this pressure, or, if the permitted
pressure for the connecting elements is lower than the pressure required, a pressure reducing valve
and safety valve (set to permitted pressure) must form an intermediate connection.

• Hose couplings and connections must be securely attached.

• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).

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

• Carry out leak test in accordance with the specifications.

Paints and lacquers

• Observe the relevant safety data sheet for all materials.

• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.

• Avoid open 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.

• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.

• Avoid body contact (eyes, hands).

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

• Make sure that working area is well ventilated.

• Avoid all knocks and jars to the containers, fixtures or workpieces.

Acids and alkaline solutions

• Observe the relevant safety data sheet for all materials.

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

• If such solutions are spilled onto clothing, remove the affected clothing immediately.

• Rinse injured parts of the body thoroughly with clean water.

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

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1.6 Standards for safety messages in the text

DANGER

In the event of immediate danger.
Consequences: Death or serious injury

• Remedial action

WARNING

In the event of potentially dangerous situations.
Consequences: Death or serious injury

• Remedial action

CAUTION

In the event of hazardous situations.
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

Note: This manual contains highlighted safety messages in accordance with the US ANSI Z535 standard which

begin with one of the signal words listed above depending on the severity of the hazard.

Safety messages

1. Read and familiarize yourself with all safety message before starting up or repairing the product.

2. Pass on all safety messages to operating, maintenance, repair and transport personnel.

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1.7 ATEX precautions (if applicable)

The following additional precautions must be taken to comply with the requirements of the ATEX
explosion protection directives:

• Unoccupied connections for the wiring harness must be sealed with protective caps.

• The entire engine wiring harness must be covered with metal guards to protect it from mechanical im‐
pact and UV radiation.

• Continuous power supply to the engine must be ensured when the engine is in the hazardous zone.

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2 General Information

2.1 Engine side and cylinder designations

Engine sides are always designated as viewed from the driving end (KS).

The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO

1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.

Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

1 Left engine side
2 KGS = Free end

3 Right engine side
4 KS = Driving end

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2.2 Engine layout

Illustrations are also applicable to 16 V

1 Exhaust outlet
2 Exhaust turbocharger
3 Intercooler
4 Air intake connection
5 Crankcase ventilation
6 Crankcase ventilation
7 Cylinder head cover

8 ECU

9 Engine lifting equipment
10 Fuel duplex filter
11 Oil filler neck
12 Engine coolant pump
13 Fuel pump
14 Oil cooler

15 Oil filter
16 Oil dipstick
17 Oil pan
18 Crankcase
19 Exhaust manifold

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1 Starter 2 Charge-air coolant pump

Engine model designation

Key to the engine model designation 12/16V 2000 Px2

12/16 Number of cylinders

V Cylinder arrangement: V engine

2000 Series

P Application

X Application segment (1, 6, 8, 9)

2 Design index

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2.3 Use

1 Service and Automation

Module (SAM)

2 Peripheral Interface

Module 601 (option)

3 Peripheral Interface

Module 602 (option)

4 CAN bus

5 Engine with generator

6 Engine governor

7 Engine monitoring (op‐

tional)

8 LOP (optional)

Up to 8 additional Peripheral Interface Modules can be connected for linking to higher-level systems.

Functions

• Control of the engine.

• Monitoring of operating states.

• Closed-loop control of fuel injection and engine speed (depending on operating state).

• Indication of faulty operating states (display SAM (1)).

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Features

• Electronic engine governing and control.

• Monitoring of inadmissible engine operating states.

• Display of fault messages and fault codes.

• Connecting cable for power supply to engine governor.

• Connecting cable for connection to a higher-level genset control system.

• Hardware interfaces to a higher-level control system (option).

• Inputs for plant sensors (option).

• Engine safety features including engine shutdown.

• Integral fault diagnosis system ITS.

• Integral load profile recorder.

• Speed droop switching possible with engine running.

• Straightforward engine governor replacement.

• Engine and interface data stored in SAM.

• Complete automatic software download following connection of a new, unprogrammed engine gov‐
ernor.

Design of the overall MDEC system

1 Monitoring and Control

System MCS-5 (PIMs
optional)

2 CAN bus between

ECS-5 and MCS-5

3 Engine Control System

ECS-5

4 RS422 interface and

RS232 interface to an
external controller

5 External controller

The design of the overall MDEC system comprising the ECS-5 and MCS-5 subsystems depends on cus‐
tomer requirements and the higher-level control system.

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Design of Engine Control System ECS-5

1 Engine with generator
2 Engine interface

3 Power supply +U

b

4 Signal connection to the

MCS devices and the
higher-level control sys‐
tems

5 Engine governor
6 System boundary

ECS-5

The Engine Control System comprises the following devices:

• Engine governor

• Sensors on engine

• Actuators on engine

• Injectors on engine

• Wiring harnesses on engine

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Basic scope of Monitoring and Control System MCS-5

1 Monitoring and Control

System MCS-5

2 Power supply +U

b

3 Signal connection to

ECS devices

4 System boundary

MCS-5

5 SAM

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Service and Automation Module (SAM)

1 Module cassette, slots

for additional I/O PIM
cards

2 Compact flash memory

card

3 Display for fault codes

and minidialog

4 Control keys for minidia‐

log
5 Diagnostic lamp
6 Interface for dialog unit

7 Connector with spring

design

Functions

SAM functions

• Display of fault codes from engine governor and SAM (3).

• Backup function, engine life data are stored,

• every hour,

• after every engine stop

• after every emergency engine stop.

• Interface for dialog unit.

Diagnosis

• Straightforward diagnosis by fault code display.

• Self-diagnosis by diagnostic lamp (5).

• Steady = SAM is OK.

• Flashing = SAM is faulty, contact Service.

• Dark = Supply voltage missing.

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Customer interface

• 24 binary outputs

• 3 PWM outputs

• 8 display outputs

• 28 channel binary input

• 10 analog inputs (e.g. PT100, 4–20 mA, 0-10 V, etc.)

• 4 frequency inputs

• 1 dialog interface

• Extendable with MCS 5 PIM I/O cards

Data connections

1 Engine governor
2 SAM

3 PIM 601 (option) serial

interface / slave

4 PIM 602 (option) serial

interface / master

Data transmission

The devices are equipped with a CAN bus for transmitting data between the individual subsystems. This
CAN bus is in redundant design.

The CAN bus is a standardized automation technology field bus which allows various systems and devi‐
ces to communicate with each other providing they are equipped with a CAN bus interface.

Tasks of the CAN bus:

CAN bus

Tasks:

• Receiving plant signals (desired speed) and commands from higher-level control systems.

• Outputting all measured values/limit values for the Monitoring and Control System.

• Outputting alarms for signaling and evaluation in the Monitoring and Control System.

• Outputting relevant signals for engine control.

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Grounding

1 PIM
2 SAM
3 Engine governor
4 Battery
5 To engine sensors

6 Generating set
7 Equipotential bonding

strip
8 Grounding
9 Equipotential bonding

strip

10 Equipotential bonding

strip

11 Mounting frame
12 GND (-)
13 +24 V VDC (+)

X! Inadmissible connec‐

tion!

Grounding

Both the engine and the generator are connected to ground (8) via equipotential bonding strips (7, 9, 10)
on the mounting frame (11).

EMC

EMC design of the overall system is based on a two-pole ungrounded power supply. This is particularly
relevant to CE labeling as per EMC directive.

Ground connection

The ground of the power supply (battery negative) and all electronic devices (-) should not be connected
to ground (8). The entire electronic system is electrically isolated from ground. This also applies to the
sensors (5). All sensor signal lines and/or supply lines are not connected to the corresponding sensor
housings.

Signal-to-noise ratio

Electrical isolation of the mechanical and electronic components significantly increases the signal-to­noise ratio. This high signal-to-noise ratio on all electrical lines is necessary for satisfactory transmission
of all data on the CAN bus and also all analog and binary sensor signals.

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2.4 ECS-5 – Use of devices

Engine governor

Central control and monitoring device for the engine

• Communication with other devices and higher-level systems via CAN bus.

• Control of injection system.

• Control of up to 20 injectors.

• Acquisition and evaluation of engine operating states.

• Monitoring of limit values.

• Self-monitoring and diagnosis,

• integral status/fault display

• fault memory

• Extensive I/O features:

• Plant side 13 inputs, 10 outputs, 2 serial interfaces,

• engine side 26 inputs, 26 outputs.

• Engine and plant-related setting variables in exchangeable memory modules.

• In case of inadmissible states and limit value violations: Initiation of power reduction, engine stop and
emergency engine stop (configurable).

• Diagnosis via RS232 interface for dialog unit.

Software structure:

Name Meaning

Download software For downloading firmware and configuration data.

Dialog software For the dialog with a PC or notebook.

Automation software for open-loop control. E.g. to control injection quantity.

Automation software for monitoring. E.g. for engine stop and emergency engine stop.

Communication software For communication with other devices and via the

CAN bus.

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Hardware structure

Item. Name Meaning

1 Cover –

2 Housing –

3 Rating plate Part and serial number

Data record and engine number

4 Screws –

5 Connector X6 Connection for dialog unit

6 Connector X4 Connection for injector wiring

harness

7 Connector X5 Connection for power supply

8 Connector X2 Connection for sensor/actuator

wiring harness

9 Connector X3 BR 2000: Not used

BR 4000: HP controller

10 Connector X1 Connection for CAN bus

11 Mounting lugs –

Technical data

Dimensions (width x height x depth) 455 mm x 277 mm x 91 mm

Draw-out clearance: +230 mm

Weight 7 kg

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Operating voltage Rated voltage: 24 VDC

Continuous voltage:

16.5 VDC to 32 VDC

Temporarily restricted operation:

11 VDC to 36 VDC

Residual ripple: Max. 8 V

pp

Power consumption Max. 30 A

Heat loss Max. 35 W

Operating temperature range 0 °C to +75 °C

Storage temperature range –10 °C to +75 °C

Relative air humidity 0% to 95 % condensing

Degree of protection IP 65 DIN 40 050

Shock 15 g/11 ms semi-sinusoidal shock

Vibration 2 Hz to 13 Hz: Xpp= ±1.6 mm

25 Hz to 100 Hz: a= ±4 g

100 Hz to 2000 Hz: Electrical noise 1.3 g rms

EMC DIN EN 50081–2

DIN EN 50082–2

IEC 1000–4–2

IEC 1000–4–3

IEC 1000–4–4

IEC 1000–4–5

IEC 1000–4–6

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2.5 MDEC – Functions

Control functions

Following engine functions are controlled:

• Engine start

• Engine stop

• Emergency start

• Restart response

• Sequences with activated “Override” function (safety system bypass).

• Nominal speed switching between two set values (optional operation as 50 Hz or 60 Hz genset).

• Injection quantity as a function of engine loading and speed.

Engine start

The starting sequence is controlled by the software integrated in the engine governor as follows.

1. Engine start

2. Start lockout time t>16 seconds.

• Starting terminated if start lockout time is t<16.

3. Start interlock.

• Start terminated if start interlock applied.

4. Emergency air-shutoff flaps open.

• Start terminated if emergency air-shutoff flaps closed.

.

5. Starter on.

6. Speed n>n1 (configurable) reached within t1 (configurable).

• Start terminated if speed is n<n1 within t1. Start speed is too low “Start speed low”.

.

7. Start injection quantity

8. Speed n>300 reached within t2 (configurable).

• Start terminated if speed is n<300 within t2 (configurable). Start speed is too low “Run up speed
low”.

9. Starter off.

10. Idling speed reached.

• Start terminated if idling speed not reached, “Idle speed low”.

11. Engine running at idling speed.

Restart response

The response of the engine is determined by the following factors on receiving a start request when the
engine is running down following a stop command:

• The engine immediately runs up to nominal speed if the engine speed is > 80 rpm;

• the engine is shut down if the engine speed is < 80 rpm. Restarting is only possible on expiry of the
start lockout time.

Emergency start

The following start interlock criteria are bypassed when override is active on starting the engine:

• Low coolant temperature (configurable).

• High coolant temperature (configurable).

• Coolant level (configurable).

Engine stop

An engine stop is tripped by activation of binary input BE1 at the engine governor or by the engine pro‐
tection system. Fuel is no longer injected as injector activation is disrupted.

Any starting procedure which has been initiated is interrupted.

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Override (safety system bypass)

The “Override” feature is used to bypass safety functions tripped by limit value violations or sensor faults
and to bypass start interlocks.

Operating states which would normally lead to engine shutdown are ignored when the “Override” function
is activated. The following operating states can also be configured to shut the engine down in override
mode:

• Coolant level

• Coolant temperature

• Coolant pressure

• Charge air coolant level

• Lube oil pressure

• Lube oil temperature

Monitoring functions

The engine management system for engines used in Oil&Gas applications fulfills the following monitoring
tasks:

• Control of analog instruments;

• engine speed (default)

• engine lube oil pressure (default)

• engine lube oil temperature (default)

• engine coolant temperature (default)

• Transmission of all measurands, warnings and alarms to monitoring system via CAN bus.

• Automatic shutdown in case of limit value violations.

Refer to the measuring-point list for order-specific configuration data.

Engine monitoring can basically be divided into two different areas:

• Engine protection system, monitors the engine during operation,

• Safety system, generates automatic engine shutdown in case of limit value violation.

These two functional areas are constantly monitored by the internal “Integral Test System (ITS)” to en‐
sure operational availability.

Engine protection system

The engine governor incorporates an integral engine protection system. It monitors the operational data
of the engine.

Tasks of the engine protection system are:

• Safeguarding the engine from critical operating states.

• Signaling alarms to operating personnel.

• Restricting engine operation to remain within admissible operating values.

Action is taken such as warning, start interlock, power reduction or engine shutdown by reducing the
quantity of fuel injected depending on the values measured.

Closed-loop control functions

Closed-loop engine control functions:

• Speed

• Injection control with mapped commencement of injection.

• Two adjustable speed droops.

• Desired speed via:

• Analog or binary speed setting on the CAN bus.

• Analog speed setting 0 V to 10 VDC / 0 V to 5 VDC / 4 mA to 20 mA.

• Binary speed setting via Up/Down signal, frequency CAN bus.

• Frequency speed setting.

• Acquisition of a load pulse signal (analog or CAN bus) in preparation for load application.

• HP fuel governor.

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Speed - injection control

Functions of the closed-loop engine speed control integrated in the engine governor:

• Maintaining the desired engine speed under changing load conditions.

• Adjusting the engine speed when the setting is changed by the operator.

Additional tasks with an effect on closed-loop engine speed control:

• Setting a defined fuel injection quantity on starting the engine.

• Engine safety shutdown.

• Optimizing operation, exhaust emissions and fuel consumption.

• Protecting the engine against overloading.

Speed droop calculation

Speed droop influences the effective setpoint speed depending on engine power. Maximum, speed-de‐
pendent engine power is limited by the DBR curve. The setpoint speed is not influenced by speed droop
at 100% power. The effective setpoint speed increases at lower power. This allows power to be balanced
when operating a number of engines in a network.

Switchable speed droop

Two different speed droops may be selected at the engine governor for stationary genset engines. Which
speed droop is active depends on whether the genset is running in isolated operation or in a parallel
network with other gensets feeding a common busbar.

The speed droop is selected by a binary input (BE4) at the engine governor.

Speed droop is required to balance the load of coupled prime movers. Speed droop can be adjusted to
meet plant requirements via the dialog unit.

Dynamic quantity limitation

Dynamic quantity limits protect the engine against overloading and optimize exhaust emission values.
The engine governor determines the maximum injection quantity based on preset and stored engine per‐
formance maps.

Following limits are applied:

• Speed-sensitive fuel quantity limitation (DBR).

• Fuel quantity limitation as a function of fuel temperature.

Fixed quantity limitation

Fixed quantity limitations are used for power limitation and power reduction to protect the engine in case
of:

• Electronic malfunctions.

• Supply voltage out of tolerance.

Fuel quantity control during engine start

The quantity of fuel injected during engine start increases along a time ramp from a set initial value to a
specified value. This value is calculated by the function q

inject

= f

(speed)

. This limits the quantity of fuel in‐

jected as a function of speed. This fuel quantity limitation is effective until idling speed has been reached.

Cylinder cutout

Only half of the injectors are activated when cylinder cutout is active. The other half of the injectors are
activated on expiry of a switchover time. This prevents white smoke being emitted when the engine is
running.

Desired speed handling

The desired speed is the command variable for the engine speed control loop.

When the engine is started it runs up to an internally programmed desired speed (for 50 Hz network fre‐
quency: 1500 rpm, for 60 Hz network frequency: 1800 rpm).

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Switching to an external speed setting takes place automatically once the nominal speed has been
reached.

The following speed setting variants are possible:

• Desired speed setting via an analog input:
The setpoint speed can be adjusted within a (configurable) range around the preset synchronous
speed (depending on the set network frequency).
In this case the voltage can either control the speed window only or cover the entire speed range.
The internal setpoint speed follows the applied speed setting value along a configurable acceleration/
deceleration curve (speed ramp). The setting value last applied is maintained or the engine is throttled
back to idling speed should the applied signal fail.
The response can be configured as desired:

• Speed setting via CAN bus.

• Speed setting via an analog speed setting input (0 V to 10 V).

• Speed setting via an analog speed setting input (4 mA to 20 mA).

• Frequency input.

• Setpoint processing via binary inputs “Setpoint speed up” (BE5)/ “Setpoint speed down” (BE6):
The setpoint speed can be adjusted within a (configurable) range around the preset synchronous
speed (depending on the set network frequency). Briefly actuating the appropriate optocoupler input
for less than 0.3 s increases or decreases the setpoint speed by 1 rpm.
The setpoint speed is automatically adjusted at a configurable rate if the input is activated for longer
than 0.3 seconds.

Safety functions

Safety shutdowns

Safety shutdowns are initiated by the engine protection system in case of:

• Limit value violations;

• Sensor faults (depending of specific configuration).

This applies to the following measuring points:

• Engine speed/overspeed (configurable)

• Engine lube oil pressure (configurable)

• Coolant level (configurable)

• Charge-air coolant temperature (configurable)

• Coolant temperature (configurable)

• Charge-air temperature (configurable)

• Engine lube oil temperature (configurable)

All safety shutdowns can be suppressed by activating the “Override” input (BE8, default).

The occurrence of safety-relevant alarms is still logged when the “Override” input has been activated.

Fault number 500 is added to the current fault number.

Integral Test System (ITS)

The ITS monitors all important functions of the engine governor and connected electrical components:

• Electronics inside the engine governor itself,

• sensors,

• actuators,

• bus communication,

• power supply.

The ITS detects any faults which occur, pinpoints them and signals accordingly by combined alarms.
Furthermore, a fault message is output via the CAN bus to a higher-level monitoring system (if applica‐
ble) and can visualized there for the operator.

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Fault messages are stored in two memories:

• Chronological memory
The fault message numbers are stored in a ring memory in chronological order of their occurrence or
cancellation together with the hour meter reading. The ring memory stores the last 80 setting and can‐
cellation procedures.

• Statistical memory
Fault message occurrences are counted in a statistical memory.
A counter counting up to max. 10 000 is set up for each fault message number .

Monitoring of engine governor electronics

The hardware and software of the engine governor is designed to allow faults in the electronic system to
be detected to enable the operator to respond accordingly to such faults. Fault signals are also forward‐
ed.

The temperature inside the engine governor housing is monitored. Should it rise above a limit value, a
fault signal is output via the combined alarm output and the CAN bus to a higher-level monitoring system
(if applicable) where it can be visualized for the operator.

Monitoring of sensors and actuators

The various sensor and actuator channels of the engine governor system are designed to tolerate faults
to a large extent (e.g. short-circuit withstandability).

Faults such as broken wires, short circuit etc. are detected by plausibility checking and are output to a
higher-level monitoring system (if applicable) in the form of a combined alarm.

Monitoring of bus communication

Bus communication is monitored by plausibility checking and timeout monitoring. Detected faults are out‐
put in the form of a combined alarm and, if possible, to a higher-level monitoring system (if applicable)
via the CAN bus.

Overspeed test

Activating this input lowers the overspeed threshold such that the engine shuts down at any speed. This
makes it possible to check that the overspeed shutdown function operates correctly.

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2.6 Peripheral Interface Modules (PIMs)

PIMs for use with processor printed circuit board MPU 23 and MPU 27

PIM design

1 Module cassette 1
2 Basic module 1
3 Printed circuit board

PIM 601/602 comprises:

• Module cassette 1 (1) to accommodate one MPU 23, MPU 27 and one PIM printed circuit board.

• Basic module 1 (2) with printed circuit board COB 1-0X (3).

• Printed Circuit Board SCB 3

Slots and terminals

1 Slot 1
2 Slot 2

Slot 1 is reserved for the microprocessor card (MPU 23 and MPU 27). All other slots may be populated
with PIM printed circuit boards.

Example: The "n" in "n09" stands for the slot and "09" designates the terminal. "209" means: Slot 2, ter‐
minal 9.

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The following information is transmitted via the optional interface modules PIM 601 and PIM 602:

• Analog operational data

• Analog limit values

• Status messages

• Alarms

• Shutdowns

Function of PIM 601

Serial interface

• Computer coupling 512

• Procedure 3964 (R)

• RS232 or

• RS422

• MTU (SLAVE)

Function of PIM 602

Serial interface

• Computer coupling 512

• Procedure 3964 (R)

• RS232 or

• RS422

• MTU (MASTER)

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2.7 Printed circuit board SCB 3

Purpose and design

Design

1 Component side
2 Soldering side
3 Top view

4 LED (red) “Printed circuit

board RESET”
5 LED (green) “Ready”
6 LED (yellow) “Interface

1: Receiving and trans‐

mitting line active”

7 LED (yellow) “Interface

2: Receiving and trans‐
mitting line active”

8 Connector RS232 inter‐

face

A yellow LED lights (o flashes) only when data interchange is active at the relevant interface. When there
is no communication at the (connected!) interface, the LED remains dark.

Features

• 2 interfaces as per RS422 or RS232 standard

• Interface are electrically isolated

Use

SCB 3 is used as an interface extension (additional serial interfaces), as an interface converter or as an
amplifier.

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Function

1 Transmission channel 1 2 Connector 3 Module housing with

SCB 3

SCB 3 is equipped with two serial transmission channels routed to the terminal strip of the PIM.

The software of the relevant processor printed circuit board determines which interface is active on which
transmission channel. Only one interface may be active for any one transmission channel.

• Transmission channel 1
is equipped with a connection for a serial RS422 interface and a serial RS232 interface.
The RS232 interface is connected via the terminals of the PIM or by a connector.
When connected by the connector, the terminals of the RS232 interface are automatically switched
off.

• Transmission channel 2
is equipped with a connection for a serial RS422 interface and a serial RS232 interface.

Data processing and interface driver control (baud rate) depend on the processor printed circuit board
used.

With processor printed circuit board MPU 23:

• Fixed 9600 kBd

With processor printed circuit board MPU 27 (project-dependent):

• 4800 kBd

• 9600 kBd

• 19200 kBd

Terminal assignment

Relationship between SCB 3 and the terminals of the PIM.

Connection terminal Name

n01 Channel 1: O1 of RS422 interface

n02 Channel 2: O1 of RS422 interface

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Connection terminal Name

n03 Channel 1: O2 of RS422 interface

n04 Channel 2: O2 of RS422 interface

n05 Channel 1: Ground (GND) of RS422 interface

n06 Channel 2: Ground (GND) of RS422 interface

n07 Channel 1: I1 of RS422 interface

n08 Channel 2: I1 of RS422 interface

n09 Channel 1: I2 of RS422 interface

n10 Channel 2: I2 of RS422 interface

n11 Channel 1: TX of RS232 interface

n12 Channel 2: TX of RS232 interface

n13 Channel 1: Ground (GND) of RS232 interface

n14 Channel 2: Ground (GND) of RS232 interface

n15 Channel 1: RX of RS232 interface

n16 Channel 2: RX of RS232 interface

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3 Technical Data

3.1 12/16 V 2000 P12 engine data

Explanation:

DL Ref. value: Continuous power
BL Ref. value: Fuel stop power

A Design value
G Guaranteed value
R Guideline value

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

- Not applicable

X Applicable

Engine model 12V2000

P12

16V2000

P12

Application group 4A 4A

Intake air temperature °C 25 25

Charge air coolant temperature °C 45 45

Barometric pressure mbar 1000 1000

Site altitude above sea level m 100 100

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

Number of cylinders 12 16

Nominal engine speed A rpm 1800 1800

Fuel stop power ISO 3046 A kW 600 800

GENERAL CONDITIONS (for maximum power)

Number of cylinders 12 16

Intake air depression (new filter) A mbar 15 15

Intake air depression, max. L mbar 30 30

Exhaust overpressure A mbar 30 30

Exhaust gas overpressure, max. L mbar 50 50

MODEL-RELATED DATA (basic design)

Number of cylinders 12 16

Engine with exhaust turbocharging (ETC) and charge-air cool‐
ing (CAC)

X X

Number of cylinders 12 16

Cylinder arrangement: V angle Degrees 90 90

Bore mm 130 130

Stroke mm 150 150

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Number of cylinders 12 16

Cylinder displacement liter 1.99 1.99

Total displacement liter 23.88 31.84

Compression ratio 16 16

Number of inlet valves per cylinder 2 2

Number of exhaust valves per cylinder 2 2

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

COOLANT SYSTEM (HT circuit)

Number of cylinders 12 16

Coolant temperature (at engine outlet: to cooling equipment) A °C 95 95

Coolant temperature after engine, warning R °C 97 97

Coolant temperature after engine, shutdown L °C 99 99

Coolant antifreeze content, max. L % 50 50

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

COOLANT SYSTEM (LT circuit)

Number of cylinders 12 16

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

A °C N N

Coolant antifreeze content, max. L % 50 50

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

LUBE OIL SYSTEM

Number of cylinders 12 16

Lube oil operating temperature before engine, from R °C 88 88

Lube oil operating temperature before engine, to R °C 98 98

Lube oil temperature before engine, warning R °C 99 99

Lube oil temperature before engine, shutdown L °C 102 102

Lube oil operating pressure before engine, from R bar 7.5 7.0

Lube oil operating pressure before engine, to R bar 8.5 8.0

Lube oil pressure before engine, warning R bar 5.5 5.5

Lube oil pressure before engine, shutdown L bar 5.0 5.0

FUEL SYSTEM

Number of cylinders 12 16

Fuel pressure at supply connection to engine, min. (during en‐
gine starting)

L bar -0.4 -0.4

Fuel pressure at supply connection on engine, max. (when en‐
gine is starting)

L bar 0.5 0.5

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GENERAL OPERATING DATA

Number of cylinders 12 16

Cold start capability: air temperature without starting aid, with‐
out preheating) - (case A)

R °C 0** 0**

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

Firing speed, from R rpm 100 100

Firing speed, to R rpm 120 120

CAPACITIES

Number of cylinders 12 16

Engine coolant, engine-side (without cooling system) R liter 46 58

Charge-air coolant, engine side R liter 19 20

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

R liter 95 123

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

R liter 90 120

Oil pan capacity, dipstick mark min. (standard oil system) (Op‐
tion: max. operating inclinations)

L liter 78 96

Oil pan capacity, dipstick mark max. (standard oil system) (Op‐
tion: max. operating inclinations)

L liter 85 103

ACOUSTICS

Number of cylinders 12 16

Exhaust noise, undamped - BL (sound power level LW, ISO

6798)

R db(A) 123 128

Engine surface noise with damped intake noise (filter) - BL
( sound-power level LW, ISO 6798)

R db(A) 117 126

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3.2 Firing order

Firing order

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

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

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3.3 Engine – Main dimensions

Engine – Main dimensions

Engine model 12 V 2000 Px2 16 V 2000 Px2

Length (A) approx. 2165 mm approx. 2505 mm

Width (B) approx. 1340 mm approx. 1340 mm

Height (C) approx. 1475 mm approx. 1495 mm

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3.4 SAM

Use/application

• Installation in enclosed control cabinets.

• Suitable for mounting on mounting rails (rail installation) or for installation with screws on the rear wall
of the cabinet (fixed installation).

•

Suitable for connection wires or leads up to AWG16 (US) (1.5 mm

2

).

Technical data

Term Unit Value

Installation position As desired, ensuring that the installed fault display is

legible.

Operating voltage VDC 24 rated value (-30%; +30%, temporary -50%)

Power consumption W Below 7 (0.25A at 24V) without additional loads.

Degree of protection: IP 40 according to DIN 40 050

Shock:

Rail mounting 10 g, 11 ms

Fixed mounting 30 g, 11 ms

Vibrations:

Rail mounting Hz 2 - 12.8:Xpp < ± 3mm

12.8 - 1000:a < 1g [rms]

Fixed mounting Hz 2 - 12.8: Xpp < ± 3 mm

12.8 - 100:a < 4g [rms]

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Term Unit Value

Ambient temperature: °C -40 – +70 with circulating ambient air.

Storage temperature: °C -40 - +100

Relative humidity % 5 – 97, no condensation.

Color: Blue (RAL5015)

Material: % Polycarbonate, reinforced with 10 % fiberglass.

Dimensions: mm L x W x H (295 x 151 x 75)

Weight: kg Approx. 1.6

Note: Values stated above may be restricted when MCS 5 extension modules are used.

EMI/EMC – Electromagnetic interference (general)

The SAM has been tested according to the following standards and meets the relevant limit values:

Standard Test

EN 55011 (Conducted emission) 10 kHz – 30 MHz, class A

EN 55011 (Radiated emission) 30 MHz – 1 GHz

IEC-60533:1999 (Conducted emission) 10 kHz – 30 MHz (type test)

EC-60533:1999 (Radiated emission) 150 kHz – 2 GHz (type test)

EN 61000-4-2 (ESD interference immunity) ±8 kV

EN 61000-4-3 (Radiated interference immunity) 80 MHz – 2 GHz

EN 61000-4-4 (Burst interference immunity) ±2 kV

EN 61000-4-5 (Surge interference immunity) ±1 kV/±2 kV

EN 50155 (Surge interference immunity) ±1.8 kV

EN 61000-4-17 (LF line-related interference) 0.03 – 10 kHz/3 Veff

EN 61000-4-29 (Line fluctuations/STANAG 1008)

IEC 60092-504 (Dielectric strength) 550 VAC/10 mA

EN 50155 (Isolation) 500 V/10 Mohm

Requirements for fulfillment of EMI/EMC limit values are as follows:

• If the housing is not grounded via the mounting plate, it must be connected to housing ground e.g. by
means of a cable with a minimum cross-section of 2.5 mm

2

. Cable length shall not exceed 10 cm.

• Only twisted-conductor cables may be used to connect sensors and actuators. The maximum length
of unshielded cables is 5 m, of shielded cables 50 m (provided wiring harness resistance allows for
this). Shielding shall be connected in the switchgear cabinet.

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Electrical requirements

Term Unit Value

Operating voltage: V 24, -30 % to +30 % (+16.8 – +32)

Permissible residual ripple less than 5% acc. to STA‐
NAG 1008.

Note: The processor is automatically reset if the voltage
falls below 7 V.

Power supply: W Below 7 W.

Without activated loads at SAM outputs

Additional output power amperage of positive or nega‐
tive line may not exceed 10 A DC.

Power connection terminals: mm 5.08 terminals (spring-type terminals)

•

A wire diameter of AWG14 (US) or 2.5 mm2 is recom‐
mended.

Electrical isolation: V • Supply ground is common reference potential (Com‐

mon Ground) for all SAM electronics.
This applies to the entire I/O range with the exception
of certain electrically isolated channels.

• SAM electronics ground is not connected to housing
ground.

• If signal cable shields are used, these must be con‐
nected to housing ground.

• Unless specified otherwise, the maximum DC insula‐
tion voltage is 500.

Mechanical design

Term Unit Value

Installation position • Horizontal (to ensure visibility of the fault display and

labels on the SAM housing).

• Note that space is required to connect cabling at the
top and bottom when installing the SAM in control
cabinets.

• The device heats up as a result of power loss from
the SAM. Heat from the SAM is dissipated through
the rear panel.
Ensure that heat can be conducted away from the
rear panel of the SAM to the mounting frame. Avoid
any additional heating of the SAM by neighboring de‐
vices.

Signal connections

The SAM module is easily replaced. The input and output signal cables are equipped with modular con‐
nectors. Common function channels are grouped together.

The wires are connected using spring terminals.

It is possible to connect two wires to one terminal if the wires are connected in a double core sleeve
using crimp technology. For example, a Phoenix AL-TWIN 2* 0.75-10 may be used.

The connector modules are connected by clicking them in place. The connector modules have code pins
to prevent polarity reversal.

MS150025/02E 2012-10 | Technical Data | 45

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Terminals

Term Unit Value

Terminal strip modules: WAGO spring terminals

Current-carrying capacity (at 70
°C):

A 10 per contact

Rated voltage: V 250

Rated surge voltage: V 2500

Wire cross-sections:

mm

2

Up to 1.5 or AWG15

Clamping range:

mm

2

0.08 – 1.5 or AWG15

Other terminals (RM 5.08) are used for power supply and CAN bus connections.

Additional printed circuit boards in slots 1 to 3

Observe the relevant technical data applicable to the printed circuit boards concerned when additional
boards are used in the SAM.

46 | Technical Data | MS150025/02E 2012-10

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3.5 SCB 3 – Technical data

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x 15

Weight kg 0.036

Input voltage VDC +5 (±5 %) from processor printed circuit board used

Power consumption mA < 100

Power loss mW < 425

Table 1: General information

Term Unit Value

Bit-serial In accordance with RS422 standard

Baud rate kBd • 9600 with MPU 23

• 4800, 9600, 19200 with MPU 27

Electrical isolation By optocoupler.

Table 2: Data transmission

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4 Operation

4.1 LOP – Controls

LOP – Controls

Item Color Inscription Meaning / Function

1 White F1 Function keys for operating the screen.

Functions vary and are displayed on the LCD screen.

2 White F2

3 White F3

4 White F4

5 White F5

6 White ALARM AC‐

KNOWLEDGE

Pressing the key the first time stops alarm signalization.

Pressing the key a second time acknowledges an active
alarm.

LED (spot) lights up when an alarm is active.

7 White DIMMER ↑ Holding down the key increases LCD background illumina‐

tion.

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Item Color Inscription Meaning / Function

8 White DIMMER ↓ Holding down the key decreases LCD background illumina‐

tion.

9 White LAMP TEST Pressing the key initiates lamp test.

10 Red TEST OVER‐

SPEED

Pressing the key initiates overspeed test.

LED (spot) lights up as long as the overspeed test is run‐
ning.

11 Green (none) (none)

12 Green (none) (none)

13 Green (none) (none)

14 White ENGINE SPEED

INCREASE

Engine speed is increased as long as the key is held down.

15 White ENGINE SPEED

DECREASE

Engine speed is decreased as long as the key is held down.

16 Green READY FOR OP‐

ERATION

Pressing the key causes changeover between “Not ready
for operation” and “Ready for operation” status.

LED (spot) lights up at "Ready for operation" switch posi‐
tion.

17 Green LOCAL OPERA‐

TION

Pressing the key switches between local operation and re‐
mote control.

LED (spot) lights up when local mode is active.

18 White START Pressing the key initiates automatic engine starting proce‐

dure.

LED (spot) lights up as long as the starting procedure is
running.

19 White STOP Pressing the key initiates automatic engine stopping proce‐

dure.

Spot LED lit when stop signal is applied (also from remote
control system).

20 Red EMERGENCY

STOP

Pressing the key initiates an immediate emergency engine
stop.

LED (spot) flashes once the emergency stop has been trip‐
ped and until the alarm has been acknowledged.

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4.2 Putting the engine into operation after extended out-of­service-periods (>3 months)

Preconditions

☑ Engine is stopped and starting disabled.

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

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

Item Task

Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).

Lube oil system Check engine oil level (→ Page 123).

Fuel prefilter Prime (→ Page 115).

Fuel prefilter, pressure
gauge

Align pointer with position of pressure indicator (→ Page 113).

Fuel system Vent (→ Page 109).

Coolant circuit If engine has been out of service for more than 1 year, change engine

coolant (→ Page 132);

Change charge-air coolant (→ Page 140).

Coolant circuit Check engine coolant level (→ Page 131);

Check charge-air coolant level (→ Page 141).

Coolant circuit Preheat coolant with preheating unit.

ECU Check plug connections (→ Page 147).

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

Engine/generator control
system

Switch ON;

Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPER‐
ATION.

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4.3 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 123);

Cooling system Check engine coolant level (→ Page 131);

Check charge-air coolant level (→ Page 141).

Cooling system Preheat coolant with preheating unit.

Fuel prefilter Drain (→ Page 114).

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

Engine/generator control
system

Switch ON;

Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPER‐
ATION.

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4.4 Start engine in manual mode (testing mode)

Preconditions

☑ Generator (if provided) not connected to network.

☑ External start interlock is not activated.

DANGER

Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!

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

WARNING

Engine noise above 85 dB (A).
Risk of damage to hearing!

• Wear ear protectors.

Preparation

Item Task

Operating mode selector
switch (if provided)

Change to manual mode.

Preheating pump (if provid‐
ed)

Switch ON.

Starting the engine

Item Task

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

If coolant temperature is

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

• > 5 °C (without preheating equipment):

Press start button.

• Automatic starting sequence is performed;

• Engine speed display instrument indicates increasing crankshaft speed;

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

Connect generator to network (if provided), run engine to reach operating
temperature )

Item Task

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

Close the generator circuit breaker.

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

ant temperature approx. 75 °C).

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4.5 Safety system – Override

CAUTION

Safety functions and engine shutdown alarms will be disregarded.
Serious damage to plant!

• Initiate emergency start only in emergency situations.

CAUTION

Inadmissible operational condition.
Major material damage!

• Use override function only in hazardous situations to ensure full capability in case of engine mal‐
functions.

Preparation

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

Bypassing the 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 52).

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

ture, pressures).

Constantly monitor plant limit values.

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4.6 Operational checks

DANGER

Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!

• Take special care when working on a running engine.

WARNING

Engine noise above 85 dB (A).
Risk of damage to hearing!

• Wear ear protectors.

Operational checks

Item Task

Control and display panels Check indicated operational data (speed, temperatures, 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 vibrations.

Fuel prefilter Check whether indicated differential pressure is within the limit

(→ Page 113).

Exhaust system Check exhaust color (→ Page 61).

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

(→ Page 119).

Air filter Check signal ring position of service indicator (→ Page 121).

Replace air filter (→ Page 120), if the signal ring is completely visible in the
service indicator control window.

Coolant pump Check relief bore (→ Page 136).

Compressed air system (if
applicable to engine)

Check operating pressure on pressure gauge;

Always fill compressed-air tank to max. pressure;

Drain condensate from compressed-air tank, pressure drop must not ex‐
ceed 1 bar.

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4.7 Stop engine in manual mode (testing mode)

Preconditions

☑ Generator (if provided) not connected to network.

☑ Engine is running in manual mode.

CAUTION

Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!

• Before stopping the engine, operate it at idle speed until operating temperatures decrease and
stable values are indicated.

Preparing the generator drive (only with generator breaker)

Item Task

Engine After opening the generator breaker (if provided), allow to cool down off-

load for approx. 5 minutes.

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

Item Task

Engine Allow to cool down for approx. 5 minutes at reduced engine speed. Ob‐

serve natural resonance of engine (installation-dependent)!

Stopping the engine

Item Task

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

Press stop button.

• Automatic stopping sequence is performed;

• Engine is stopped.

After stopping the engine

Item Task

Coolant pump Allow to run on for sufficient time after stopping.

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4.8 Emergency stop

CAUTION

An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to components!

• Initiate emergency stop only in emergency situations.

Emergency stop from LOP

Item Task

EMERGENCY STOP but‐
ton

Press.

• Engine is stopped by switching off power supply to ECU;

• Signalization (e.g. by horn, flashing lamp) is released.

After emergency stop from LOP

Item Task

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

Press button for alarm acknowledgement.

• Audible and visual signalization stops.

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4.9 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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4.10 After stopping the engine – putting the engine out of service

Preconditions

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

After stopping the engine

Item Task

Cooling system Drain engine coolant (→ Page 133);

Drain charge-air coolant (→ Page 139) if:

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

• the engine room is not heated;

• the coolant is not maintained at a suitable temperature;

• the antifreeze concentration is insufficient for the engine-room tempera‐
ture;

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

-40°C.

Engine/generator/pump
controller

Switch OFF.

Air intake and exhaust sys‐
tem

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, preserve engine (→ MTU-Preservation and Represer‐
vation Specifications A001070/..).

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4.11 Plant cleaning

Preconditions

☑ Engine is stopped and starting disabled.

☑ Operating voltage is not present.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Steam jet cleaner

- 1

Cleaner (Hakupur 312)

30390 1

WARNING

Compressed air
Risk of injury!

• Do not direct compressed-air jet at persons.

• Wear protective goggles / safety mask and ear protectors.

WARNING

Water jet.
Risk of injury and scalding!

• Do not direct water jet at persons.

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

CAUTION

Excessive reaction time of cleaning agents on components.
Damage to component!

• Observe manufacturer's instructions.

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

NOTICE

Dry with compressed air.
Damage to component!

• Never aim compressed air directly at electronic components.

Plant cleaning

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

2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.

3. During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must
be observed. The temperature of the cleaning medium must not exceed 80 °C.

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

5. Carry out external cleaning as follows:

a) Seal all openings in a suitable fashion.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.

Note: Never aim compressed air directly at electronic components.

e) Dry engine.

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5 Maintenance

5.1 Maintenance task reference table [QL1]

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

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

Task Maintenance tasks

W0500 Check engine oil level. (→ Page 54)

W0501 Visually inspect engine for leaks and general condition. (→ Page 54)

W0503 Check signal ring position of service indicator on air filter. (→ Page 54)

W0505 Check relief bores of water pump(s). (→ Page 54)

W0506 Check engine for abnormal running noises, exhaust color and

vibrations.

(→ Page 54)

W0507 Drain water and contaminants from fuel prefilter. (→ Page 54)

W0508 Check reading on differential pressure gage of fuel prefilter. (→ Page 54)

W1001 Replace fuel filter or fuel filter element. (→ Page 110)

W1002 Check valve clearance. (→ Page 95)

W1003 Check belt condition and tension, replace if necessary. (→ Page 142)

W1005 Replace air filter. (→ Page 120)

W1006 Replace fuel injectors. (→ Page 102)

W1007 Replace fuel injection pump(s). (→ Page 98)

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

the interval (years) is reached, at the latest.

(→ Page 125)

W1010 Coolant cooler: Check exterior of cooler elements for dirt.

W1011 Perform endoscopic examination of combustion chambers. (→ Page 87)

W1056 Replace fuel pressure maintaining valve. (→ Page 106)

W1140 Clean wire meshes of crankcase breather. (→ Page 91)

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6 Troubleshooting

6.1 Troubleshooting

Engine does not turn when starter is actuated

Component Cause Measure

Battery Flat or defective Charge or replace (see manufacturer's

documentation).

Cable connections faulty Check if cable connections are proper‐

ly secured (see manufacturer's docu‐
mentation).

Starter (electric) Engine wiring or starter faulty Check if cable connections are proper‐

ly secured, contact Service.

Starter (compressed
air)

Starting-air pressure not available Check firm seating of connections,

check starting-air pressure and main
valve of compressed-air system. Con‐
tact Service.

Engine wiring Faulty Check (→ Page 144).

Engine governor Plug-in connections possibly loose Check plug-in connections

(→ Page 147).

Engine Blocked (engine cannot be barred

manually)

Contact Service.

Engine turns but does not fire

Component Cause Measure

Starter Poor rotation by starter: Battery flat or

defective

Charge or replace battery (see manu‐
facturer's documentation).

Engine wiring Faulty Check (→ Page 144).

Fuel system Air in fuel system Vent fuel system (→ Page 109).

Engine governor Faulty Contact Service.

Engine fires unevenly

Component Cause Measure

Fuel injection equip‐
ment

Injector faulty Replace (→ Page 102).

Injection pump defective Replace (→ Page 98).

Engine wiring Faulty Check (→ Page 144).

Fuel system Air in fuel system Vent fuel system (→ Page 109).

Engine governor Faulty Contact Service.

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Engine does not reach rated speed

Component Cause Measure

Fuel supply Fuel inlet blocked Completely open shutoff valve up‐

stream of fuel prefilter.

Fuel prefilter clogged Replace (→ Page 117).

Easy-change fuel filter contaminated Replace (→ Page 110).

Air supply Air filter clogged Check signal ring position of contami‐

nation indicator (→ Page 121).

Fuel injection equip‐
ment

Injector faulty Replace (→ Page 102).

Injection pump defective Replace (→ Page 98).

Engine wiring Faulty Check (→ Page 144).

Engine Overloaded Contact Service.

Engine speed not steady

Component Cause Measure

Fuel injection equip‐
ment

Injector faulty Replace (→ Page 102).

Injection pump defective Replace (→ Page 98).

Speed sensor Faulty Contact Service.

Fuel system Air in fuel system Vent fuel system (→ Page 109).

Engine governor Faulty Contact Service.

Charge-air temperature too high

Component Cause Measure

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

Intercooler Contaminated Contact Service.

Engine room Air-intake temperature too high Check fan;

check air inlet/outlet ducts.

Charge-air pressure too low

Component Cause Measure

Air supply Air filter clogged Check signal ring position of contami‐

nation indicator (→ Page 121).

Intercooler Contaminated Contact Service.

Exhaust turbocharger Faulty Contact Service.

Coolant leaks at intercooler

Component Cause Measure

Intercooler Leaking, major coolant discharge Contact Service.

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Black exhaust gas

Component Cause Measure

Air supply Air filter clogged Check signal ring position of contami‐

nation indicator (→ Page 121).

Fuel injection equip‐
ment

Injector faulty Replace (→ Page 102).

Injection pump defective Replace (→ Page 98).

Engine Overloaded Contact Service.

Blue exhaust gas

Component Cause Measure

Engine oil Engine oil level too high Drain engine oil (→ Page 124).

Oil separator or oil-preseparator of
crankcase breather clogged

Replace (→ Page 93).

Exhaust turbocharger

Cylinder head

Piston rings

Cylinder liner

Faulty Contact Service.

White exhaust gas

Component Cause Measure

Engine Not at operating temperature Run engine to reach operating temper‐

ature.

Fuel system Water in fuel Check fuel system at fuel prefilter

Drain fuel prefilter (→ Page 114).

Intercooler Leaking Contact Service.

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6.2 Fault indication on printed circuit board SAM

The structure of the display (1) is as follows:

• First line

• Fault indication

• # (2) = Alarm is no longer active, does not appear on next power-up,

• A = Currently active alarms,

• B = Alarm was active during the last hour,

• C = Alarm was active during the last four hours,

• C = Alarm was active during the last four to twelve hours,

• E = Alarm was active more than twelve hours ago.
.

• Fault type (e.g. SE03).

• Node number at which the fault occurred (e.g. nd11).

• Second line

• Running text, providing more information about the fault currently displayed

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

Fault type – fault message text

SE No. Fault message text

0 Sensor Temperature 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 Temperature Compensation Error

9 I/O-Module Slot2 Defect

10 I/O-Module Slot3 Defect

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SE No. Fault message text

11 I/O-Module Slot4 Defect

12 Serial Connection 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 fault codes and fault messages

Fault code Fault message Meaning Action

005 L1 T-CHARGE AIR Charge air temperature too

high (1st limit value)

Reduce power.

009 L1 T-INTERCOOLER Charge-air coolant temper‐

ature too high (1st limit val‐
ue)

Reduce power.

015 L1 P-LUBE OIL Oil pressure too low

(1st limit value)

Check oil level, top up as necessary
(→ Engine operating instructions).

016 L2 P-LUBE OIL Oil pressure too low

(2nd limit value)

automatic engine shut‐
down.

1. Check oil level, top up as nec‐
essary (→ Engine operating in‐
structions).

2. Attempt to restart engine (→ En‐
gine operating instructions).

019 L1 T-EXHAUST A Exhaust temperature en‐

gine A side too high
(1st limit value)

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service.

020 L2 T-EXHAUST A Exhaust temperature en‐

gine A side too high
(2nd limit value)

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service.

021 L1 T-EXHAUST B Exhaust temperature en‐

gine B side too high
(1st limit value)

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service.

022 L2 T-EXHAUST B Exhaust temperature en‐

gine B side too high
(2nd limit value)

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service.

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Fault code Fault message Meaning Action

023 L1 COOLANT LEVEL Coolant level too low

(1st limit value)

Check coolant level in expansion
tank (→ Engine operating instruc‐
tions).

024 L2 COOLANT LEVEL Coolant level too low

(2nd limit value)

Check coolant level in expansion
tank (→ Engine operating instruc‐
tions).

025 L1 P-OILFILTER

DIFF

Oil filter differential pres‐
sure too high (1st limit val‐
ue)

Check oil filter (→ Engine operating
instructions).

027 L1 LEVEL LEAKAGE

FUEL

Leak fuel (1st limit value). Check fuel system (→ Engine oper‐

ating instructions).

030 ENGINE OVER‐

SPEED

Engine overspeed; auto‐
matic emergency engine
stop.

1. Acknowledge alarm.

2. Attempt to restart engine.

031 CHARGER 1 OVER‐

SPEED1

ETC 1 – speed violation
(1st limit value).

• Engine management system au‐
tomatically reduces power.

• Check air filter (→ Engine op‐

erating instructions).

032 CHARGER 1 OVER‐

SPEED2

ETC 1 – speed violation.
(2nd limit value)

• Engine management system au‐
tomatically reduces power.

• Check air filter (→ Engine operat‐
ing instructions).

044 L1 LEVEL INTER‐

COOLER

Charge air coolant level too
high/low (1st limit value
violated).

Check coolant level (→ Engine op‐
erating instructions).

045 L2 LEVEL INTER‐

COOLER

Charge air coolant level too
high/low (2nd limit value
violated).

Check coolant level (→ Engine op‐
erating instructions).

051 L1 T-LUBE OIL Oil temperature too high

(1st limit value)

Reduce power.

052 L2 T-LUBE OIL Lube oil temperature too

high (2nd limit value)

1. Reduce power.

2. Check oil level (→ Engine oper‐
ating instructions).

057 L1 P-COOLANT Coolant pressure too low

(1st limit value)

.

Check coolant circuit

058 L2 P-COOLANT Coolant pressure too low

(2nd limit value)

• Automatic engine shutdown.

• Check coolant level (→ Engine
operating instructions).

065 L1 P-FUEL Fuel inlet pressure too low

(1st limit value)

(→ Engine operating instructions)

• Check fuel lines for leakage.

• Clean fuel prefilter.

• Rinse fuel prefilter.

• Replace fuel prefilter element .

• Replace fuel filter.

066 L2 P-FUEL Fuel inlet pressure too low

(2nd limit value)

(→ Engine operating instructions)

• Check fuel lines for leakage.

• Clean fuel prefilter.

• Rinse fuel prefilter.

• Replace fuel prefilter element .

• Replace fuel filter.

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Fault code Fault message Meaning Action

067 L1 T-COOLANT Coolant temperature too

high (1st limit value);

Reduce power.

068 L2 T-COOLANT Coolant temperature too

high (2nd limit value);

automatic engine shutdown

1. Allow engine to cool down.

2. Contact Service

• Check engine coolant cooler,
clean if dirty (→ Engine
Workshop Manual).

3. Restart engine.

089 ENGINE SPEED

LOW

Engine speed has failed to
reach 200 rpm. Stop is ac‐
tivated.

Check for additional messages.

100 EDM NOT VALID Checksum error in Engine

Data Module EDM/EE‐
PROM 1.

Redundant design of EDM allows
engine management system to re‐
main operational.

101 IDM NOT VALID Checksum error in Inter‐

face Data Module IDM/EE‐
PROM 2.

Redundant design of EDM allows
engine management system to re‐
main operational.

102 INVALID FUEL

CONS. 1

Invalid fuel consumption
display, checksum error in
EDM/EEPROM 1 (redun‐
dant data record 1).

Contact Service.

103 INVALID FUEL

CONS. 2

Invalid fuel consumption
display, checksum error in
IDM/EEPROM 2 (redun‐
dant data record 2).

Contact Service.

104 OP HOURS1 NOT

VALID

Checksum error of hour
meter in EDM/EEPROM 1

Hour meter remains operational.

105 OP HOURS2 NOT

VALID

Checksum error of hour
meter in IDM/EEPROM 2

Hour meter remains operational.

106 ERR REC1 NOT

VALID

Checksum error of fault
memory in EDM/EE‐
PROM 1 (redundant data
record 1).

Faults are still recorded.

107 ERR REC2 NOT

VALID

Checksum error of fault
memory in IDM/EE‐
PROM 2 (redundant data
record 2).

Faults are still recorded.

118 L1 SUPPLY VOLT.

LOW

Supply voltage too low
(1st limit value)

Contact Service.

• Check engine governor supply
voltage.

119 L2 SUPPLY VOLT.

LOW

Supply voltage too low
(2nd limit value)

Contact Service.

• Check engine governor supply
voltage.

120 L1 SUPPLY VOLT.

HIGH

Supply voltage too high
(1st limit value).

Contact Service.

• Check engine governor supply
voltage.

121 L2 SUPPLY VOLT.

HIGH

Supply voltage too high
(2nd limit value);

automatic engine shutdown
(configurable):

Contact Service.

• Check engine governor supply
voltage.

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Fault code Fault message Meaning Action

122 L1 T-ELECTRONIC Temperature in ECU hous‐

ing too high (1st limit value)

1. Improve engine room ventila‐
tion.

2. Reduce engine power.

134 15V POS ECU DE‐

FECT

Internal voltage (-15 VDC)
faulty;

automatic engine shut‐
down.

Replace engine governor (→ En‐
gine operating instructions).

136 15V NEG ECU DE‐

FECT

Internal voltage (-15 VDC)
missing;

automatic engine shutdown

Contact Service.

139 L1 TE BUFFER

TEST

Temperature sensor supply
voltage faulty.

Contact Service.

• Check sensors;

• replace engine governor.

140 TE BUF. ECU DE‐

FECT

Temperature sensor supply
voltage faulty.

Contact Service.

• Check sensors;

• replace engine governor.

142 BANK1 ECU DE‐

FECT

Power output stage for
control of solenoid valves
on bank 1 is faulty;

engine does not start.

Replace engine governor (→ En‐
gine operating instructions).

144 BANK2 ECU DE‐

FECT

Power output stage for
control of solenoid valves
on bank 2 is faulty;

engine does not start.

Replace engine governor (→ En‐
gine operating instructions).

145 15V_GOOD ECU

DEFECT

Power supply is faulty;

automatic engine shut‐
down.

Replace engine governor (→ En‐
gine operating instructions).

146 L1 AD-TEST1 SUP‐

PLY

A/D converter supply volt‐
age too low.

Replace engine governor (→ En‐
gine operating instructions).

147 AD-TEST1 ECU DE‐

FECT

Electronics faulty;

automatic engine shut‐
down.

Replace engine governor (→ En‐
gine operating instructions).

148 L1 AD-TEST2 SUP‐

PLY

A/D converter supply volt‐
age too low.

Replace engine governor (→ En‐
gine operating instructions).

149 AD-TEST2 ECU DE‐

FECT

Internal electronics faulty;

automatic engine shut‐
down.

Replace engine governor (→ En‐
gine operating instructions).

150 L1 AD-TEST3 SUP‐

PLY

Internal electronics faulty;
automatic engine shut‐
down.

Replace engine governor (→ En‐
gine operating instructions).

151 AD-TEST3 ECU DE‐

FECT

Internal electronics faulty;

automatic engine shut‐
down.

Replace engine governor (→ En‐
gine operating instructions).

186 CAN 1 BUS OFF CAN 1 in Bus-Off state:

• Either short circuit on
bus.

• Or strong magnetic
fields disrupting bus.

Contact Service.

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

• Check shielding, improve shield‐
ing as necessary.

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Fault code Fault message Meaning Action

187 CAN 1 ERROR PAS‐

SIVE

CAN 1 in Error-Passive
state, minor bus disruption
or missing CAN node .

Contact Service.

• Check that at least one CAN
node is present. Check cabling
as necessary.

• Check shielding, improve shield‐
ing as necessary.

188 CAN 2 BUS OFF CAN 2 in Bus-Off state:

• Either short circuit on
bus.

• Or strong magnetic
fields disrupting bus.

Contact Service.

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

• Check shielding, improve shield‐
ing as necessary.

189 CAN 2 ERROR PAS‐

SIVE

CAN 2 in Error-Passive
state, minor bus disruption
or missing CAN node .

Contact Service.

• Check that at least one CAN
node is present. Check cabling
as necessary.

• Check shielding, improve shield‐
ing as necessary.

201 SD T-COOLANT Sensor B06 faulty (coolant

temperature).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

202 SD T-FUEL Sensor B33 faulty (fuel

temperature).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

203 SD T-CHARGE AIR Sensor B09 faulty (charge

air temperature) A-side.

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

205 SD T-COOLANT IN‐

TERC.

Sensor fault (charge-air
coolant temperature).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

206 SD T-EXHAUST A Sensor B4.21 faulty (ex‐

haust temperature ) engine
side A.

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

207 SD T-EXHAUST B Sensor B4.22 faulty (ex‐

haust temperature ) engine
side B.

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

208 SD P-CHARGE AIR Sensor B10 faulty (charge-

air pressure) A-side.

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

211 SD P-LUBE OIL Sensor B05 faulty (lube oil

pressure).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

212 SD P-COOLANT Sensor B16 faulty (coolant

pressure).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

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Fault code Fault message Meaning Action

216 SD T-LUBE OIL Sensor B07 faulty (lube oil

temperature).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

219 SD T-INTAKE AIR Sensor B03 faulty (intake

air temperature).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

220 SD COOLANT LEV‐ELSensor F33 faulty (engine

coolant level 1).

1. Switch system off and back on;

2. check fault message;

3. check cabling (→ Engine oper‐
ating instructions);

4. Contact Service

• Check sensor.

222 SD LEVEL LEAK‐

AGE FUEL

Sensor fault (leak fuel). 1. Check cabling (→ Engine oper‐

ating instructions);

2. Contact Service

• Check sensor.

223 SD LEVEL INTER‐

COOLER

Sensor fault (charge air
coolant level).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

229 SD ENG. SPEED

SENSORS

Sensor fault crankshaft
speed and camshaft
speed.

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

230 SD CRANKSHAFT

SPEED

Sensor B13 faulty (crank‐
shaft speed).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

231 SD CAMSHAFT

SPEED

Sensor B1 faulty (camshaft
speed).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

232 SD CHARGER

SPEED 1

Sensor B44 faulty (ETC
speed 1).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

240 SD P-FUEL Sensor B34 faulty (fuel

pressure).

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check sensor.

245 SD POWER SUP‐

PLY

Sensor fault (ECU operat‐
ing voltage).

Replace engine governor (→ En‐
gine operating instructions).

246 SD T-ELECTRONIC Temperature sensor for

measuring electronics tem‐
perature faulty.

Replace engine governor (→ En‐
gine operating instructions).

250 SD CAN SPEED DE‐

MAND

Sensor fault (CAN setpoint
speed).

Contact Service.

• Check CAN communication.

266 SD SPEED DE‐

MAND AN.

External speed setting faul‐
ty.

(→ Engine operating instructions)

1. Check cabling

2. Check speed setting.

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Fault code Fault message Meaning Action

267 SD SP. DEM. TEST

BENCH

External test bench speed
setting faulty.

Check potentiometer and cabling
(→ Engine operating instructions).

270 SD SPEED DE‐

MAND

Sensor fault frequency set‐
ting.

1. Check cabling (→ Engine oper‐
ating instructions);

2. Contact Service

• Check setpoint speed sen‐

sor.

301...310 TIMING CYLINDER

(A1- A10)

Timing bank 1 (solenoid
valve 1) ... Timing bank 1
(solenoid valve 10)

Replace injector if fault message oc‐
curs frequently (→ Engine operating
instructions).

311...320 TIMING CYLINDER

(B1- B10)

Timing bank 2 (solenoid
valve 1) ... Timing bank 2
(solenoid valve 10)

Replace injector if fault message oc‐
curs frequently (→ Engine operating
instructions).

321...330 WIRING CYLINDER

(A1- A10)

Wiring bank 1 (solenoid
valve 1) ... Wiring bank 1
(solenoid valve 10)

Contact Service.

• Check solenoid valve.

331...340 WIRING CYLINDER

(B1- B10)

Wiring bank 2 (solenoid
valve 1) ... Wiring bank 2
(solenoid valve 10)

Contact Service.

• Check solenoid valve.

341...350 OPEN_LOAD CYL.

(A1- A10)

Open load bank 1 (sole‐
noid valve 1) ... Open load
bank 1 (solenoid valve 10)

Contact Service.

• Check solenoid valve.

351...360 OPEN_LOAD CYL.

(B1- B10)

Open load bank 2 (sole‐
noid valve 1) ... Open load
bank 2 (solenoid valve 10)

Contact Service.

• Check solenoid valve.

361 POWER STAGE

FAIL 1

Fault in ECU (solenoid
valve output stage bank 1).

(→ Engine operating instructions)

1. Check solenoid valve cabling.

2. Replace engine governor.

362 POWER STAGE

FAIL 2

Fault in ECU (solenoid
valve output stage bank 2).

(→ Engine operating instructions)

1. Check solenoid valve cabling.

2. replace engine governor.

363 STOP STAGE FAIL 1 Fault in solenoid valve, ca‐

bling or ECU;

automatic engine shut‐
down.

1. Check cabling (→ Engine oper‐
ating instructions).

2. Attempt to restart engine.

364 STOP STAGE FAIL 2 Fault in solenoid valve, ca‐

bling or in ECU;

automatic engine shut‐
down.

1. Check cabling (→ Engine oper‐
ating instructions).

2. Attempt to restart engine

365 STOP MV-WIRING Fault in solenoid valve ca‐

bling;

automatic engine shut‐
down.

1. Check cabling (→ Engine oper‐
ating instructions).

2. Attempt to restart engine.

371 TRAN.OUT1 EN‐

GINE DEF

Binary transistor output en‐
gine 1 faulty.

(→ Engine operating instructions)

• Check charger valve/cabling re‐
pair as necessary

• Replace engine governor.

372 TRAN.OUT2 EN‐

GINE DEF

Binary transistor output en‐
gine 2 faulty.

(→ Engine operating instructions)

• Check air recirculation valve/ca‐
bling repair as necessary.

• Replace engine governor.

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Fault code Fault message Meaning Action

373 TRAN.OUT3 EN‐

GINE DEF

Binary transistor output en‐
gine 3 faulty.

-

374 TRAN.OUT4 EN‐

GINE DEF

Binary transistor output en‐
gine 4 faulty.

-

381 TRAN.OUT1 PLANT

DEF

Binary transistor output
TAA 1 faulty.

Check cabling to plant.

382 TRAN.OUT2 PLANT

DEF

Binary transistor output
TAA 2 faulty.

Check cabling to plant.

383 TRAN.OUT3 PLANT

DEF

Binary transistor output
TAA 3 faulty.

Check cabling to plant.

384 TRAN.OUT4 PLANT

DEF

Binary transistor output
TAA 4 faulty.

Check cabling to plant.

385 TRAN.OUT5 PLANT

DEF

Binary transistor output
TAA 5 faulty.

Check cabling to plant.

386 TRAN.OUT6 PLANT

DEF

Binary transistor output
TAA 6 faulty.

Check cabling to plant.

390 MCR EXCEEDED MCR violation 1. No action necessary if alarm

only signaled temporarily;

2. contact Service if alarm sig‐
naled permanently.

392 L1 T-COOLANT RED Redundant coolant temper‐

ature (1st limit value).

1. Check cabling (→ Engine oper‐
ating instructions).

2. Contact Service

• Check sensor.

393 L2 T-COOLANT RED Redundant coolant temper‐

ature (2nd limit value).

1. Check cabling (→ Engine oper‐
ating instructions).

2. Contact Service

• Check sensor.

394 L1 P-LUBE OIL RED Redundant lube oil pres‐

sure (1st limit value).

1. Check cabling (→ Engine oper‐
ating instructions).

2. Contact Service

• Check sensor.

395 L2 P-LUBE OIL RED Redundant lube oil pres‐

sure (2nd limit value).

1. Check cabling (→ Engine oper‐
ating instructions).

2. Contact Service

• Check sensor.

396 TD COOLANT Transmitter deviation cool‐

ant temperature.

1. Check cabling (→ Engine oper‐
ating instructions).

2. Contact Service

• Check sensor.

397 TD OIL PRESSURE Transmitter deviation en‐

gine oil pressure.

1. Check cabling (→ Engine oper‐
ating instructions).

2. Contact Service

• Check sensor.

72 | Troubleshooting | MS150025/02E 2012-10

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6.3 ECU alarms

The ECU generates alarms which are indicated in different ways depending on the equipment configura‐
tion:

• as four-digit code on a PIM

• as alarm text on a display

• as four-digit code on a dialog PC

The four-digit code consists of one letter and three figures:

• The letter encodes when the fault occurred the last time:
A = currently present
B = within the last operating hour
C = one to four operating hours ago
D = four to twelve operating hours ago
Alarms that occurred more than twelve hours ago are deleted automatically.

• The three figures encode the fault itself as listed in the table below.

Alarms can also be caused by defective sensors / actuators. If troubleshooting in accordance with the
following table is not successful, contact Service to have the sensors / actuators checked and, if re‐
quired, replaced.

Fault
code

Alarm text Meaning Task

004 L2 T-FUEL Fuel temperature too high

(2nd limit)

Cool fuel tank.

005 L1 T-CHARGE

AIR

Charge-air temperature too
high (1st limit)

Reduce power.

006 L2 T-CHARGE

AIR

Charge-air temperature too
high (2nd limit)

Reduce power.

009 L1 T-INTER‐

COOLER

Charge-air coolant tempera‐
ture too high (1st limit)

Reduce power.

015 L1 P-LUBE OIL Lube-oil pressure too low (1st

limit)

Check engine-oil level and top up, if re‐
quired (→ Page 123);

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Fault
code

Alarm text Meaning Task

016 L2 P-LUBE OIL Lube-oil pressure too low (2nd

limit)

automatic engine shutdown

1. Check engine-oil level and top up, if
required (→ Page 123);

2. Try to re-start the engine
(→ Page 52).

3. Contact Service.

023 L1 COOLANT

LEVEL

Engine coolant level too low Check coolant level and top up, if re‐

quired (→ Page 131) .

024 L2 COOLANT

LEVEL

Engine coolant level too low Check coolant level and top up, if re‐

quired (→ Page 131).

030 ENGINE OVER‐

SPEED

Engine overspeed; automatic
engine shutdown

1. Acknowledge alarm.

2. Try to re-start the engine
(→ Page 52).

3. Contact Service.

033 L1 P-FUELFIL‐

TER DIFF

Differential pressure before/af‐
ter fuel filter too high

Replace fuel filter (→ Page 110).

051 L1 T-LUBE OIL Lube-oil temperature too high

(1st limit)

Reduce power.

052 L2 T-LUBE OIL Lube-oil temperature too high

(2nd limit)

1. Reduce power.

2. If fault occurs repeatedly: Contact
Service.

067 L1 T-COOLANT Coolant temperature too high

(1st limit) warning

Reduce power.

068 L2 T-COOLANT Coolant temperature too high

(2nd limit)

automatic engine shutdown

1. Allow the engine to cool down.

2. Check coolant cooler (elements etc.)
and clean contaminated parts (see
manufacturer's documentation).

3. Re-start the engine (→ Page 52).

4. If fault occurs repeatedly: Contact
Service.

069 L1 T-EXTERN 1 Violation of first limit for exter‐

nal temperature channel 1

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

070 L2 T-EXTERN 1 Violation of second limit for

external temperature channel
1

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

071 L1 T-EXTERN 2 Violation of first limit for exter‐

nal temperature channel 2

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

072 L2 T-EXTERN 2 Violation of second limit for

external temperature channel
2

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

073 L1 P-EXTERN 1 Violation of first limit for exter‐

nal pressure channel 1

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

074 L2 P-EXTERN 1 Violation of second limit for

external pressure channel 1

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

075 L1 P-EXTERN 2 Violation of first limit for exter‐

nal pressure channel 2

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

076 L2 P-EXTERN 2 Violation of second limit for

external pressure channel 2

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

077 LIM EXT.COOL‐

ANT LEV.

Alarm from external coolant
level monitoring

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

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Fault
code

Alarm text Meaning Task

078 LIM INTER‐

COOLER LEV.

Alarm from external charge-air
coolant level monitoring

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

079 L Bin-EXTERN 3 Alarm from external binary

channel 3

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

080 L Bin-EXTERN 4 Alarm from external binary

channel 4

(Depending on the corresponding meas‐
uring point, which is read via CAN bus)

089 ENGINE SPEED

LOW

Engine speed lower than 200
rpm;

automatic engine shutdown

Re-start the engine (→ Page 52).

090 IDLE SPEED

LOW

Idle speed not reached within
a specified period;

Termination of starting proce‐
dure.

Note further alarms.

091 RUN UP SPEED

LOW

Run-up speed not reached
within a specified period;

Termination of starting proce‐
dure.

Note further alarms.

092 START SPEED

LOW

Starter speed not reached
within a specified period;

Termination of starting proce‐
dure.

Note further alarms.

093 PREHEAT

TEMP. LIMIT2

Coolant preheating tempera‐
ture too low during starting
(2nd limit)

Termination of starting proce‐
dure (depending on project
design)

Check preheating pump / preheating sys‐
tem (see manufacturer's documentation).

094 PREHEAT

TEMP. LIMIT1

Coolant preheating tempera‐
ture too low during starting
(1st limit)

Check preheating pump / preheating sys‐
tem (see manufacturer's documentation).

100 EDM NOT VALID Check sum error of measur‐

ing-point data in EDM

If fault occurs repeatedly: Contact Serv‐
ice.

101 IDM NOT VALID Check sum error of measur‐

ing-point data in IDM

If fault occurs repeatedly: Contact Serv‐
ice.

102 INVALID FUEL

CONS. 1

Check sum error of accumu‐
lated fuel consumption data in
EDM (redundant data record

1)

If fault occurs repeatedly: Contact Serv‐
ice.

103 INVALID FUEL

CONS. 2

Check sum error of accumu‐
lated fuel consumption data in
EDM (redundant data record

2)

If fault occurs repeatedly: Contact Serv‐
ice.

104 OP HOURS1

NOT VALID

Check sum error of hour me‐
ter data in EDM

If fault occurs repeatedly: Contact Serv‐
ice.

105 OP HOURS2

NOT VALID

Check sum error of hour me‐
ter data in IDM

If fault occurs repeatedly: Contact Serv‐
ice.

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TIM-ID: 0000003157 - 001

Fault
code

Alarm text Meaning Task

106 ERR REC1 NOT

VALID

Check sum error of fault mem‐
ory in EDM (redundant data
record 1)

If fault occurs repeatedly: Contact Serv‐
ice.

107 ERR REC2 NOT

VALID

Check sum error of fault mem‐
ory in EDM (redundant data
record 2)

If fault occurs repeatedly: Contact Serv‐
ice.

118 L1 SUPPLY

VOLT. LOW

Supply voltage too low (1st
limit)

Check ECU supply voltage.

119 L2 SUPPLY

VOLT. LOW

Supply voltage too low (2nd
limit)

Check ECU supply voltage.

120 L1 SUPPLY

VOLT. HIGH

Supply voltage too high (1st
limit)

Check ECU supply voltage.

121 L2 SUPPLY

VOLT. HIGH

Supply voltage too high (2nd
limit)

automatic engine shutdown
(depending on project design)

Check ECU supply voltage.

If engine was stopped: Start engine
(→ Page 52).

122 L1 T-ELEC‐

TRONIC

Temperature in ECU housing
too high (1st limit)

1. Improve engine room ventilation.

2. Reduce engine power.

134 15V POS ECU

DEFECT

Electronic equipment defec‐
tive;

automatic engine shutdown

Contact Service.

136 15V NEG ECU

DEFECT

Electronic equipment defec‐
tive;

automatic engine shutdown

Contact Service.

137 L1 5V BUFFER

TEST

Power supply for pressure
sensors defective.

1. Disconnect connectors X2 and X3
from ECU. If alarm does not disap‐
pear: Contact Service.

2. Check wiring (pressure sensors).

3. Contact Service.

138 SENSORPO‐

WERDEFECT

Power supply for pressure
sensors defective.

1. Disconnect connectors X2 and X3
from ECU. If alarm does not disap‐
pear: Contact Service.

2. Check wiring (pressure sensors).

3. Contact Service.

139 L1 TE BUFFER

TEST

Internal electronic fault (tem‐
perature sensors)

Contact Service.

140 TE BUF. ECU

DEFECT

Internal electronic fault (tem‐
perature sensors)

Contact Service.

142 BANK1 ECU DE‐

FECT

Internal electronic fault;

Engine does not start

Contact Service.

144 BANK2 ECU DE‐

FECT

Internal electronic fault;

Engine does not start

Contact Service.

145 15V_GOOD ECU

DEFECT

Electronic equipment defec‐
tive;

automatic engine shutdown

Contact Service.

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TIM-ID: 0000003157 - 001

Fault
code

Alarm text Meaning Task

146 L1 AD-TEST1

SUPPLY

A/D-converter supply voltage
too low

Contact Service.

147 AD-TEST1 ECU

DEFECT

Electronic equipment defec‐
tive;

automatic engine shutdown

Contact Service.

148 L1 AD-TEST2

SUPPLY

A/D-converter supply voltage
too low

Contact Service.

149 AD-TEST2 ECU

DEFECT

Electronic equipment defec‐
tive;

automatic engine shutdown

Contact Service.

150 L1 AD-TEST3

SUPPLY

A/D-converter supply voltage
too low

Contact Service.

151 AD-TEST3 ECU

DEFECT

Electronic equipment defec‐
tive;

automatic engine shutdown

Contact Service.

170 MI MODULE

FAIL

Module in maintenance pre‐
dictor either defective or miss‐
ing

Contact Service.

171 MI NOT ACTIVE Maintenance predictor no

more activated

Contact Service.

173 MODULE WRITE

LIMIT

EEPROM write limit reached Contact Service.

180 CAN1 NODE

LOST

At least one device not detect‐
ed on Default CAN bus

1. Check wiring (CAN bus).

2. Contact Service.

181 CAN2 NODE

LOST

At least one device not detect‐
ed on Redundant CAN bus

1. Check wiring (CAN bus).

2. Contact Service.

182 CAN WRONG

PARAMETERS

Consistency error in CAN pa‐
rameters

Contact Service.

183 CAN NO PU-DA‐TAError during loading of CAN

project design data into ECU.

Contact Service.

184 CAN PU-DATA

EE-FAIL

Error during project design da‐
ta download in EEPROMs

Contact Service.

185 CAN LESS MAIL‐

BOXES

Error during CAN initialization. Contact Service.

186 CAN1 BUS OFF Severe fault on Default CAN

bus;

automatic change-over to Re‐
dundant CAN bus

Contact Service.

187 CAN1 ERROR

PASSIVE

Light fault on Default CAN bus
(e.g.shortage overload)

(none)

188 CAN2 BUS OFF Severe fault on Redundant

CAN bus;

automatic change-over to De‐
fault CAN bus

Contact Service.

189 CAN2 ERROR

PASSIVE

Light fault on Redundant CAN
bus (e.g.short-time overload)

(none)

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TIM-ID: 0000003157 - 001

Fault
code

Alarm text Meaning Task

201 SD T-COOLANT Sensor defect (coolant tem‐

perature)

1. Check wiring.

2. Contact Service.

202 SD T-FUEL Sensor defect (Fuel tempera‐

ture)

1. Check wiring.

2. Contact Service.

203 SD T-CHARGE

AIR

Sensor defect (charge-air
temperature)

1. Check wiring.

2. Contact Service.

205 SD T-COOLANT

INTERC.

Sensor defect (charge-air
coolant temperature)

1. Check wiring.

2. Contact Service.

208 SD P-CHARGE

AIR

Sensor defect (charge-air
pressure)

1. Check wiring.

2. Contact Service.

211 SD P-LUBE OIL Sensor defect (lube oil pres‐

sure)

1. Check wiring.

2. Contact Service.

216 SD T-LUBE OIL Sensor defect (lube oil tem‐

perature)

1. Check wiring.

2. Contact Service.

220 SD COOLANT

LEVEL

Sensor defect (coolant level) 1. Check wiring.

2. Contact Service.

229 SD ENG.SPEED

SENSORS

Sensor defect (crankshaft
speed) and sensor defect
(camshaft speed)

1. Check wiring.

2. Contact Service.

230 SD CRANK‐

SHAFT SPEED

Sensor defect (crankshaft
speed)

1. Check wiring.

2. Contact Service.

231 SD CAMSHAFT

SPEED

Sensor defect (camshaft
speed)

1. Check wiring.

2. Contact Service.

245 SD POWER

SUPPLY

Sensor defect (ECU operating
voltage)

Contact Service.

246 SD T-ELEC‐

TRONIC

Sensor defect (temperature in
ECU)

Contact Service.

250 SD CAN SPEED

DEMAND

Sensor defect (CAN nominal
speed demand)

1. Check speed transmitter.

2. Check wiring (CAN bus).

3. Contact Service.

266 SD SPEED DE‐

MAND AN.

Sensor defect (analog nomi‐
nal speed demand)

1. Check speed transmitter.

2. Check wiring.

3. Contact Service.

267 SD

SP.DEM.TEST
BENCH

Sensor defect (analog speed
demand);

NOTE:

Only used in test-stand opera‐
tion.

1. Check speed transmitter.

2. Check wiring.

3. Contact Service.

270 SD SPEED DE‐

MAND FI1

Sensor defect (frequency in‐
put for speed demand);

1. Check speed transmitter.

2. Check wiring.

3. Contact Service.

271 SD T-EXTERN 1 External device defective

(CAN T-EXTERN 1)

Contact Service.

272 SD T-EXTERN 2 External device defective

(CAN T-EXTERN 2)

Contact Service.

273 SD P-EXTERN 1 External device defective

(CAN P-EXTERN 1)

Contact Service.

78 | Troubleshooting | MS150025/02E 2012-10

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Fault
code

Alarm text Meaning Task

274 SD P-EXTERN 2 External device defective

(CAN P-EXTERN 2)

Contact Service.

275 SD EXT.COOL‐

ANT LEVEL

External coolant-level monitor‐
ing defective (CAN)

Contact Service.

276 SD INTERCOOL‐

ER LEVEL

External charge-air coolant­level monitoring defective
(CAN)

Contact Service.

277 SD BIN-EXTERN3External device defective

(CAN BIN-EXTERN 3)

Contact Service.

278 SD BIN-EXTERN4External device defective

(CAN BIN-EXTERN 4)

Contact Service.

301 TIMING CYLIN‐

DER A1

Injection timing fault cylinderA1If fault occurs repeatedly: Contact Serv‐

ice.

302 TIMING CYLIN‐

DER A2

Injection timing fault cylinderA2If fault occurs repeatedly: Contact Serv‐

ice.

303 TIMING CYLIN‐

DER A3

Injection timing fault cylinderA3If fault occurs repeatedly: Contact Serv‐

ice.

304 TIMING CYLIN‐

DER A4

Injection timing fault cylinderA4If fault occurs repeatedly: Contact Serv‐

ice.

305 TIMING CYLIN‐

DER A5

Injection timing fault cylinderA5If fault occurs repeatedly: Contact Serv‐

ice.

306 TIMING CYLIN‐

DER A6

Injection timing fault cylinderA6If fault occurs repeatedly: Contact Serv‐

ice.

307 TIMING CYLIN‐

DER A7

Injection timing fault cylinderA7If fault occurs repeatedly: Contact Serv‐

ice.

308 TIMING CYLIN‐

DER A8

Injection timing fault cylinderA8If fault occurs repeatedly: Contact Serv‐

ice.

309 TIMING CYLIN‐

DER A9

Injection timing fault cylinderA9If fault occurs repeatedly: Contact Serv‐

ice.

310 TIMING CYLIN‐

DER A10

Injection timing fault cylinder
A10

If fault occurs repeatedly: Contact Serv‐
ice.

311 TIMING CYLIN‐

DER B1

Injection timing fault cylinderB1If fault occurs repeatedly: Contact Serv‐

ice.

312 TIMING CYLIN‐

DER B2

Injection timing fault cylinderB2If fault occurs repeatedly: Contact Serv‐

ice.

313 TIMING CYLIN‐

DER B3

Injection timing fault cylinderB3If fault occurs repeatedly: Contact Serv‐

ice.

314 TIMING CYLIN‐

DER B4

Injection timing fault cylinderB4If fault occurs repeatedly: Contact Serv‐

ice.

315 TIMING CYLIN‐

DER B5

Injection timing fault cylinderB5If fault occurs repeatedly: Contact Serv‐

ice.

316 TIMING CYLIN‐

DER B6

Injection timing fault cylinderB6If fault occurs repeatedly: Contact Serv‐

ice.

317 TIMING CYLIN‐

DER B7

Injection timing fault cylinderB7If fault occurs repeatedly: Contact Serv‐

ice.

318 TIMING CYLIN‐

DER B8

Injection timing fault cylinderB8If fault occurs repeatedly: Contact Serv‐

ice.

MS150025/02E 2012-10 | Troubleshooting | 79

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Fault
code

Alarm text Meaning Task

319 TIMING CYLIN‐

DER B9

Injection timing fault cylinderB9If fault occurs repeatedly: Contact Serv‐

ice.

320 TIMING CYLIN‐

DER B10

Injection timing fault cylinder
B10

If fault occurs repeatedly: Contact Serv‐
ice.

321 WIRING CYLIN‐

DER A1

Faulty wiring to solenoid valve
cylinder A1;

Misfiring

1. Check wiring.

2. Contact Service.

322 WIRING CYLIN‐

DER A2

Faulty wiring to solenoid valve
cylinder A2;

Misfiring

1. Check wiring.

2. Contact Service.

323 WIRING CYLIN‐

DER A3

Faulty wiring to solenoid valve
cylinder A3;

Misfiring

1. Check wiring.

2. Contact Service.

324 WIRING CYLIN‐

DER A4

Faulty wiring to solenoid valve
cylinder A4;

Misfiring

1. Check wiring.

2. Contact Service.

325 WIRING CYLIN‐

DER A5

Faulty wiring to solenoid valve
cylinder A5;

Misfiring

1. Check wiring.

2. Contact Service.

326 WIRING CYLIN‐

DER A6

Faulty wiring to solenoid valve
cylinder A6;

Misfiring

1. Check wiring.

2. Contact Service.

327 WIRING CYLIN‐

DER A7

Faulty wiring to solenoid valve
cylinder A7;

Misfiring

1. Check wiring.

2. Contact Service.

328 WIRING CYLIN‐

DER A8

Faulty wiring to solenoid valve
cylinder A8;

Misfiring

1. Check wiring.

2. Contact Service.

329 WIRING CYLIN‐

DER A9

Faulty wiring to solenoid valve
cylinder A9;

Misfiring

1. Check wiring.

2. Contact Service.

330 WIRING CYLIN‐

DER A10

Faulty wiring to solenoid valve
cylinder A10;

Misfiring

1. Check wiring.

2. Contact Service.

331 WIRING CYLIN‐

DER B1

Faulty wiring to solenoid valve
cylinder B1;

Misfiring

1. Check wiring.

2. Contact Service.

332 WIRING CYLIN‐

DER B2

Faulty wiring to solenoid valve
cylinder B2;

Misfiring

1. Check wiring.

2. Contact Service.

333 WIRING CYLIN‐

DER B3

Faulty wiring to solenoid valve
cylinder B3;

Misfiring

1. Check wiring.

2. Contact Service.

80 | Troubleshooting | MS150025/02E 2012-10

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Fault
code

Alarm text Meaning Task

334 WIRING CYLIN‐

DER B4

Faulty wiring to solenoid valve
cylinder B4;

Misfiring

1. Check wiring.

2. Contact Service.

335 WIRING CYLIN‐

DER B5

Faulty wiring to solenoid valve
cylinder B5;

Misfiring

1. Check wiring.

2. Contact Service.

336 WIRING CYLIN‐

DER B6

Faulty wiring to solenoid valve
cylinder B6;

Misfiring

1. Check wiring.

2. Contact Service.

337 WIRING CYLIN‐

DER B7

Faulty wiring to solenoid valve
cylinder B7;

Misfiring

1. Check wiring.

2. Contact Service.

338 WIRING CYLIN‐

DER B8

Faulty wiring to solenoid valve
cylinder B8;

Misfiring

1. Check wiring.

2. Contact Service.

339 WIRING CYLIN‐

DER B9

Faulty wiring to solenoid valve
cylinder B9;

Misfiring

1. Check wiring.

2. Contact Service.

340 WIRING CYLIN‐

DER B10

Faulty wiring to solenoid valve
cylinder B10;

Misfiring

1. Check wiring.

2. Contact Service.

341 OPEN_LOAD

CYL. A1

Disconnection in wiring to sol‐
enoid valve cylinder A1;

Misfiring

1. Check wiring.

2. Contact Service.

342 OPEN_LOAD

CYL. A2

Disconnection in wiring to sol‐
enoid valve cylinder A2;

Misfiring

1. Check wiring.

2. Contact Service.

343 OPEN_LOAD

CYL. A3

Disconnection in wiring to sol‐
enoid valve cylinder A3;

Misfiring

1. Check wiring.

2. Contact Service.

344 OPEN_LOAD

CYL. A4

Disconnection in wiring to sol‐
enoid valve cylinder A4;

Misfiring

1. Check wiring.

2. Contact Service.

345 OPEN_LOAD

CYL. A5

Disconnection in wiring to sol‐
enoid valve cylinder A5;

Misfiring

1. Check wiring.

2. Contact Service.

346 OPEN_LOAD

CYL. A6

Disconnection in wiring to sol‐
enoid valve cylinder A6;

Misfiring

1. Check wiring.

2. Contact Service.

347 OPEN_LOAD

CYL. A7

Disconnection in wiring to sol‐
enoid valve cylinder A7;

Misfiring

1. Check wiring.

2. Contact Service.

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Fault
code

Alarm text Meaning Task

348 OPEN_LOAD

CYL. A8

Disconnection in wiring to sol‐
enoid valve cylinder A8;

Misfiring

1. Check wiring.

2. Contact Service.

349 OPEN_LOAD

CYL. A9

Disconnection in wiring to sol‐
enoid valve cylinder A9;

Misfiring

1. Check wiring.

2. Contact Service.

350 OPEN_LOAD

CYL. A10

Disconnection in wiring to sol‐
enoid valve cylinder A10;

Misfiring

1. Check wiring.

2. Contact Service.

351 OPEN_LOAD

CYL. B1

Disconnection in wiring to sol‐
enoid valve cylinder B1;

Misfiring

1. Check wiring.

2. Contact Service.

352 OPEN_LOAD

CYL. B2

Disconnection in wiring to sol‐
enoid valve cylinder B2;

Misfiring

1. Check wiring.

2. Contact Service.

353 OPEN_LOAD

CYL. B3

Disconnection in wiring to sol‐
enoid valve cylinder B3;

Misfiring

1. Check wiring.

2. Contact Service.

354 OPEN_LOAD

CYL. B4

Disconnection in wiring to sol‐
enoid valve cylinder B4;

Misfiring

1. Check wiring.

2. Contact Service.

355 OPEN_LOAD

CYL. B5

Disconnection in wiring to sol‐
enoid valve cylinder B5;

Misfiring

1. Check wiring.

2. Contact Service.

356 OPEN_LOAD

CYL. B6

Disconnection in wiring to sol‐
enoid valve cylinder B6;

Misfiring

1. Check wiring.

2. Contact Service.

357 OPEN_LOAD

CYL. B7

Disconnection in wiring to sol‐
enoid valve cylinder B7;

Misfiring

1. Check wiring.

2. Contact Service.

358 OPEN_LOAD

CYL. B8

Disconnection in wiring to sol‐
enoid valve cylinder B8;

Misfiring

1. Check wiring.

2. Contact Service.

359 OPEN_LOAD

CYL. B9

Disconnection in wiring to sol‐
enoid valve cylinder B9;

Misfiring

1. Check wiring.

2. Contact Service.

360 OPEN_LOAD

CYL. B10

Disconnection in wiring to sol‐
enoid valve cylinder B10;

Misfiring

1. Check wiring.

2. Contact Service.

361 POWER STAGE

FAIL 1

Defect in ECU (solenoid valve
power stage)

Contact Service.

362 POWER STAGE

FAIL 2

Defect in ECU (solenoid valve
power stage)

Contact Service.

82 | Troubleshooting | MS150025/02E 2012-10

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Fault
code

Alarm text Meaning Task

363 STOP POWER

STAGE 1

Solenoid valve or wiring or
ECU defective

automatic engine shutdown

1. Check wiring.

2. Try to re-start the engine
(→ Page 52).

3. Contact Service.

364 STOP POWER

STAGE 2

Solenoid valve or wiring or
ECU defective

automatic engine shutdown

1. Check wiring.

2. Try to re-start the engine
(→ Page 52).

3. Contact Service.

365 STOP MV-WIR‐

ING

Solenoid-valve wiring faulty;

automatic engine shutdown

1. Check wiring.

2. Try to re-start the engine
(→ Page 52).

3. Contact Service.

381 TRAN.OUT1

PLANT DEF

Binary transistor output
plant 1 defective

Contact Service.

382 TRAN.OUT2

PLANT DEF

Binary transistor output
plant 2 defective

Contact Service.

383 TRAN.OUT3

PLANT DEF

Binary transistor output
plant 3 defective

Contact Service.

384 TRAN.OUT4

PLANT DEF

Binary transistor output
plant 4 defective

Contact Service.

385 TRAN.OUT5

PLANT DEF

Binary transistor output
plant 5 defective

Contact Service.

386 TRAN.OUT6

PLANT DEF

Binary transistor output
plant 6 defective

Contact Service.

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7 Task Description

7.1 Engine

7.1.1 Engine – Barring manually

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Barring tool for 12V engines

F6558556 1

Barring tool for 16V engines

F6558557 1

DANGER

Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!

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

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

Engine – Barring manually

1. Remove cover from flywheel housing.

2. Install barring tool (arrow) on flywheel hous‐
ing.

3. Rotate crankshaft in engine direction of ro‐
tation. Apart from the normal compression
resistance, there should be no abnormal re‐
sistance.

Result: If the resistance exceeds the normal com‐

pression resistance, contact Service.

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

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7.1.2 Engine – Barring with starting system

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Connector pliers

0135315483 1

DANGER

Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!

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

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

Engine – Barring with starting
system

1. Disengage the bayonet coupling (4) of con‐
nector X4 with connector pliers (2) and
withdraw connector (3) from engine gover‐
nor.

2. Bar engine in unloaded condition: Press
START button.

3. Let the crankshaft rotate until oil pressure is
indicated.

4. Engine start is automatically interrupted
when specified starting period is expired. If
necessary, re-start the engine after approx.
20 seconds.

5. Plug connector X4 (3) and use connector
pliers (2) to secure the bayonet coupling (4)
by turning it clockwise until it latches into
place.

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7.1.3 Engine – Test run

DANGER

Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!

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

WARNING

Engine noise above 85 dB (A).
Risk of damage to hearing!

• Wear ear protectors.

Engine – Test run

1. Start engine (→ Page 52).

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

3. Carry out operational checks (→ Page 54).

4. Stop engine (→ Page 55).

86 | Task Description | MS150025/02E 2012-10

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7.2 Cylinder Liner

7.2.1 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 97).

2. Remove injector (→ Page 103).

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 Action

• Thin carbon coating on circumference of carbon scraper ring

• Slight localized additive deposits at top edge

• Singular smooth areas at lower edge

• Carbon deposits on circumference in clearance between top piston
ring and bottom edge of carbon scraper ring

• First signs of marks left by top piston ring

• Bright mark on entire circumference

• Consistent honing pattern without objections

• First signs of marks left by lower cooling bores

• Running pattern seems darker

No action required

• Dark areas with even or varying degrees of discoloration

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

• Dark areas in the upper section of the cooling bore, remaining cir‐
cumference without objections

• Piston rings without objections

Further endoscopic examina‐
tion required as part of main‐
tenance work

• On the entire circumference, apart from light areas of discoloration
(that do not impair operation) clearly darker stripes that start at the
top piston ring

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

• Heat discoloration of piston rings

Cylinder liner must be re‐
placed; Service must be con‐
tacted

1. Compile endoscopy report using the table.

2. Use technical terms for description of the liner surface (→ Page 89).

3. Depending on findings:

• do not take any action or

• carry out a further endoscopic examination as part of maintenance work or

• contact Service; cylinder liner must be replaced.

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Final steps

1. Install injector (→ Page 103).

2. Install cylinder head cover (→ Page 97).

88 | Task Description | MS150025/02E 2012-10

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

Terms used for endoscopic examination

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

Findings Action

Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐

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

Findings not critical.

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

area and cross through the hone pattern in the direction of stroke.

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/ex‐
haust) along the transverse engine axis.

Findings not critical.

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

tern is still visible. Smoothened areas appear brighter and more brilliant than the
surrounding running surface.

Findings not critical.

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

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

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐

perature differences around the liner. It appears rather darker within the honed
structure in contrast to the bright metallic running surface. The honing pattern is
undisturbed. Discolorations extend in stroke direction and may be interrupted.

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 dis‐

coloration from TDC to BDC in the running surface and the start of localized
damage to the honing pattern.

Cylinder liners with a large number of black lines around the running surface
have limited service life and should be replaced.

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Findings Action

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

over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be‐
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
clearly defined (straight) edge to the undisturbed surface. The damaged surface
is usually discolored. The circumferential length varies.

Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be
replaced.

Seizure marks, scuff‐
ing

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

Replace liner.

Evaluation of findings and further measures

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

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7.3 Crankcase Breather

7.3.1 Crankcase breather – Wire mesh cleaning

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Cleaner
Diesel fuel
Grease (Kluthe Hakuform 30-10/Emulgier)

X00029933 1

Sealing ring

(→ Spare Parts Catalog)

Screw

(→ Spare Parts Catalog)

WARNING

Fuels are combustible.
Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

Compressed air
Risk of injury!

• Do not direct compressed-air jet at persons.

• Wear protective goggles / safety mask and ear protectors.

CAUTION

Excessive reaction time of cleaning agents on components.
Damage to component!

• Observe manufacturer's instructions.

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

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Crankcase breather – Wire mesh
cleaning

1. Remove hose from oil separator hous‐
ing (1).

2. Remove cylinder head cover (5).

3. Release screws (4), remove deflector plate
(6) and retainer (7).

4. Take off oil separator housing (1).

5. Remove sealing ring (8) from oil separator
housing (1).

6. Remove individual parts from oil separator
housing (1).

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

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

9. Clean residual parts with cleaner.

10. Remove cleaner.

11. Insert washer (2) and filter element (wire
mesh) (3) in the correct sequence in the oil
separator housing (1).

12. Coat sealing ring (8) with grease and insert
in the groove of the oil separator housing
(1).

13. Install oil separator housing (1), deflector
plate (6) and retainer (7) with new screws
(4) on the cylinder head cover (5).

14. Install cylinder head cover (5).

15. Install hose on oil separator housing (1),
ensuring that it is not subjected to tension.

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7.3.2 Crankcase breather – Oil separator element replacement, diaphragm check
and replacement

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 6-50 Nm

F30027336 1

Ratchet adapter

F30027340 1
Engine oil
Filter element

(→ Spare Parts Catalog)

Diaphragm

(→ 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 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 dia‐
phragm (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 seal (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 diaphragms in further oil separators in the same way.

94 | Task Description | MS150025/02E 2012-10

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7.4 Valve Drive

7.4.1 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 gauge

Y20010128 1

Torque wrench, 20–100 Nm

F30026582 1

Ratchet adapter

F30027340 1

Measuring device

Y4341106 1

Preparatory steps

1. Remove cylinder head cover (→ Page 97).

2. Install barring tool (→ Page 84).

3. Disassemble fuel injector of cylinder A1
(→ Page 103).

4. Screw the measuring device into the fuel in‐
jector orifice.

5. Turn the crankshaft, checking the dial
gauge, in the direction of engine rotation
until the piston stands at the breakover
point on the dial gauge display: Cylinder is
in TDC position.

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Checking valve clearance at two
crankshaft positions

1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC

I Inlet valve

X Exhaust valve

1. Check TDC position of piston in cylinder A1:

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

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

2. Check valve clearance with cold engine:

• Inlet = 0.4 mm;

• Exhaust = 0.6 mm;

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

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

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

Adjusting valve clearance

1. Loosen locknut (1) and unscrew adjusting
screw (2) slightly.

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

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

4. Tighten locknut (1) to 50 Nm, holding ad‐
justing screw (2) firmly with screwdriver.

5. Check whether the feeler gauge just passes
through between valve bridge and rocker
arm.

Result: If not, adjust valve clearance.

Final steps

1. Remove barring tool.

2. Follow reverse sequence of working steps for installation.

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7.4.2 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

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 with gasket
from cylinder head.

2. Clean installation surface.

3. Check condition of gasket in cylinder head
cover.

4. Replace damaged gasket(s).

5. Install cylinder head cover with screws.

Final steps

1. Slide rubber sleeves onto the relevant pipe connection.

2. Tighten all clamps.

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7.5 Injection Pump / HP Pump

7.5.1 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 99).

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7.5.2 Injection pump – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Crowfoot wrench, 19 mm

F30027424 1

Crowfoot wrench, 22 mm

F30027425 1

Torque wrench, 20–100 Nm

F30026582 1

Ratchet adapter

F30027340 1

Transition piece

F30006234 1

Torque wrench, 0.5–5 Nm

0015384230 1

Grease (Kluthe Hakuform 30–10/Emulgier)

X00029933

Sealing ring

(→ Spare Parts Catalog)

Sealing ring

(→ Spare Parts Catalog)

DANGER

Unguarded rotating and moving engine components.
Risk of serious injury – Danger to life!

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

WARNING

Fuels are combustible.
Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Preparatory steps

1. Shut off fuel supply line before fuel filter.

2. Remove engine control system (→ Page 149).

3. Drain fuel (→ Page 108).

4. Remove charge-air pipes and all seals.

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Removing injection pump

1. Mark installation position of injection pump.

2. Disconnect wiring (1) from injection pump.

3. Remove fuel line (2).

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

• The pretensioned compression spring

will press the injection pump out of the
crankcase, if this does not happen:

a) Turn crankshaft with engine barring tool

(→ Page 84)

• The pump cam presses the injection
pump out of the crankcase, if not:

.

b) 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 rigs from injection pump.

8. Seal all openings with appropriate covers
after removal.

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 grease and fit on‐
to injection pump.

Note: Sealing ring (2) Ø45 mm

4. Coat sealing ring (2) with grease and fit on‐
to injection pump.

5. Coat roller (arrowed) with engine oil.

6. Clean sealing face and fuel bores in crank‐
case.

7. Use barring tool (→ Page 84) to position the
pump cams on the camshaft at base circle.

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