MTU 16 V 4000 C10, 12 V 4000 C20R, 16 V 4000 C11, 16 V 4000 C11R, 16 V 4000 C20 Operating Instructions Manual

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Operating Instructions

Diesel engine 12 V 4000 C10, C10R, C11, C11R 12 V 4000 C20, C20R, C21, C21R 16 V 4000 C10, C11, C11R 16 V 4000 C20, C20R, C21, C21L

MS150049/02E

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Printed in Germany

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.

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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 Crankshaft transport locking device 8

1.5 Crankshaft transport locking device – For transport with flanged-on generator 11

1.6 Safety regulations for startup and operation 13

1.7 Safety regulations for maintenance and repair work 14

1.8 Fire prevention and environmental protection, auxiliary materials, fluids and lubricants 17

1.9 Standards for safety messages in the text 19

2 General Information

2.1 Engine side and cylinder designations 20

2.2 Engine – Overview 21

2.3 Sensors, actuators and injectors – Overview 23

3 Technical Data

3.1 Engine data 12 V 4000 C10, C10R, C11, C11R 26

3.2 Engine data 16 V 4000 C10, C11, C11R 29

3.3 Engine data 12 V 4000 C20, C20R, C21, C21R 32

3.4 Engine data 16 V 4000 C20, C20R, C21, C21L 35

3.5 Firing order 38

3.6 Engine – Main dimensions 39

4 Operation

4.1 Putting the engine into operation after extended out-of-service periods (>3 months) 40

4.2 Putting the engine into operation after scheduled out-of-service-period 41

4.3 Starting the engine in manual mode 42

4.4 Operational checks 43

4.5 Stopping the engine in manual mode 44

4.6 After stopping the engine 45

4.7 Plant cleaning 46

5 Maintenance

5.1 Maintenance task reference table [QL1] 47

6 Troubleshooting

6.1 Troubleshooting 49

6.2 Fault messages from DDEC engine governor 52

7 Task Description

7.1 Engine 72

7.1.1 Engine – Barring manually 72

7.1.2 Engine – Barring with starting system 73

7.2 Cylinder Liner 74

7.2.1 Cylinder liner – Endoscopic examination 74

7.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners 76

7.3 Crankcase Breather 78

7.3.1 Crankcase breather – Filter element replacement 78

7.3.2 Crankcase breather (open-circuit crankcase ventilation) – Filter element cleaning 80

7.4 Running Gear 81

7.4.1 Grounding device – Check carbon brush 81

7.4.2 Grounding device – Carbon brush replacement 83

7.5 Valve Drive 84

7.5.1 Valve gear – Lubrication 84

7.5.2 Valve clearance – Check and adjustment 85

7.5.3 Cylinder head cover – Removal and installation 89

7.6 Injection Pump / HP Pump 90

7.6.1 HP pump – Relief bore check 90

7.7 Injection Valve / Injector 91

7.7.1 Injector – Replacement 91

7.7.2 Injector – Removal and installation 92

7.8 Fuel System 97

7.8.1 Fuel system – Venting 97

7.9 Fuel Filter 98

7.9.1 Fuel filter – Replacement 98

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7.10 Charge-Air Cooling 99

7.10.1 Charge-air cooler – Check water drain for coolant leakage and absence of restrictions 99

7.11 Starting Equipment 100

7.11.1 Starter – Condition check 100

7.11.2 Cold start system with ether injection – Check 101

7.12 Air Intake 102

7.12.1 Service indicator – Check 102

7.13 Lube Oil System, Lube Oil Circuit 103

7.13.1 Engine oil – Level check 103

7.13.2 Engine oil – Change 104

7.13.3 Engine oil – Sample extraction and analysis 106

7.14 Oil Filtration / Cooling 107

7.14.1 Engine oil filter – Replacement 107

7.14.2 Oil indicator filter – Check 108

7.14.3 Centrifugal oil filter – Cleaning and filter sleeve replacement 110

7.15 Coolant Circuit, General, HighTemperature Circuit 112

7.15.1 Engine coolant – Level check 112

7.15.2 Engine coolant – Change 113

7.15.3 Engine coolant – Draining 114

7.15.4 Engine coolant – Filling 115

7.15.5 Engine coolant pump – Relief bore check 117

7.15.6 Coolant filter – Replacement 118

7.15.7 Engine coolant – Sample extraction and analysis 119

7.16 Low-Temperature Circuit 120

7.16.1 Charge-air coolant – Level check 120

7.16.2 Charge-air coolant – Change 121

7.16.3 Charge-air coolant – Drainage 122

7.16.4 Charge-air coolant – Filling 123

7.16.5 Charge-air coolant pump – Relief bore check 126

7.17 Engine Mounting / Support 127

7.17.1 Engine mounting – Check 127

7.18 Belt Drive 128

7.18.1 Drive belt – Condition check 128

7.19 Battery-Charging Generator 129

7.19.1 Battery-charging generator – Condition check 129

7.19.2 Battery-charging generator – Check 130

7.19.3 Battery-charging generator – Removal and installation 131

7.19.4 Battery-charging generator – Drive belt and belt tensioner replacement 133

7.19.5 Battery-charging generator – Drive belt tension adjustment 135

7.20 Fan Drive 136

7.20.1 Fan drive – Adjust and check drive belt tension 136

7.20.2 Fan drive – Drive belt replacement 138

7.21 Auxiliary PTO 139

7.21.1 Compressor – Check 139

7.22 Wiring (General) for Engine/Gearbox/Unit 140

7.22.1 Engine wiring – Check 140

7.23 Accessories for (Electronic) Engine Governor / Control System 141

7.23.1 DDEC and connectors – Cleaning 141

7.23.2 DDEC – Checking plug-in connections 143

8 Appendix A

8.1 Abbreviations 144

8.2 MTU contact persons/service partners 147

9 Appendix B

9.1 Special Tools 148

9.2 Index 154

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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

Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.

Always use the lifting eyes on the engine when transporting an engine separately.

Only use transport and lifting devices approved by MTU.

The engine/genset must only be transported in installation position: maximum permissible diagonal pull 10°.

Remove any loose parts on the genset.

Raise the engine/genset slowly. The lifting ropes or chains must not make contact with the engine or its components. Readjust lifting device as necessary.

Pay attention to the center of gravity of the engine/genset.

For special packaging with aluminium foil: Suspend the engine/genset by the lifting eyes on the bearing pedestal or transport by means of handling equipment (forklift truck) capable of bearing the load.

Fit the crankshaft transportation lock on the engine and fit the engine mount locking devices prior to transport.

Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip‐ ping and tipping when driving up or down inclines and ramps.

Placement after transport

Place the engine/genset on a firm, flat surface only.

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

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

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1.4 Crankshaft transport locking device

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 10-60Nm

F30452769 1

Torque wrench, 60-320Nm

F30452768 1

Engine oil

Note: The transport locking device on both sides protects the crankshaft bearings from shocks and possible

vibration damage during engine transport.

For installation and removal of the transport locking device, follow the instructions below:

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

2. Prior to every engine transport (without generator) , the transport locking device on both sides must be installed according to the instructions.

3. If the engine is to be moved together with the generator, the transport locking device for the generator must also be installed (→ Page 11).

4. Always use the screws supplied with or installed in the transport locking device to secure it on the en‐ gine.

5. Starting or barring the engine is allowed only with the transport locking device removed. If the generator is already mounted on the engine, ensure that the transport locking device of the generator is also re‐ moved.

6. Attach this documentation to a highly visible area of the engine.

Removing the transport locking device from driving end (KS), version A

1. Remove parts (1) to (8) from engine. Spacer sleeves (5), optional.

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

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Installing the transport locking device on driving end (KS), version A

1. Screw holder (4) with spacer sleeves (5) and screws (6) onto crankshaft. Spacer sleeves (5), optional.

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

Name Size Type Lubricant Value/Standard

Screw M16 Tightening torque (Engine oil) 160Nm +16Nm

3. Screw nut (3) with washer (2) onto holder (4). Screw on carrier (1) with washer (7) and nut (8) and tight‐ en nut (8) to the specified tightening torque using the torque wrench.

Name Size Type Lubricant Value/Standard

Nut M24 Tightening torque (Engine oil) 100Nm +10Nm

4. Secure with nut (3).

5. Mark the engine as "Fitted with transport locking device".

Removing the transport locking device from driving end (KS), version B

1. Release the locknuts (2) on both sides of the flywheel housing, remove screw (3) and take off holder (8).

2. Unscrew screws (5) and remove with wash‐ ers (4), cover plate (7) sign (6) and plates (1).

3. Store the removed parts of the transport locking device carefully for possible reuse together with this documentation.

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Installing the transport locking device on driving end (KS), version B

1. Secure plate (1) with screws (5) and washers (4) together with cover plate (7) at the bores on both sides of the flywheel housing and tighten to the specified tightening torque.

Name Size Type Lubricant Value/Standard

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

2. Screw locknut (2) onto screws (3) up to the end of the thread.

3. Insert holder (8) through opening in plate (1) and secure with screw (3).

4. Tighten screws (3) alternately with torque wrench to the specified tightening torque.

Name Size Type Lubricant Value/Standard

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

5. Place locknuts (2) of screw (3) in position on both sides of plate (1) and lock.

6. Fit sign (6) to mark the engine as "Fitted with transport locking device".

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1.5 Crankshaft transport locking device – For transport with flanged-on generator

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 10-60Nm

F30452769 1

Torque wrench, 60-320Nm

F30452768 1

Engine oil

Note: The transport locking device on the engine protects the crankshaft bearings from shocks and vibration

damage during genset transport.

The following must be taken into account when removing/installing the transport locking device:

1. The transport locking device must remain installed as long as possible during genset installation in order to avoid damage.

2. Prior to every genset transport, the transport locking device must be reinstalled on the engine and gener‐ ator according to the instructions.

3. Always use the screws supplied with or installed in the transport locking device to secure it on the en‐ gine.

4. Starting or barring the engine is allowed only with the transport locking device removed from engine and generator.

Removing the transport locking device from driving end (KS)

1. Release nut (11) on both sides.

2. Remove screw (5), washer (4), holder (3) and screw (6) from flywheel (2).

3. Remove screw (9), washer (8) and hold‐ er (7) from crankcase (12).

4. Install the two screws with washers to secure the diaphragm coupling to the flywheel.

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 250Nm +25Nm

Installing the transport locking device on driving end (KS)

1. Remove the transport locking device installed by MTU (→ Page 8).

2. Remove protective cover from flywheel housing (1).

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3. Install the holders (7) on both sides of the crankcase (12) with screw (9) and washer (8). Tighten screw (9).

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 290Nm +20Nm

4. To allow the holders (3) to be secured on each side of the flywheel (2), the corresponding screws and washers must be removed from the driving end.

5. Leave the unscrewed screws with washers on engine and screw back in when the transport locking de‐ vice has been removed.

6. Place screw (6) in the recess of holder (3) and insert through the opening at the flywheel housing (1). Secure holder (3) with screw (5) and washer (4) to flywheel (2). Tighten screw (5).

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 180Nm +18Nm

7. Fit conical spring washer (10) on screw (6) and tighten nut (11).

Name Size Type Lubricant Value/Standard

Nut Tightening torque (Engine oil) 27Nm +3Nm

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1.6 Safety regulations for startup and operation

Safety requirements for initial operation

Before the engine or plant is put into operation for the first time, the engine or plant must be installed and accepted in accordance with MTU specifications.

Before the engine or plant is put into operation for the first time, all official authorizations must be availa‐ ble and commissioning preconditions met.

When putting the engine / plant into operation, always ensure:

• that all maintenance and repair work has been completed;

• that all loose parts have been removed from rotating machine components;

• that no-one is present in the danger zone of rotating machine components.

Immediately after putting the engine or plant into operation, make sure that all control and display instru‐ ments as well as the monitoring, signaling and alarm systems work properly.

Safety regulations for equipment operation

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

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

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

Engine malfunctions and engine emergency stop

The procedures for cases of emergency, in particular, engine emergency stop, must be practiced regu‐ larly.

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

• inform supervisor(s) in charge,

• analyze the message,

• if required, carry out emergency operations e.g. emergency stop.

Engine operation

The following conditions must be fulfilled before starting the engine or plant:

• Wear ear protection.

• Ensure that the engine room is well ventilated.

• Do not inhale engine exhaust gases.

• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.

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

• Protect battery terminals, battery-charger terminals and cables against accidental contact.

Operation of electrical equipment

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

Observe the safety instructions for these devices.

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1.7 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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1.8 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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1.9 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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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 – Overview

Figure applies to 16V4000 Cxy analogously

1 Oil cooler 2 Fan coupling 3 Crankcase breather 4 Control valve for fan

coupling 5 Centrifugal oil filter 6 Exhaust outlet 7 Turbocharger

8 Combustion-air inlet

9 Charge-air cooler 10 Charge-air line 11 Starter 12 Engine governor 13 Easy-change fuel filter 14 Oil filter

15 Air conditioning com‐

pressor drive 16 HP pump 17 Engine mounting 18 Battery-charging gener‐

ator 19 Charge-air coolant

pump 20 Charge-air coolant ther‐

mostat 21 Engine coolant outlet

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1 Charge-air line 2 Cylinder head / cylinder

head cover 3 Crankcase breather 4 Coolant circuit / vent

connection 5 Oil cooler 6 Charge-air coolant out‐

let 7 Engine coolant inlet

8 Lifting eyes

9 Crankcase breather 10 Charge-air coolant inlet 11 Engine coolant pump 12 Inspection port cover 13 Oil filler neck 14 Oil pan

15 Crankcase 16 Flywheel housing 17 Flywheel 18 Charge-air line 19 Charge-air cooler

Engine model designation

Key to the engine model designations 12/16V 4000 Cxy

12 / 16 Number of cylinders

V Cylinder arrangement: V engine

4000 Series

C Application: Construction and Industrial, mobile

x Application segment: 1, 2

y Configuration status: 0, 1

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2.3 Sensors, actuators and injectors – Overview

1 Engine coolant temper‐

ature

2 Crankshaft speed

3 Charge-air temperature 4 Charge-air pressure

The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and necessa‐ ry activities (→ Page 91).

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1 Camshaft speed 2 Fuel pressure (LP)

3 Fuel temperature

4 Fuel high pressure

5 Charge-air coolant pres‐

sure

6 Engine coolant pressure

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1 Lube oil temperature 2 Lube oil pressure

3 Crankcase pressure 4 Charge-air coolant tem‐

perature

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3 Technical Data

3.1 Engine data 12 V 4000 C10, C10R, C11, C11R

Explanation

Abbr. Meaning

DL Reference value: Continuous power

BL Reference value: Fuel stop power

A Design value

G Guaranteed value

R Guideline value

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

ting)

N Not yet defined value

- Not applicable

X Applicable

12 V 4000 C11: T1237K33 / 06N04M 1328

12 V 4000 C11R: T1237K33 / 06N04M 1329

REFERENCE CONDITIONS

Engine model 12V

4000

C10

12V

4000

C10R

12V

4000

C11

12V

4000

C11R

Application group 5A, 5B 5A, 5B 5A, 5B 5A, 5B

Intake air temperature °C 25 25 25 25

Barometric pressure mbar 1000 1000 1000 1000

Site altitude above sea level m 100 100 100 100

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

Number of cylinders 12 12 12 12

Rated engine speed A rpm - - 1900 1900

Continuous power (without fan) (fuel stop power)

A kW - - 1286 1193

GENERAL CONDITIONS (for maximum power)

Number of cylinders 12 12 12 12

Intake depression (new filter) A mbar 30 - 30 30

Intake depression, max. L mbar 50 - 50 50

Exhaust overpressure A mbar 37 - 37 37

Exhaust pressure, max. L mbar 50 - 50 50

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MODEL RELATED DATA (basic design)

Number of cylinders 12 12 12 12

Cylinder arrangement: V angle Degrees 90 90 90 90

Bore mm 165 165 165 165

Stroke mm 190 190 190 190

Displacement of a cylinder Liters 4.1 4.1 4.1 4.1

Displacement, total Liters 48.80 48.80 48.80 48.80

Number of inlet valves per cylinder 2 2 2 2

Number of exhaust valves per cylinder 2 2 2 2

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 12 12 12 12

Charge-air pressure before cylinder R bar 2.0 - 2.1 1.95

Exhaust gas temperature R °C 385 - 395 382

COOLANT SYSTEM (HT circuit)

Number of cylinders 12 12 12 12

Coolant temperature (at engine connec‐ tion: outlet to cooling equipment)

A °C 90 - 95 95

Coolant pump: inlet pressure, max. R °C 1.5 - 1.5 1.5

Thermostat: Starts to open R % 76 - 76 76

Thermostat: Fully open R bar 87 - 87 87

LUBE OIL SYSTEM

Number of cylinders 12 12 12 12

Lube oil operating pressure upstream of engine, from

R bar 6.1 - 6.3 6.3

FUEL SYSTEM

Number of cylinders 12 12 12 12

Fuel temperature before pump, max. L °C 60 - 60 60

CAPACITIES

Number of cylinders 12 12 12 12

Engine coolant capacity, engine side (without cooling equipment)

R Liters 127 - 127 127

Charge-air coolant, engine side R Liters 33 - 33 33

Engine oil, max. R Liters 198 - 198 198

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 12 12 12 12

Engine weight, dry (basic engine config‐ uration acc. to scope of delivery specifi‐ cation)

R kg 6044 6044 6044 6044

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NOISE

Number of cylinders 12 12 12 12

Unsilenced exhaust noise at 1m dis‐ tance

R dB(A) 108 - 110 108

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3.2 Engine data 16 V 4000 C10, C11, C11R

Explanation

Abbr. Meaning

DL Reference value: Continuous power

BL Reference value: Fuel stop power

A Design value

G Guaranteed value

R Guideline value

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

ting)

N Not yet defined value

- Not applicable

X Applicable

16 V 4000 C11: T1637K33 / 06N04M 1477

16 V 4000 C11R: T1637K33 / 06N04M 1336

REFERENCE CONDITIONS

Engine model 16 V

4000

C10

16 V

4000

C11

16 V

4000

C11R

Application group 5A, 5B 5A, 5B 5A, 5B

Intake air temperature °C 25 25 25

Barometric pressure mbar 1000 1000 1000

Site altitude above sea level m 100 100 100

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

Number of cylinders 16 16 16

Rated engine speed A rpm - 1900 1800

Continuous power (without fan) (fuel stop power)

A kW - 1715 1600

GENERAL CONDITIONS (for maximum power)

Number of cylinders 16 16 16

Intake depression (new filter) A mbar 30 30 30

Intake depression, max. L mbar 50 50 50

Exhaust overpressure A mbar 37 37 37

Exhaust pressure, max. L mbar 50 50 50

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MODEL RELATED DATA (basic design)

Number of cylinders 16 16 16

Cylinder arrangement: V angle Degrees 90 90 90

Bore mm 165 165 165

Stroke mm 190 190 190

Displacement of a cylinder Liters 4.1 4.1 4.1

Displacement, total Liters 65.0 65.0 65.0

Number of inlet valves per cylinder 2 2 2

Number of exhaust valves per cylinder 2 2 2

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 16 16 16

Charge-air pressure before cylinder R bar 2.0 2.1 1.95

Exhaust gas temperature R °C 375 377 376

COOLANT SYSTEM (HT circuit)

Number of cylinders 16 16 16

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

A °C 95 95 95

Coolant pump: inlet pressure, max. R °C 1.5 1.5 1.5

Thermostat: Starts to open R % 76 76 76

Thermostat: Fully open R bar 87 87 87

LUBE OIL SYSTEM

Number of cylinders 16 16 16

Lube oil operating pressure upstream of en‐ gine, from

R bar 6,1 6,1 6,0

FUEL SYSTEM

Number of cylinders 16 16 16

Fuel temperature before pump, max. L °C 60 60 60

CAPACITIES

Number of cylinders 16 16 16

Engine coolant capacity, engine side (without cooling equipment)

R Liters 164 164 164

Charge-air coolant, engine side R Liters 42 42 42

Engine oil, max. R Liters 230 230 230

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 16 16 16

Engine weight, dry (basic engine configura‐ tion acc. to scope of delivery specification)

R kg 7083 7083 7083

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NOISE

Number of cylinders 16 16 16

Unsilenced exhaust noise at 1m distance R dB(A) 108 110 108

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3.3 Engine data 12 V 4000 C20, C20R, C21, C21R

Explanation

Abbr. Meaning

DL Reference value: Continuous power

BL Reference value: Fuel stop power

A Design value

G Guaranteed value

R Guideline value

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

ting)

N Not yet defined value

- Not applicable

X Applicable

12 V 4000 C21: T1237K33 / 06N04M 1326

12 V 4000 C21R: T1237K33 / 06N04M 1327

REFERENCE CONDITIONS

Engine model 12V

4000

C20

12V

4000

C20R

12V

4000

C21

12V

4000

C21R

Application group 5A, 5B 5A, 5B 5A, 5B 5A, 5B

Intake air temperature °C 25 25 25 25

Barometric pressure mbar 1000 1000 1000 1000

Site altitude above sea level m 100 100 100 100

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

Number of cylinders 12 12 12 12

Rated engine speed A rpm 1900 1900 1900 1900

Continuous power (without fan) (fuel stop power)

A kW 1500 - 1510 1398

GENERAL CONDITIONS (for maximum power)

Number of cylinders 12 12 12 12

Intake depression (new filter) A mbar 25 - 30 30

Intake depression, max. L mbar 50 - 50 50

Exhaust overpressure A mbar 30 - 37 37

Exhaust pressure, max. L mbar 50 - 50 50

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MODEL RELATED DATA (basic design)

Number of cylinders 12 12 12 12

Cylinder arrangement: V angle Degrees 90 90 90 90

Bore mm 165 165 165 165

Stroke mm 190 190 190 190

Displacement of a cylinder Liters 4.1 4.1 4.1 4.1

Displacement, total Liters 48.80 48.80 48.80 48.80

Number of inlet valves per cylinder 2 2 2 2

Number of exhaust valves per cylinder 2 2 2 2

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 12 12 12 12

Charge-air pressure before cylinder R bar 2.5 - 2.4 2.2

Exhaust gas temperature R °C 415 - 431 413

COOLANT SYSTEM (HT circuit)

Number of cylinders 12 12 12 12

Coolant temperature (at engine connec‐ tion: outlet to cooling equipment)

A °C 92 - 95 95

Coolant pump: inlet pressure, max. R °C 1.5 - 1.5 1.5

Thermostat: Starts to open R % 76 - 76 76

Thermostat: Fully open R bar 87 - 87 87

LUBE OIL SYSTEM

Number of cylinders 12 12 12 12

Lube oil operating pressure upstream of engine, from

R bar 6.5 - 6.1 6.3

FUEL SYSTEM

Number of cylinders 12 12 12 12

Fuel temperature before pump, max. L °C 60 - 60 60

CAPACITIES

Number of cylinders 12 12 12 12

Engine coolant capacity, engine side (without cooling equipment)

R Liters 160 - 127 127

Charge-air coolant, engine side R Liters 33 - 33 33

Engine oil, max. R Liters 198 - 198 198

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 12 12 12 12

Engine weight, dry (basic engine config‐ uration acc. to scope of delivery specifi‐ cation)

R kg 6044 6044 6044 6044

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NOISE

Number of cylinders 12 12 12 12

Unsilenced exhaust noise at 1m dis‐ tance

R dB(A) 108 - 110 108

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3.4 Engine data 16 V 4000 C20, C20R, C21, C21L

Explanation

Abbr. Meaning

DL Reference value: Continuous power

BL Reference value: Fuel stop power

A Design value

G Guaranteed value

R Guideline value

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

ting)

N Not yet defined value

- Not applicable

X Applicable

16 V 4000 C21: T1637K33 / 06N04M 1476

16 V 4000 C21L: T1637K33 / 06N04M 1475

REFERENCE CONDITIONS

Engine model 16 V

4000

C20

16 V

4000

C20R

16 V

4000

C21

16 V

4000

C21L

Application group 5A, 5B 5A, 5B 5A, 5B 5A, 5B

Intake air temperature °C 25 25 25 25

Barometric pressure mbar 1000 1000 1000 1000

Site altitude above sea level m 100 100 100 100

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

Number of cylinders 16 16 16 16

Rated engine speed A rpm 1900 1900 1900 1900

Continuous power (without fan) (fuel stop power)

A kW 2013 1864 1864 2013

GENERAL CONDITIONS (for maximum power)

Number of cylinders 16 16 16 16

Intake depression (new filter) A mbar 25 - 30 30

Intake depression, max. L mbar 50 - 50 50

Exhaust overpressure A mbar 30 - 37 37

Exhaust pressure, max. L mbar 50 - 50 50

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MODEL RELATED DATA (basic design)

Number of cylinders 16 16 16 16

Cylinder arrangement: V angle Degrees 90 90 90 90

Bore mm 165 165 165 165

Stroke mm 190 190 190 190

Displacement of a cylinder Liters 4.1 4.1 4.1 4.1

Displacement, total Liters 65.0 65.0 65.0 65.0

Number of inlet valves per cylinder 2 2 2 2

Number of exhaust valves per cylinder 2 2 2 2

COMBUSTION AIR / EXHAUST GAS

Number of cylinders 16 16 16 16

Charge-air pressure before cylinder R bar 2.5 - 2.3 2.4

Exhaust gas temperature R °C 490 - 395 415

COOLANT SYSTEM (HT circuit)

Number of cylinders 16 16 16 16

Coolant temperature (at engine connec‐ tion: outlet to cooling equipment)

A °C 92 - 95 95

Coolant pump: inlet pressure, max. R °C 1.5 - 1.5 1.5

Thermostat: Starts to open R % 76 - 76 76

Thermostat: Fully open R bar 87 - 87 87

LUBE OIL SYSTEM

Number of cylinders 16 16 16 16

Lube oil operating pressure upstream of engine, from

R bar 6.5 - 6.3 6.1

FUEL SYSTEM

Number of cylinders 16 16 16 16

Fuel temperature before pump, max. L °C 60 - 60 60

CAPACITIES

Number of cylinders 16 16 16 16

Engine coolant capacity, engine side (without cooling equipment)

R Liters 164 - 164 164

Charge-air coolant, engine side R Liters 42 - 42 42

Engine oil, max. R Liters 230 - 230 230

WEIGHTS / MAIN DIMENSIONS

Number of cylinders 16 16 16 16

Engine weight, dry (basic engine config‐ uration acc. to scope of delivery specifi‐ cation)

R kg 7083 7083 7083 7083

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NOISE

Number of cylinders 16 16 16 16

Unsilenced exhaust noise at 1m dis‐ tance

R dB(A) 108 - 112 114

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3.5 Firing order

Firing order

Number of cylin‐ ders

Firing order

8V A1-B4-A4-A2-B3-A3-B2-B1

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

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

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

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3.6 Engine – Main dimensions

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

12 V 4000 Cxy approx. 2540 mm approx. 1620 mm approx. 1990 mm

16 V 4000 Cxy approx. 3010 mm approx. 1620 mm approx. 1990 mm

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4 Operation

4.1 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 Action

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

Valve gear Lubricate valve gear every ≥ 6 months (→ Page 84).

Lube oil system Check engine oil level (→ Page 103);

Bar engine with startingsystem (→ Page 73).

Fuel system Vent (→ Page 97).

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

(→ Page 113).

Change charge-air coolant (→ Page 121).

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

Check charge-air coolant level (→ Page 120).

Coolant circuit Preheat coolant with preheating unit, if fitted.

DDEC Check plug-in connections (→ Page 143).

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

Preconditions

☑ Engine is stopped and starting disabled.

Startup

Item Action

Lube oil system Check engine oil level (→ Page 103).

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

Check charge-air coolant level (→ Page 120).

Coolant circuit Preheat coolant with coolant preheating unit (if applicable).

Engine control system Put into operation.

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4.3 Starting the engine in manual mode

Preconditions

☑ Engine is not under load.

☑ 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 Action

Operating mode switch (if applicable)

Switch to manual mode.

Coolant preheating unit (if applicable).

Switch ON.

Starting the engine

Item Action

Switchgear cabinet, opera‐ tor station etc. (depending on manufacturer).

1. If no coolant preheater is fitted, make sure that the coolant tempera‐ ture is > 40 °C.

2. Press start button.

• Automatic starting procedure is performed;

• Engine speed instrument indicates increasing speed;

• After the starting sequence is completed, engine is running at idle

speed.

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4.4 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 Action

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

Engine operation Visually inspect engine and attached components for condition and leaks;

Check for abnormal running noise, exhaust discoloration and vibrations (→ Page 49).

Battery-charging generator Check for dirt, clean as necessary (→ Page 130).

HP pump Check relief bore (→ Page 90).

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

LT coolant pump Check relief bore (→ Page 126).

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4.5 Stopping the engine in manual mode

Preconditions

☑ Engine is not under load.

☑ Engine is running in manual mode.

CAUTION

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

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

Preparation

Item Action

Engine Operate engine at idling speed for approx. 5 minutes.

Stopping the engine

Item Action

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

Press stop button.

• Automatic stopping sequence is executed.

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4.6 After stopping the engine

Preconditions

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

After stopping the engine

Item Action

Coolant circuit Drain coolant (→ Page 114)(→ Page 122) if:

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

• the coolant is not maintained at a suitable temperature;

• antifreeze concentration is 50 % and outside temperature is below

-40°C.

Engine control system Switch off.

Air intake and exhaust sys‐ tem

Out-of-service-period > 1 week:

Seal engine's air and exhaust sides.

Out-of-service-period > 1 month:

Preserve engine (→ MTU Fluids and Lubricants Specifications A001061/.. ).

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4.7 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 Option Maintenance tasks

W0500 Check engine oil level. (→ Page 103)

W0501 Visually inspect engine for leaks and general condition. (→ Page 43)

W0502 X Check intercooler drain(s). (→ Page 99)

W0503 Check signal ring position of service indicator on air filter. (→ Page 102)

W0504 Check relief bores of HP fuel pump. (→ Page 43)

W0505 Check relief bores of water pump(s). (→ Page 117)

W0506 Check engine for abnormal running noises, exhaust color

and vibrations .

(→ Page 43)

W0507 X Drain water and contaminants from fuel prefilter. -

W0508 X Check reading on differential pressure gage of fuel prefil‐

ter.

W0525 Check battery-charging generator for contamination, clean

as necessary.

(→ Page 130)

W1001 Replace fuel filter or fuel filter element. (→ Page 98)

W1003 Check belt condition and tension, replace if necessary. (→ Page 128)

W1006 Replace fuel injectors. (→ Page 91)

W1009 X Check layer thickness of oil residue, clean and replace fil‐

ter sleeve of centrifugal oil filter (if fitted) at every oil change, at the latest.

(→ Page 110)

W1011 Perform endoscopic examination of combustion chambers. (→ Page 74)

W1036 Replace coolant filter. (→ Page 118)

W1046 Crankcase breather: Replace filter or filter element. (→ Page 78)

W1047 X Check and clean oil indicator filter. (→ Page 108)

W1164 Replace filter element and sealing ring depending on de‐

gree of contamination, when the limit (years) is reached, at the latest.

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

adjustment after 1,000 operating hours!

(→ Page 85)

W1463 Check general condition of engine mounting (visual inspec‐

tion).

(→ Page 127)

W1481 Replace supplementary fuel filter or filter element of sup‐

plementary fuel filter.

W1697 X Check carbon brushes at flywheel, replace if necessary. (→ Page 81)

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Task Option Maintenance tasks

W1698 X Replace carbon brushes at flywheel. (→ Page 83)

W1716 Cleaning battery-charging generator. (→ Page 131)

Table 1: Maintenance task reference table [QL1]

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6 Troubleshooting

6.1 Troubleshooting

Engine does not turn when starter is actuated

Component Cause Action

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

documentation).

Cable connections faulty Check if cable connections are proper‐

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

Starter Engine cabling or starter faulty Check if cable connections are proper‐

ly secured, contact Service.

Engine cabling Faulty Check (→ Page 140).

Engine/generator control system

Assemblies or connectors possibly loose

Perform visual inspection (see manu‐ facturer's documentation).

DDEC Plug-in connections possibly loose Check plug-in connections

(→ Page 143).

Engine Running gear blocked (engine cannot

be barred manually)

Contact Service.

Engine turns but does not fire

Component Cause Action

Starter Poor rotation by starter: Battery low or

faulty

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

Engine cabling Faulty Check (→ Page 140).

Fuel system Air in fuel system Vent fuel system (→ Page 97).

DDEC Faulty Contact Service.

Engine fires unevenly

Component Cause Action

Fuel injection equip‐ ment

Injector faulty Replace (→ Page 91).

Engine cabling Faulty Check (→ Page 140).

Fuel system Air in fuel system Vent fuel system (→ Page 97).

DDEC Faulty Contact Service.

Engine does not reach rated speed

Component Cause Action

Fuel supply Fuel prefilter clogged Clean or replace filter element.

Easy-change fuel filter clogged Replace (→ Page 98).

Air supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 102).

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Component Cause Action

Fuel injection equip‐ ment

Injector faulty Replace (→ Page 91).

Engine cabling Faulty Check (→ Page 140).

Engine Overloaded Contact Service.

Engine speed not steady

Component Cause Action

Fuel injection equip‐ ment

Injector faulty Replace (→ Page 91).

Speed sensor Faulty Contact Service.

Fuel system Air in fuel system Vent fuel system (→ Page 97).

DDEC Faulty Contact Service.

Charge air temperature too high

Component Cause Action

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

Intercooler Contaminated Contact Service.

Engine room Air-intake temperature too high Check fans and intake/exhaust lines.

Charge-air pressure too low

Component Cause Action

Air supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 102).

Intercooler Contaminated Contact Service.

Exhaust turbocharger Faulty Contact Service.

Coolant leaks at intercooler

Component Cause Action

Intercooler Leaking, major coolant discharge Contact Service.

Black exhaust gas

Component Cause Action

Air supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 102).

Fuel injection equip‐ ment

Injector faulty Replace (→ Page 91).

Engine Overloaded Contact Service.

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Blue exhaust gas

Component Cause Action

Engine oil Too much oil in engine Drain engine oil (→ Page 104).

Filter element in oil separator is clog‐ ged

Replace (→ Page 78).

Exhaust turbocharg‐ er, cylinder head, pis‐ ton rings, cylinder lin‐ er

Faulty Contact Service.

White exhaust gas

Component Cause Action

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

ature.

Fuel system Water in fuel Drain fuel prefilter

Check fuel system.

Intercooler Leaking Contact Service.

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6.2 Fault messages from DDEC engine governor

The DDEC engine governor generates alarms which are indicated in different ways depending on the equipment configuration:

• Two-digit flashing code

• Fault code and text on a display or PC screen

To facilitate troubleshooting without additional auxiliary equipment, the two-digit flash codes can be read out from the DDEC by means of the vehicle-side alarm lamps CHECK ENGINE LIGHT (yellow) and STOP ENGINE LIGHT (red).

Two switches (DIAGNOSTIC REQUEST) must be provided in the plant in this case. The first switch is used for reading out the flash codes of the master DDEC unit, the second one to read out the receiver DDEC unit. The flash-code signals from master and receiver are transmitted to the same alarm lamps.

Active codes: Inactive codes:

indicated by STOP ENGINE LIGHT (red) indicated by CHECK ENGINE LIGHT (yellow)

Activation of “FLASH-CODES”:

1. Set “IGNITION” switch to ON.C.

2. Actuate “DIAGNOSTIC REQUEST” switch of Master or Receiver.

3. Read-off codes.

4. Identify fault on the basis of the DDC fault code list.

Example:

Active code 23: Inactive code 34:

STOP ENGINE LIGHT lamp

flashes:

CHECK ENGINE LIGHT lamp

flashes:

Flashing phase 1 Flashing phase 2 Flashing phase 1 Flashing phase 2

О О О О О О О О О О О О

2 x flash 3 x flash 3 x flash 4 x flash

There is a pause lasting 0.5 seconds between flashing phases 1 and 2. There is a pause of approx. 3 seconds on changing between active and inactive code.

Switch off the “DIAGNOSTIC REQUEST” and “IGNITION” switches to cancel “FLASH-CODE” indication.

The “IGNITION” switch may only be switched back on after a 30 sec. delay.

Precise fault diagnosis is, however, not possible using this method as any one flashing code may be used to cover several different fault causes.

Detailed diagnosis is possible using the Diagnostic Data Reader (DDR) readout/programming unit.

The Diagnostic Data Reader (DDR) is used to:

• Read out DDEC electronics fault messages

• Change a limited scope of parameters Active and inactive fault codes can be read out with the DDR via separate menus. Inactive fault codes stored in the governor can also be deleted.

Refer to the DDR device description for details of the range of features.

The DDR (part no. 5355383601/77) comprises:

• One Pro Link 9000 basic unit

• One cartridge to accommodate a PCMCIA plug-in circuit board (MPC cartridge)

• One PCMCIA plug-in circuit board

• One connecting cable

• An additional adapter cable is also required (part no. J 38500 60A)

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Additional accessories:

• Printer (part no. J-38699) for direct connection to the DDR

• Spare paper (part no. J-38480-5) for the printer (5 rolls respectively)

The following information is available on reading out the fault codes with the DDR.

Example:

33 MID:128 Engine

TURBO BOOST SENSOR

INPUT VOLTAGE HIGH

▴ A1 PID: 102 FMI:3 ▾

Explanation:

• 33 → Flashing code

• MID: 128 →Information about the source of the fault message

• TURBO-BOOST-SENSOR-INPUT-VOLTAGE-HIGH → Fault text

• ▴ ▾ → more faults pending A= active, I= inactive

MID (Message Identification Character)

• Information about the source of the fault message: MID 128 → Master MID 175 → Receiver 1 MID 183 → Receiver 2

PID (Parameter Identification Character).

• Information to identify transmitted data: (e.g. engine speed, coolant temperature etc.) PID 0-127 → 1 data byte PID 128-191 → 2 data bytes PID 192-253 → Variable

SID (Subsystem Identification Character)

• Information about the source of fault messages from subordinate systems which may be replaced as a unit (e.g. injectors).

FMI (Failure Mode Identifier)

• Information about the type of fault which has occurred. FMI 0 → Measured value above limit value (monitoring of TOO HIGH) example: Coolant temperature FMI 1 → Measured value below limit value (monitoring of TOO LOW) example: Lube oil pressure FMI 3 → Signal disrupted or signal above admissible measuring range (sensor failure) FMI 4 → Signal short-circuited to (-) supply of sensor or signal below admissible measuring range (sensor failure)

Flashi ng code

PID SID FMI Description Maintenance tasks

11 187 4 Position sensor of variable

speed governor → voltage too low.

Contact Service.

11 187 7 Control system/ variable

speed governor→ voltage too high.

Contact Service.

12 187 3 Position sensor of variable

speed governor → voltage too high.

Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

13 111 4 Coolant level sensor, input

voltage too low.

1. Check coolant condition (→ Page 119).

2. Check coolant level, top up if required (→ Page 112).

3. Check cabling.

4. Contact Service.

13 111 6 Sensor "Top up coolant", in‐

put voltage too low.

1. Check coolant condition (→ Page 119).

2. Check coolant level, top up if required (→ Page 112).

3. Check cabling.

4. Contact Service.

14 52 3 Temperature sensor/inter‐

cooler, input voltage too high.

1. Check cabling.

2. Contact Service.

14 110 3 Coolant temperature sen‐

sor, input voltage too high.

1. Check cabling.

2. Contact Service.

14 175 3 Oil temperature sensor, in‐

put voltage too high.

Contact Service.

15 52 4 Temperature sensor/inter‐

cooler, input voltage too low.

1. Check cabling.

2. Contact Service.

15 110 4 Coolant temperature sen‐

sor, input voltage too low.

1. Check cabling.

2. Contact Service.

15 175 4 Oil temperature sensor, in‐

put voltage too low.

Contact Service.

16 111 3 Coolant level sensor, input

voltage too high.

1. Check coolant condition (→ Page 119).

2. Check coolant level, top up if required (→ Page 112).

3. Check cooler for dirt.

4. Check cabling.

5. Contact Service.

16 111 5 Sensor "Top up coolant", in‐

put voltage too high.

1. Check cabling.

2. Contact Service.

17 51 3 Throttle sensor, input volt‐

age too high.

1. Check cabling.

2. Contact Service.

17 72 3 Blower bypass position, in‐

put voltage too high.

1. Check cabling.

2. Contact Service.

17 354 3 Humidity sensor, electric

circuit defective / high (ver‐ sion 33.0 or later).

1. Check cabling.

2. Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

18 51 4 Throttle sensor, input volt‐

age too low.

1. Check cabling.

2. Contact Service.

18 72 4 Blower bypass position, in‐

put voltage too low.

1. Check cabling.

2. Contact Service.

18 354 4 Humidity sensor, electric

circuit defective / low (ver‐ sion 33.0 or later).

1. Check cabling.

2. Contact Service.

21 91 3 Throttle sensor, input volt‐

age too high.

1. Check cabling.

2. Contact Service.

22 91 4 Throttle sensor, input volt‐

age too low.

1. Check cabling.

2. Contact Service.

23 174 3 Fuel temperature sensor,

input voltage too high.

1. Check cabling.

2. Contact Service.

23 65 Oxygen concentration cir‐

cuit, input voltage too high.

1. Check cabling.

2. Contact Service.

24 174 4 Fuel temperature sensor,

input voltage too high.

1. Check cabling.

2. Contact Service.

24 65 4 Oxygen concentration cir‐

cuit, input voltage too low.

1. Check cabling.

2. Contact Service.

25 Reserved for “No Codes”. No troubleshooting.

26 25 11 Aux. shutdown 1 active. Contact Service.

26 61 11 Aux. shutdown 2 active. Contact Service.

27 105 3 Inlet elbow temperature

sensor, input voltage too high.

1. Check cabling.

2. Contact Service.

27 171 3 Outside temperature sen‐

sor, input voltage too high.

1. Check cabling.

2. Contact Service.

27 172 3 Air temperature sensor, in‐

put voltage too high.

1. Check cabling.

2. Contact Service.

28 105 4 Inlet elbow temperature

sensor, input voltage too low.

1. Check cabling.

2. Contact Service.

28 171 4 Outside temperature sen‐

sor, input voltage too low.

1. Check cabling.

2. Contact Service.

28 172 4 Air temperature sensor, in‐

put voltage too low.

1. Check cabling.

2. Contact Service.

29 351 4 Circuit exhaust turbocharg‐

er inlet temperature defec‐ tive / low (version 33.0 or later).

1. Check cabling.

2. Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

29 404 4 Temperature sensor/ ex‐

haust turbocharger outlet, input voltage too low (ver‐ sion 32.0 or later).

1. Check cabling.

2. Contact Service.

31 51 3 Auxiliary output 3, open cir‐

cuit (side "high") S3.

Contact Service.

31 51 4 Auxiliary output 3, ground

short circuit (side "high") S3.

Contact Service.

31 51 7 Auxiliary output 3, fault in

mechanical system S3.

Contact Service.

31 52 3 Auxiliary output 4, open cir‐

cuit (side "high") S3.

Contact Service.

31 52 4 Auxiliary output 4, ground

short circuit (side "high") T3.

Contact Service.

31 52 7 Auxiliary output 4, fault in

mechanical system T3.

Contact Service.

32 238 3 SEL, short circuit on battery

circuit (plus).

1. Check cabling.

2. Contact Service.

32 238 4 SEL, open circuit . 1. Check cabling.

2. Contact Service.

32 239 3 CEL, short circuit on battery

circuit (plus).

1. Check cabling.

2. Contact Service.

32 239 4 CEL, open circuit . 1. Check cabling.

2. Contact Service.

33 102 3 Charge pressure sensor, in‐

put voltage too high.

1. Check cabling.

2. Contact Service.

34 102 4 Charge pressure sensor, in‐

put voltage too low.

1. Check cabling.

2. Contact Service.

35 19 3 Oil pressure sensor upper

level, input voltage too high.

1. Check cabling.

2. Contact Service.

35 100 3 Oil pressure sensor, input

voltage too low.

1. Check cabling.

2. Contact Service.

36 19 4 Oil pressure sensor upper

level, input voltage too high.

1. Check cabling.

2. Contact Service.

36 100 4 Oil pressure sensor, input

voltage too low.

1. Check cabling.

2. Contact Service.

37 18 3 Fuel pressure sensor upper

level, input voltage too high.

1. Check cabling.

2. Contact Service.

37 94 3 Fuel pressure sensor, input

voltage too high.

1. Check cabling.

2. Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

37 95 3 Fuel differential pressure

sensor, input voltage too high.

1. Check cabling.

2. Contact Service.

38 18 4 Fuel pressure sensor upper

level, input voltage too low.

1. Check cabling.

2. Contact Service.

38 94 4 Fuel pressure sensor, input

voltage too low.

1. Check cabling.

2. Contact Service.

38 95 4 Fuel differential pressure

sensor, input voltage too low.

1. Check cabling.

2. Contact Service.

39 146 2 EGR system leaking,

charge-air pressure (ver‐ sion 33.0 or later).

Contact Service.

39 146 12 EGR system leaking, ex‐

haust brake operation (ver‐ sion 33.0 or later).

Contact Service.

39 146 7 EGR valve does not re‐

spond (version 33.0 or lat‐ er).

Contact Service.

39 147 2 VNT nozzles do not re‐

spond, charge-air pressure (version 33.0 or later).

Contact Service.

39 147 11 VNT nozzles at maximum,

exhaust brake operation (version 33.0 or later).

Contact Service.

39 147 12 VNT nozzles do not re‐

spond, brake pressure (ver‐ sion 33.0 or later).

Contact Service.

39 147 14 Exhaust gas recirculation

flow too low, VNT nozzles do not respond, charge-air pressure (version 33.0 or later).

Contact Service.

39 147 7 VNT vanes do not respond,

EGR (version 33.0 or later).

Contact Service.

39 152 7 No signal from EGR valve

(version 29.0 or later).

1. Check contamination indica‐ tor signal ring position (→ Page 102).

2. Contact Service.

39 153 7 VNT vanes do not respond,

(version 29.0 or later).

1. Check contamination indica‐ tor signal ring position (→ Page 102).

2. Contact Service.

41 21 0 Too many SRS (TRS miss‐

ing).

Contact Service.

42 21 1 Too few SRS (SRS miss‐

ing).

Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

43 111 1 Coolant level too low. 1. Check coolant level, top up if

required (→ Page 112).

2. Contact Service.

44 52 0 Intercooler coolant temper‐

ature too high.

1. Check coolant condition (→ Page 119).

2. Check coolant level, top up if required (→ Page 120).

3. Check intercooler for contam‐ ination.

4. Contact Service.

44 105 0 Inlet elbow temperature too

high.

1. Check contamination indica‐ tor signal ring position (→ Page 102).

2. Contact Service.

44 110 0 Coolant temperature too

high.

1. Check coolant condition (→ Page 119).

2. Check coolant level, top up if required (→ Page 112).

3. Check cooler for dirt.

4. Contact Service.

44 172 0 Air inlet temperature too

high.

1. Check contamination indica‐ tor signal ring position (→ Page 102).

2. Contact Service.

44 175 0 Oil temperature too high. 1. Check engine oil level

(→ Page 103).

2. Contact Service.

105 14 Inlet elbow temperature:

power reduction.

1. Check contamination indica‐ tor signal ring position (→ Page 102).

2. Contact Service.

110 14 Coolant temperature: power

reduction.

1. Check coolant condition (→ Page 119).

2. Check coolant level, top up if required (→ Page 112).

3. Check cooler for dirt.

4. Contact Service.

45 19 1 High range: Oil pressure

too low.

1. Check engine oil level (→ Page 103).

2. Contact Service.

45 100 1 Oil pressure too low. 1. Check engine oil level

(→ Page 103).

2. Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

46 168 1 ECM battery voltage too

low.

Contact Service.

46 214 1 Real-time clock auxiliary

battery, voltage too low (version 29.0 or later).

Contact Service.

46 232 1 Sensor supply voltage too

low.

Contact Service.

47 18 0 High range: Fuel pressure

too high.

Contact Service.

47 94 0 Fuel pressure too high. Contact Service.

47 102 0 Charge pressure too high. Contact Service.

47 106 0 Air inlet pressure too high. Contact Service.

47 164 0 Injection control pressure

too high.

Contact Service.

48 18 1 High range: Fuel pressure

too low.

1. Check fuel prefilter.

2. Check fuel filter (→ Page 98).

3. Fill tank as necessary.

4. Contact Service.

48 94 1 Fuel pressure too low. 1. Check fuel prefilter.

2. Check fuel filter (→ Page 98).

3. Fill tank as necessary.

4. Contact Service.

48 106 1 Air inlet pressure too low. Contact Service.

48 164 1 Injection control pressure

too low.

Contact Service.

48 351 1 Exhaust turbocharger inlet

temperature below range (version 33.0 or later).

Contact Service.

48 404 1 Exhaust turbocharger outlet

temperature too low (ver‐ sion 33.0 or later).

Contact Service.

48 411 1 EGR OPD low (version 33.0

or later).

Contact Service.

48 412 1 EGR temperature too low

(version 33.0 or later).

Contact Service.

48 154 1 EGR temperature too low. Contact Service.

48 155 1 EGR differential pressure

too low.

Contact Service.

49 351 0 Temperature at exhaust tur‐

bocharger inlet above range (version 33.0 or later).

1. Check contamination indica‐ tor signal ring position (→ Page 102).

2. Check exhaust system.

3. Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

49 404 0 Temperature at exhaust tur‐

bocharger outlet too high (version 32.0 or later).

1. Check contamination indica‐ tor signal ring position (→ Page 102).

2. Check exhaust system.

3. Contact Service.

404 14 TCO temperature- power

reduction.

Contact Service.

51 351 3 Temperature sensor on ex‐

haust turbocharger inlet, cir‐ cuit defective / high.

1. Check cabling.

2. Contact Service.

51 404 3 Temperature sensor on ex‐

haust turbocharger outlet, input voltage too high (ver‐ sion 32.0 or later).

1. Check cabling.

2. Contact Service.

52 254 12 A/D conversion, fault. Contact Service.

53 253 2 Nonvolatile check sum er‐

ror.

Contact Service.

53 253 12 EEPROM write error. Contact Service.

53 253 13 Out of calibrated range. Contact Service.

54 84 12 Vehicle's speed sensor de‐

fect.

1. Check cabling.

2. Contact Service.

55 216 14 Fault in another control unit

(version 27.0 or later). This fault is stored in conjunction with another fault in order to indicate missing information from another control unit .

Contact Service.

55 231 12 Data link J1939, fault. Contact Service.

55 248 8 System-related data link,

fault (Master).

Contact Service.

55 248 9 System-related data link

(Receiver).

Contact Service.

56 250 12 Data link J1587, fault. Contact Service.

57 249 12 Data link J1922, fault. Contact Service.

58 92 0 Torque too high. Contact Service.

61 xxx 0 Reaction time injection noz‐

zle xxx too long.

Contact Service.

62 26 3 Auxiliary output 1, short cir‐

cuit on battery circuit (plus) F3.

Contact Service.

62 26 4 Auxiliary output 1, open cir‐

cuit F3.

Contact Service.

62 26 7 Auxiliary output 1, mechani‐

cal system does not re‐ spond correctly F3.

Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

62 40 3 Auxiliary output 2, short cir‐

cuit on battery circuit (plus) A2.

Contact Service.

62 40 4 Auxiliary output 2, open cir‐

cuit A2.

Contact Service.

62 40 7 Auxiliary output 2, mechani‐

cal system does not re‐ spond correctly A2.

Contact Service.

62 53 3 Auxiliary output 5, short cir‐

cuit on battery circuit (plus) W3.

Contact Service.

62 53 4 Auxiliary output 5, open cir‐

cuit W3.

Contact Service.

62 53 7 Auxiliary output 5, mechani‐

cal system does not re‐ spond correctly W3.

Contact Service.

62 54 3 Auxiliary output 6, short cir‐

cuit on battery circuit (plus) X3.

Contact Service.

62 54 4 Auxiliary output 6, open cir‐

cuit X3.

Contact Service.

62 54 7 Auxiliary output 6, mechani‐

cal system does not re‐ spond correctly X3.

Contact Service.

62 55 3 Auxiliary output 7, short cir‐

cuit on battery circuit (plus) Y3.

Contact Service.

62 55 4 Auxiliary output 7, open cir‐

cuit Y3.

Contact Service.

62 55 7 Auxiliary output 7, mechani‐

cal system does not re‐ spond correctly Y3.

Contact Service.

62 56 3 Auxiliary output 8, short cir‐

cuit on battery circuit (plus) A1.

Contact Service.

62 56 4 Auxiliary output 8, open cir‐

cuit A1.

Contact Service.

62 56 7 Auxiliary output 8, mechani‐

cal system does not re‐ spond correctly A1.

Contact Service.

63 57 0 PWM 1 above normal

range.

Contact Service.

63 57 1 PWM 1 below normal

range.

Contact Service.

63 57 3 PWM 1 short circuit on bat‐

tery circuit (plus).

Contact Service.

63 57 4 PWM 1 open circuit. Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

63 58 0 PWM 2 above normal

range.

Contact Service.

63 58 1 PWM 2 below normal

range.

Contact Service.

63 58 3 PWM 2 short circuit on bat‐

tery circuit (plus).

Contact Service.

63 58 4 PWM 2 open circuit. Contact Service.

63 59 0 PWM 3 above normal

range.

Contact Service.

63 59 1 PWM 3 below normal

range.

Contact Service.

63 59 3 PWM 3 short circuit on bat‐

tery circuit (plus).

Contact Service.

63 59 4 PWM 3 open circuit. Contact Service.

63 60 0 PWM 4 above normal

range.

Contact Service.

63 60 1 PWM 4 below normal

range.

Contact Service.

63 60 3 PWM 4 short circuit on bat‐

tery circuit (plus).

Contact Service.

63 60 4 PWM 4 open circuit. Contact Service.

64 103 0 Turbocharger speed too

high.

Contact Service.

64 103 8 Exhaust turbocharger

speed sensor, input signal faulty (irregular period).

Contact Service.

65 51 0 Throttle position above nor‐

mal range.

Contact Service.

65 51 1 Throttle position below nor‐

mal range.

Contact Service.

65 51 2 Throttle position not regular. Contact Service.

65 51 7 Throttle does not respond. Contact Service.

65 107 3 Air filter differential pressure

sensor, voltage too high.

1. Check cabling.

2. Contact Service.

65 107 4 Air filter differential pressure

sensor, voltage too low.

1. Check cabling.

2. Contact Service.

66 99 3 Oil filter differential pressure

sensor, voltage too high.

1. Check cabling.

2. Contact Service.

66 99 4 Oil filter differential pressure

sensor, voltage too low.

1. Check cabling.

2. Contact Service.

66 76 0 Engine knock level above

normal range.

Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

66 76 3 Knock sensor, input voltage

too high.

Contact Service.

66 76 4 Knock sensor, input voltage

too low.

Contact Service.

66 76 7 Knock sensor does not re‐

spond.

Contact Service.

67 20 3 Coolant pressure sensor,

high range (input voltage too high).

Contact Service.

67 20 4 Coolant pressure sensor,

high range (input voltage too low).

Contact Service.

67 106 3 Air inlet pressure sensor, in‐

put voltage too high.

Contact Service.

67 106 4 Air inlet pressure sensor, in‐

put voltage too low.

Contact Service.

67 109 3 Coolant pressure sensor,

input voltage too high.

Contact Service.

67 109 4 Coolant pressure sensor,

input voltage too low.

Contact Service.

68 230 5 Idle detection pedal travel

sensor (TPS), fault in circuit (circuit disrupted).

Contact Service.

68 230 6 Idle detection pedal travel

sensor (TPS), fault in circuit (short-circuit to ground).

Contact Service.

71 xxx 1 Reaction time injection noz‐

zle xxx too short.

Contact Service.

72 84 0 Vehicle's speed too high. Contact Service.

72 84 11 Vehicle's speed too high

(absolute).

Contact Service.

72 65 0 Oxygen concentration too

high.

Contact Service.

72 65 1 Oxygen concentration too

low.

Contact Service.

73 107 0 Air filter differential pressure

too high.

1. Check contamination indica‐ tor signal ring position (→ Page 102).

2. Contact Service.

73 77 0 Gas valve position above

normal range.

Contact Service.

73 77 1 Gas valve position below

normal range.

Contact Service.

73 77 3 Gas valve position input

voltage too high.

Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

73 77 4 Gas valve position input

voltage too low.

Contact Service.

73 77 7 Gas dosing valve does not

respond.

Contact Service.

73 151 14 ESS transmission, engaged

gear step jamming.

Contact Service.

73 226 11 Transmission idling switch

defective, (ESS transmis‐ sion).

Contact Service.

73 227 2 Analog auxiliary input: data

failing irregularly or defec‐ tive (ESS transmission).

Contact Service.

73 227 3 Analog auxiliary input 1,

voltage too high (ESS transmission).

Contact Service.

73 227 4 Analog auxiliary input 1,

voltage too low (ESS trans‐ mission).

Contact Service.

74 70 4 Optimized idle security

loop) ground short circuit.

Contact Service.

74 99 0 Oil filter badly clogged. 1. Replace oil filter

(→ Page 107)

2. Contact Service.

75 168 0 ECM battery voltage too

high.

Contact Service.

75 214 0 Real-time clock backup,

battery voltage too high (version 29.0 or later).

Contact Service.

75 232 0 Sensor supply voltage too

high.

Contact Service.

76 121 0 Engine overspeed with ex‐

haust brake.

Contact Service.

77 3 0 Cylinder head temperature

too high.

Contact Service.

77 19 0 High range: oil pressure too

high.

Contact Service.

77 20 0 High range: coolant pres‐

sure too high.

Contact Service.

77 72 0 Blower bypass position too

high.

Contact Service.

77 72 1 Blower bypass position too

low.

Contact Service.

77 73 1 Fire pump pressure too low. Contact Service.

77 81 0 Exhaust back pressure too

high.

Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

77 81 1 Exhaust back pressure too

low.

Contact Service.

77 81 3 Exhaust back pressure sen‐

sor voltage too high.

Contact Service.

77 81 4 Exhaust back pressure sen‐

sor voltage too low.

Contact Service.

77 81 12 Exhaust back pressure near

limit for power reduction.

Contact Service.

77 95 1 Fuel filter differential pres‐

sure too low.

Contact Service.

77 99 1 Oil filter differential pressure

too low.

Contact Service.

77 100 0 Engine oil pressure too

high.

Contact Service.

77 102 1 Charge-air pressure too

low.

Contact Service.

77 105 1 Inlet elbow temperature too

low.

Contact Service.

77 107 1 Air filter differential pressure

too low.

Contact Service.

77 108 0 Atmospheric pressure too

high.

Contact Service.

77 108 1 Atmospheric pressure too

low.

Contact Service.

77 109 0 Coolant pressure too high. Contact Service.

77 110 1 Coolant temperature too

low.

Contact Service.

77 111 0 Coolant level too high. 1. Check engine coolant level

(→ Page 112).

2. Contact Service.

77 171 0 Outside temperature too

high.

Contact Service.

77 171 1 Outside temperature too

low.

Contact Service.

77 172 1 Intake air temperature too

low.

Contact Service.

77 174 0 Fuel temperature too high. Contact Service.

77 174 1 Fuel temperature too low. Contact Service.

77 175 1 Engine oil temperature too

low.

Contact Service.

77 222 14 Theft protection faulty. Contact Service.

77 251 10 Clock module with irregular

alteration speed.

Contact Service.

77 251 13 Clock module faulty. Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

77 252 10 Clock module with irregular

alteration speed.

Contact Service.

77 252 13 Clock module faulty. Contact Service.

77 354 0 Relative air humidity above

range (version 33.0 or lat‐ er).

Contact Service.

77 354 1 Relative air humidity under

range (version 33.0 or lat‐ er).

Contact Service.

77 446 0 Cylinder head temperature

above range (version 33.0 or later).

Contact Service.

77 151 11 Maintenance display lamp,

faulty / service interval ex‐ ceeded (version 32.0 or lat‐ er).

Contact Service.

78 86 14 Self-adaptive speed control

faulty (version 27.0 or later).

Contact Service.

81 98 3 Oil level sensor, input volt‐

age too high.

Contact Service.

81 101 3 Crankcase pressure sen‐

sor, input voltage too high.

Contact Service.

81 153 3 Crankcase pressure, input

voltage too high (version

27.0 or later).

Contact Service.

81 164 3 Injection control pressure

sensor, input voltage too high.

Contact Service.

81 173 3 Exhaust temperature sen‐

sor, input voltage too high.

Contact Service.

81 411 3 EGR OPD, circuit defec‐

tive / high (version 33.0 or later).

Contact Service.

81 412 3 EGR temperature too high

(version 33.0 or later).

Contact Service.

81 129 3 Exhaust duct temperature

1, sensor voltage too high (version 32.0 or later).

Contact Service.

81 130 3 Exhaust duct temperature

2, sensor voltage too high (version 32.0 or later).

Contact Service.

81 131 3 Exhaust duct temperature

3, sensor voltage too high (version 32.0 or later).

Contact Service.

81 132 3 Exhaust duct temperature

4, sensor voltage too high (version 32.0 or later).

Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

81 133 3 Exhaust duct temperature

5, sensor voltage too high (version 32.0 or later).

Contact Service.

81 134 3 Exhaust duct temperature

6, sensor voltage too high (version 32.0 or later).

Contact Service.

81 135 3 Exhaust duct temperature

7, sensor voltage too high (version 32.0 or later).

Contact Service.

81 136 3 Exhaust duct temperature

8, sensor voltage too high (version 32.0 or later).

Contact Service.

81 137 3 Exhaust duct temperature

9, sensor voltage too high (version 32.0 or later).

Contact Service.

81 138 3 Exhaust duct temperature

10, sensor voltage too high (version 32.0 or later).

Contact Service.

81 139 3 Exhaust duct temperature

11, sensor voltage too high (version 32.0 or later).

Contact Service.

81 140 3 Exhaust duct temperature

12, sensor voltage too high (version 32.0 or later).

Contact Service.

81 141 3 Exhaust duct temperature

13, sensor voltage too high (version 32.0 or later).

Contact Service.

81 142 3 Exhaust duct temperature

14, sensor voltage too high (version 32.0 or later).

Contact Service.

81 143 3 Exhaust duct temperature

15, sensor voltage too high (version 32.0 or later).

Contact Service.

81 144 3 Exhaust duct temperature

16, sensor voltage too high (version 32.0 or later).

Contact Service.

81 154 3 EGR temperature, input

voltage too high.

Contact Service.

81 155 3 EGR differential pressure,

input voltage too high.

Contact Service.

81 277 9 EGR mass flow, intelligent

sensor does not respond (version 33.0 or later).

Contact Service.

81 277 12 EGR mass flow, intelligent

sensor failure (version 33.0 or later).

Contact Service.

82 98 4 Oil level sensor, input volt‐

age too low.

Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

82 101 4 Crankcase pressure sen‐

sor, input voltage too low.

Contact Service.

82 153 4 Crankcase pressure sen‐

sor, input voltage (version

27.0 or later).

Contact Service.

82 164 4 Injection control pressure

sensor, input voltage too low.

Contact Service.

82 173 4 Exhaust temperature sen‐

sor, input voltage too low.

Contact Service.

82 411 4 EGR OPD, sensor circuit

defective / low (version 33.0 or later).

Contact Service.

82 412 4 EGR temperature too low

(version 33.0 or later).

Contact Service.

82 129 4 Exhaust duct temperature

1, sensor voltage too low (version 32.0 or later).

Contact Service.

82 130 4 Exhaust duct temperature

2, sensor voltage too low (version 32.0 or later).

Contact Service.

82 131 4 Exhaust duct temperature

3, sensor voltage too low (version 32.0 or later).

Contact Service.

82 132 4 Exhaust duct temperature

4, sensor voltage too low (version 32.0 or later).

Contact Service.

82 133 4 Exhaust duct temperature

5, sensor voltage too low (version 32.0 or later).

Contact Service.

82 134 4 Exhaust duct temperature

6, sensor voltage too low (version 32.0 or later).

Contact Service.

82 135 4 Exhaust duct temperature

7, sensor voltage too low (version 32.0 or later).

Contact Service.

82 136 4 Exhaust duct temperature

8, sensor voltage too low (version 32.0 or later).

Contact Service.

82 137 4 Exhaust duct temperature

9, sensor voltage too low (version 32.0 or later).

Contact Service.

82 138 4 Exhaust duct temperature

10, sensor voltage too low (version 32.0 or later).

Contact Service.

82 139 4 Exhaust duct temperature

11, sensor voltage too low (version 32.0 or later).

Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

82 140 4 Exhaust duct temperature

12, sensor voltage too low (version 32.0 or later).

Contact Service.

82 141 4 Exhaust duct temperature

13, sensor voltage too low (version 32.0 or later).

Contact Service.

82 142 4 Exhaust duct temperature

14, sensor voltage too low (version 32.0 or later).

Contact Service.

82 143 4 Exhaust duct temperature

15, sensor voltage too low (version 32.0 or later).

Contact Service.

82 144 4 Exhaust duct temperature

16, sensor voltage too low (version 32.0 or later).

Contact Service.

82 154 4 EGR- temperature, input

voltage too high.

Contact Service.

82 155 4 EGR differential pressure

input voltage too low.

Contact Service.

82 412 9 EGR temperature, intelli‐

gent sensor does not re‐ spond (version 33.0 or lat‐ er).

Contact Service.

82 412 12 EGR temperature, intelli‐

gent sensor failure (version

33.0 or later).

Contact Service.

83 73 0 Pump pressure too high. Contact Service.

83 98 0 Oil level is too high. 1. Check engine oil level

(→ Page 103).

2. Contact Service.

83 101 0 Crankcase pressure too

high.

Contact Service.

83 153 0 Crankcase pressure too

high (version 27.0 or later).

Contact Service.

83 173 0 Exhaust temperature too

high.

Contact Service.

83 411 0 EGR OPD, high (version

33.0 or later).

Contact Service.

83 412 0 EGR temperature too high

(version 33.0 or later).

Contact Service.

83 129 0 Exhaust duct temperature

1, sensor voltage too high (version 32.0 or later).

Contact Service.

83 130 0 Exhaust duct temperature

2, sensor voltage too high (version 32.0 or later).

Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

83 131 0 Exhaust duct temperature

3, sensor voltage too high (version 32.0 or later).

Contact Service.

83 132 0 Exhaust duct temperature

4, sensor voltage too high (version 32.0 or later).

Contact Service.

83 133 0 Exhaust duct temperature

5, sensor voltage too high (version 32.0 or later).

Contact Service.

83 134 0 Exhaust duct temperature

6, sensor voltage too high (version 32.0 or later).

Contact Service.

83 135 0 Exhaust duct temperature

7, sensor voltage too high (version 32.0 or later).

Contact Service.

83 136 0 Exhaust duct temperature

8, sensor voltage too high (version 32.0 or later).

Contact Service.

83 137 0 Exhaust duct temperature

9, sensor voltage too high (version 32.0 or later).

Contact Service.

83 138 0 Exhaust duct temperature

10, sensor voltage too high (version 32.0 or later).

Contact Service.

83 139 0 Exhaust duct temperature

11, sensor voltage too high (version 32.0 or later).

Contact Service.

83 140 0 Exhaust duct temperature

12, sensor voltage too high (version 32.0 or later).

Contact Service.

83 141 0 Exhaust duct temperature

13, sensor voltage too high (version 32.0 or later).

Contact Service.

83 142 0 Exhaust duct temperature

14, sensor voltage too high (version 32.0 or later).

Contact Service.

83 143 0 Exhaust duct temperature

15, sensor voltage too high (version 32.0 or later).

Contact Service.

83 144 0 Exhaust duct temperature

16, sensor voltage too high (version 32.0 or later).

Contact Service.

84 98 1 Oil level low. 1. Check engine oil level

(→ Page 103).

2. Contact Service.

84 101 1 Crankcase pressure too

low.

Contact Service.

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Flashi ng code

PID SID FMI Description Maintenance tasks

84 153 1 Crankcase pressure too low

(version 27.0 or later).

Contact Service.

85 190 0 Engine speed too high. Contact Service.

85 190 14 Engine overspeed signal

(version 28.0 or later).

Contact Service.

86 73 3 Pump pressure sensor, in‐

put voltage too high.

Contact Service.

86 108 3 Atmospheric pressure sen‐

sor, input voltage too high.

Contact Service.

87 73 4 Pump pressure sensor, in‐

put voltage too low.

Contact Service.

87 108 4 Atmospheric pressure sen‐

sor, input voltage too low.

Contact Service.

88 20 1 High range: coolant pres‐

sure too low.

Contact Service.

88 109 1 Coolant pressure too low. Contact Service.

89 95 0 Fuel differential pressure

too high.

Contact Service.

89 111 12 Coolant level, maintenance

indication, fault.

1. Check engine coolant level (→ Page 112).

2. Contact Service.

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7 Task Description

7.1 Engine

7.1.1 Engine – Barring manually

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Barring device

F6555766 1

Adapter

F6558528 1

Ratchet with extension

F30006212 1

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.

Barring the engine manually

1. Remove guard plate.

2. Install barring device (2) with adapter on the flywheel housing in the 6 o'clock position.

3. Set ratchet (1) onto barring device (2).

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

5. Remove barring tool in reverse order.

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7.1.2 Engine – Barring with starting system

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.

Barring engine with starting system

1. Remove screws (1, 3) and take off perforat‐ ed plate (2).

2. Withdraw plug (5) from crankshaft angle sensor for injection timing of any cylinder (→ Page 23). For this purpose, unlock latch (4).

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

Note: Interrupt engine start after maximum ten

seconds for thirty seconds to prevent starter from overheating.

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

Note: If no oil pressure is indicated after three

start cycles, contact Service.

5. Slide connector (5) until lock (4) latches into position.

6. Fit perforated plate (2) and secure with two screws (1, 3).

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Page 74

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.

Barring device

F6555766 1

Ratchet with extension

F30006212 1

Endoscope

Y20097353 1

Preparatory steps

1. Remove cylinder head cover (→ Page 89).

2. Remove injector (→ Page 92).

Positioning crankshaft at BDC

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

2. Insert endoscope into cylinder liner through injector seat.

Cylinder liner endoscopic examination

Findings Measure

• Thin carbon coating on carbon scraper ring

• Slight localized additive deposits at top edge

• Localized smooth areas at bottom edge

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

• First signs of marks left by top piston ring

• Bright mark on entire circumference

• Faultless, even honing pattern

• First signs of marks left by lower cooling bores

• Running pattern seems darker

No 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 cannot be faulted

• Piston rings cannot be faulted

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

• On the entire circumference, apart from light areas of discoloration (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.

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Page 75

1. Compile endoscopy report using the table.

2. Use technical terms for description of the liner surface (→ Page 76).

3. Depending on findings:

• Do not take any action or

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

• contact Service; cylinder liner must be replaced.

Final steps

1. Install injector (→ Page 92).

2. Install cylinder head cover (→ Page 89).

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Page 76

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 Measure

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

ucts, particles, broken-off burrs). Removed cylinders clearly exhibit such scor‐ ing 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 honing pattern in the direction of stroke.

Findings not critical.

Scored area These areas consist of scores of different lengths and depths next to one an‐

other. In most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/exhaust) along the transverse engine axis.

Findings not critical.

Smoothened area Smoothened areas are changes to the running surface but almost the whole

honing pattern is still visible. Smoothened areas appear brighter and more bril‐ liant than the surrounding running surface.

Findings not critical.

Polished area Polished areas are on the running surface and show local removal of the hon‐

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

New cylinder liners must be fitted in the following cases

Polished area:

covers more than 20% of the entire piston running surface,

covers more than 30° of the circumference and extends over more than 50% of piston stroke,

is wider than 15 mm over the entire piston stroke.

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 interrupt‐ ed.

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

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

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

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Findings Measure

Discolorations (Heat) These are caused by a disturbance in the liner / ring tribosystem. Usually they

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

Liners with heat discoloration starting in the TDC-ring 1 have to be replaced.

Seizures, Seizure marks

Seizure marks are of irregular circumferential length and depth. Can be caused by either the piston skirt or the piston crown. Material deposits on the liner (smears) show heavy discoloration and scoring.

Replace liner.

Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough in‐ vestigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid un‐ necessary disassembly work, it is recommended that another inspection be carried out after further oper‐ ation of the engine.

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Page 78

7.3 Crankcase Breather

7.3.1 Crankcase breather – Filter element replacement

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 10-60Nm

F30452769 1 Engine oil Filter insert

(→ 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.

Crankcase breather (closed-circuit crankcase ventilation) – Filter element replacement

1. Loosen clamps (1), push rubber sleeves (2) over pipe (3).

2. Release band clamp (4) with lever (6).

3. Remove cover (7).

4. Replace filter element (5).

5. Fit cover (7).

6. Operate lever (6) to tension clamping band (4).

7. Push back rubber sleeve (2) and tighten clamp (1).

8. Replace further filter elements in the same way.

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Crankcase breather (open-circuit crankcase ventilation) – Filter element cleaning or replacement

1. Clean filter externally.

2. Release vent hose on oil separator cov‐ er (1) and remove.

3. Remove oil separator cover (1).

4. Loosen clamp (5).

5. Clean or replace filter element (2) (→ Page 80).

6. Insert new sealing ring (3).

7. Install cleaned or new filter element (2) with filter holder (5).

8. Mount oil separator cover (1).

9. Tighten nut of clamp (4) with torque wrench to specified tightening torque.

Name Size Type Lubricant Value/Standard

Nut Tightening torque (Engine oil) 9Nm +1Nm

10. Push vent hose onto oil separator cover (3) and bolt on.

11. Replace further filter elements (2) in the same way.

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Page 80

7.3.2 Crankcase breather (open-circuit crankcase ventilation) – Filter element cleaning

Preconditions

☑ Engine is stopped and starting disabled.

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.

Clean filter element

1. Remove filter element (→ Page 78).

2. Clean filter element with cleaning agent.

3. Remove cleaner.

4. Blow out filter element thoroughly with compressed air.

5. Install filter element (→ Page 78).

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Page 81

7.4 Running Gear

7.4.1 Grounding device – Check carbon brush

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Cold cleaner (Hakutex 60)

50602

Carbon brush

(→ Spare Parts Catalog)

WARNING

Compressed air Risk of injury!

• Do not direct compressed-air jet at persons.

• Wear protective goggles / safety mask and ear protectors.

CAUTION

Unsuitable cleaning tool. Damage to component!

• Observe manufacturer's instructions.

• Use appropriate cleaning tool.

Remove grounding assembly

1. Remove screws (1) with washers.

2. Remove grounding device (2) from flywheel housing (3).

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Page 82

Checking grounding device

Item Findings Measure

Carbon brush Damaged

Wear limit 45 mm (new condition 60mm)

Fit new part (→ Page 83)

Press carbon brush against spring pressure

Spring broken, damaged Fit new part (→ Page 83)

Running surface on adapter contaminated, corroded Clean

Cleaning running surface on adapter

1. Clean running surface of carbon brushes on adapter with cold cleaner.

2. Remove stubborn deposits with soft brush.

3. Blow out adapter with compressed air.

Installing grounding device

1. Check mounting surface on flywheel housing for cleanness.

2. Install grounding device on flywheel housing and secure with screws.

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Page 83

7.4.2 Grounding device – Carbon brush replacement

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Loctite 270

40083

Carbon brush

(→ Spare Parts Catalog) 2

Replace carbon brush

1. Loosen screw (5).

2. Disconnect cable (6) from screw (5).

3. Loosen screws (3).

4. Remove screws (2).

5. Remove carbon brush (1) from grounding device (4).

6. Fit new carbon brush (1) in grounding de‐ vice (4).

7. Tighten screws (2) by hand.

8. Insert screws (3) as far as the stop and tighten screws lightly.

9. Tighten screws (2).

Note: Apply Loctite 270 only to threads.

10. Secure cable (6) with screw (5).

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Page 84

7.5 Valve Drive

7.5.1 Valve gear – Lubrication

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Engine oil

Valve gear – Lubrication

1. Remove cylinder head covers (→ Page 89).

2. Fill oil chambers of valve bridges with oil.

3. Fill oil chambers of rocker arms and adjust‐ ing screws with oil.

4. Install cylinder head covers (→ Page 89).

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Page 85

7.5.2 Valve clearance – Check and adjustment

Preconditions

☑ Engine shut down 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

Y20098771 1

Torque wrench, 60-320Nm

F30452768 1

Socket box wrench

F30039526 1

Engine oil

Preparatory steps

1. Remove cylinder head cover (→ Page 89).

2. Install barring device (→ Page 72).

3. Rotate crankshaft with barring device in en‐ gine direction of rotation until "TDC-A1" mark and pointer are aligned.

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Page 86

Diagram for 8V engines (two crankshaft positions)

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

I Inlet valve

X Exhaust valve

Diagram for 12V engines (two crankshaft positions)

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

I Inlet valve

X Exhaust valve

Diagram for 16V engines (two crankshaft positions)

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

I Inlet valve

X Exhaust valve

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Page 87

Diagram for 20V engines (two crankshaft positions)

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

I Inlet valve

X Exhaust valve

Checking valve clearance at two crankshaft positions

1. Check TDC position of piston in cylinder A1:

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

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

2. Check valve clearance with cold engine:

• Inlet valves (long rocker arm) = 0.2 mm

• Exhaust valves (short rocker arm) = 0.5 mm

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

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

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

Adjusting valve clearance

1. Release locknut (1).

2. Insert feeler gauge (3) between valve bridge and rocker arm.

3. Using Allen key, set adjusting screw (2) so that the specified valve clearance is reached.

4. Feeler gauge (3) must just pass through the gap.

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

Name Size Type Lubricant Value/Standard

Nut M16 x 1.5 Tightening torque (Engine oil) 90Nm +9Nm

6. Replace or rectify adjusting screws and/or locknuts which do not move freely.

7. Check valve clearance.

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Final steps

1. Remove barring device (→ Page 72).

2. Install cylinder head cover (→ Page 89).

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Page 89

7.5.3 Cylinder head cover – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Gasket

(→ Spare Parts Catalog)

Removing cylinder head cover

1. Clean very dirty cylinder head covers prior to removal.

2. Remove screws.

3. Remove cylinder head cover with gasket from cylinder head.

Installing cylinder head cover

1. Clean mating face.

2. Check condition of gasket, replace if necessary.

3. Place gasket and cylinder head cover on cylinder head.

4. Install cylinder head cover.

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7.6 Injection Pump / HP Pump

7.6.1 HP pump – Relief bore check

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.

HP pump – Relief bore check

1. Check relief bore for oil and fuel discharge by visual inspection.

2. If relief bore is contaminated, stop the en‐ gine, disable engine start, and clean relief bore.

3. Note the following in case of fluid dis‐ charge:

• Heavy discharge means continuous dis‐

charge of fluids (leakage). Contact Serv‐ ice.

• Minor discharge of fluids up to 10 drops

per day is normal (moistening) and not considered a leakage.

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7.7 Injection Valve / Injector

7.7.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Injector

(→ Spare Parts Catalog)

Replacing injector

u Remove injector and install new injector (→ Page 92).

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7.7.2 Injector – Removal and installation

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Installation and removal tool for injector

F6790161 1

Milling cutter

F30452739 1

Slotted screwdriver

F30452578 1

Torque wrench, 1-20Nm

F30044239

Torque wrench, 10-60Nm

F30452769 1

Torque wrench, 60-320Nm

F30452768 1

Assembly paste (Optimoly Paste White T)

40477 1

Grease (Kluthe Hakuform 30-10/emulsifier)

X00029933 1

Engine oil

WARNING

Fuels are combustible. Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

CAUTION

Removal of all injectors. Damage to component!

• Ensure that the high-pressure fuel accumulator is secured on the engine through two HP lines.

CAUTION

Cable damage during operation. Fire hazard!

• Twist cables when installing.

• Ensure that cables do not touch components.

Preparatory steps

1. Close off fuel supply to engine.

2. Remove cylinder head cover (→ Page 89).

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Removing injector

Note: Always replace the first and last injectors of

one engine side first. Replace the inner in‐ jectors only after the installation of the outer injectors on this engine side is completed.

1. Release the cable terminal threaded con‐ nection (arrows) on the injector and remove cable terminals.

2. Remove screw (2) and take off hold-down clamp (1).

3. Remove high-pressure fuel line (5).

4. Install installation/removal device on the cylinder head.

5. Remove injector with installation/removal device.

6. Remove the installation/removal device.

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7. Remove sealing ring (1) from injector or use a self-made hook to take it out of the cylin‐ der head.

8. Remove O-rings (2) from injector.

9. Cover all connections and installation bores, or seal with suitable plugs.

Installing injector

1. Prior to installation, remove all blanking plugs.

2. Coat injector with assembly paste in the area of the nozzle retaining nut.

3. Fit new O-rings on injector and coat with grease.

4. Fit new sealing ring with grease on injector, observe installation position of sealing ring.

5. Clean sealing face on cylinder head and protective sleeve with milling cutter.

6. Insert injector into cylinder head, making sure that the HP line connections are aligned correctly.

7. Push in the injector using the installation/re‐ moval device.

8. Remove the installation/removal device.

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9. Use slotted screwdriver to check thrust ring at both line ends for secure seating.

10. Tighten loose thrust ring to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Thrust ring Tightening torque 5Nm to 10Nm

11. Coat screw head mating face (2) and thread with engine oil.

12. Fit hold-down clamp (1) in correct position by hand. Tighten screw (2) with torque wrench to the specified initial tightening torque.

Name Size Type Lubricant Value/Standard

Screw M12 Preload torque (Engine oil) 5Nm to 10Nm

13. Fit O-rings (4) and (6) on high-pressure fuel line (5) and coat with grease.

14. Tighten high-pressure fuel line (5) to the specified initial tightening torque.

Name Size Type Lubricant Value/Standard

HP line Preload torque (Engine oil) 5Nm to 10Nm

15. Tighten screw (2) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard

Screw M12 Tightening torque 100Nm + 10Nm

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16. Tighten union nut of adapter (limiting valve) with torque wrench to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Union nut Tightening torque 140Nm + 10Nm

17. Tighten union nut of adapter (injector) with torque wrench to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Union nut Tightening torque 120Nm +10Nm

18. Twist cable several times.

19. Insert cable lugs (arrows) underneath the screws on the injector and tighten screws with torque wrench to the specified tightening torque.

Name Size Type Lubricant Value/Standard

Screw Tightening torque 1.5Nm

Final steps

1. Install cylinder head cover (→ Page 89).

2. Open up fuel supply to engine.

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7.8 Fuel System

7.8.1 Fuel system – Venting

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Filling device

B80144852 1

Diesel fuel

WARNING

Fuels are combustible. Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Venting LP fuel system

1. Connect filling device to connection (4).

2. Disconnect return line at connection (1).

3. Use hand pump to fill fuel system, providing pressure of min. 0.5 bar / max. 2.0 bar, until fuel emerges without bubbles at connec‐ tion (1).

4. Connect return line to connection (1).

5. Open vent plug (2) on filter housing (3).

6. Use hand pump to fill fuel system, providing pressure of min. 0.5 bar / max. 2.0 bar, until fuel emerges without bubbles at connec‐ tion (2).

7. Close threaded vent plug (2).

8. Remove filling device and seal connec‐ tion (4).

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7.9 Fuel Filter

7.9.1 Fuel filter – Replacement

Preconditions

☑ Engine shut down and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Filter wrench

F30379104 1 Engine oil Easy-change filter

(→ Spare Parts Catalog) 2

WARNING

Fuels are combustible. Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Replacing fuel filter

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

2. Clean sealing surface on filter head.

3. Slightly lubricate seal on the easy-change filter (arrow).

4. Screw on the easy-change filter by hand until the seal makes contact and tighten fin‐ ger-tight.

5. Replace further easy-change filters in the same way.

6. Vent fuel system (→ Page 97).

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7.10 Charge-Air Cooling

7.10.1 Charge-air cooler – Check water drain for coolant leakage and absence of restrictions

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.

WARNING

Compressed air Risk of injury!

• Do not direct compressed-air jet at persons.

• Wear protective goggles / safety mask and ear protectors.

Checking charge-air cooler water drain for coolant leakage and absence of restrictions

1. With the engine running check the drain bore(s) on the right and left of the engine for emerging air (at driving end). If no air escapes:

• Clean condensate drain bore(s)

• Blow out with compressed air

2. If a large amount of coolant is continuously discharged, the charge-air cooler is leaking. Contact Service.

Emergency measures prior to engine start with a leaking charge-air cooler

1. Remove injectors (→ Page 92).

2. Bar engine manually (→ Page 72).

3. Bar engine with starting system to blow out combustion chambers (→ Page 73).

4. Install injectors (→ Page 92).

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7.11 Starting Equipment

7.11.1 Starter – Condition check

Preconditions

☑ Engine is stopped and starting disabled.

Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.

2. Check wiring (→ Page 140).

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