MTU C13, C13R, C23R, C13L, C23 Operating Instructions Manual

Operating Instructions

Diesel engine

12 V 4000 C13, C13R, C13L
12 V 4000 C23, C23R
16 V 4000 C13, C13R, C13L
16 V 4000 C23, C23R

M015695/03E

Printed in Germany

© 2013 Copyright MTU Friedrichshafen GmbH

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

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

Subject to alterations and amendments.

Table of Contents

1 Safety

1.1 Important provisions for all products 5

1.2 Personnel and organizational requirements 6

1.3 Transport 7

1.4 Crankshaft transport locking device 8

1.5 Crankshaft transportation lock – For
transport with flange-mounted generator 10

1.6 Safety regulations for startup and operation 12

1.7 Safety regulations for maintenance and
repair work 13

1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 16

1.9 Standards for safety notices in the text 18

2 General Information

2.1 Engine side and cylinder designations 19

2.2 Engine layout 20

2.3 Sensors and actuators – Overview 21

3 Technical Data

3.1 12/16 V 4000 C13/13R/13L engine data:
Application group 5A, optimized fuel
consumption 25

3.2 12/16 V 4000 C13/13R/13L engine data:
Application group 5A, optimized exhaust
emissions (EPA Stage 2) 32

3.3 12/16 V 4000 C23/23R engine data:
Application group 5B, optimized fuel
consumption 39

3.4 12/16 V 4000 C23/23R engine data:
Application group 5B, optimized exhaust
emissions (EPA Stage 2) 43

3.5 Firing order 47

3.6 Main engine dimensions 48

4 Operation

4.1 Preparations for recommissioning the
engine after extended out-of-service periods
(>3 months) 49

4.2 Putting the engine into operation after
scheduled out-of-service-period 50

4.3 Starting the engine in manual mode 51

4.4 Stopping the engine in manual mode 52

4.5 After shutting down the engine 53

4.6 Plant cleaning 54

5 Maintenance

5.1 Maintenance task reference table [QL1] 55

6 Troubleshooting

6.1 Troubleshooting 56

6.2 Fault messages of the engine governor
ADEC (ECU 7) for series 4000 C&I engines 59

7 Task Description

7.1 Engine 78

7.1.1 Cranking engine manually 78

7.1.2 Engine – Barring with starting system 80

7.2 Cylinder Liner 81

7.2.1 Cylinder liner – Endoscopic examination 81

7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 83

7.3 Crankcase Breather 85

7.3.1 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 85

7.4 Running Gear 87

7.4.1 Grounding device – Carbon brush check 87

7.4.2 Grounding device – Carbon brush replacement 89

7.5 Valve Drive 90

7.5.1 Valve gear – Lubrication 90

7.5.2 Valve clearance – Check and adjustment 91

7.5.3 Cylinder head cover – Removal and
installation 95

7.6 Injection Pump / HP Pump 96

7.6.1 HP pump – Filling with engine oil 96

7.7 Injection Valve / Injector 97

7.7.1 Injector – Replacement 97

7.7.2 Injector – Removal and installation 98

7.8 Fuel System 103

7.8.1 Fuel system – Venting 103

7.9 Fuel Filter 104

7.9.1 Fuel filter – Replacement 104

7.9.2 Draining fuel prefilter 105

7.9.3 Fuel prefilter – Draining 106

7.10 Charge-Air Cooling 107

7.10.1 Intercooler – Checking condensate drain for
coolant discharge and obstructions 107

7.11 Air Intake 108

7.11.1 Service indicator – Signal ring position check 108

7.12 Starting Equipment 109

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7.12.1 Starter – Condition check 109

7.13 Lube Oil System, Lube Oil Circuit 110

7.13.1 Checking engine oil level 110

7.13.2 Checking engine oil level 111

7.13.3 Engine oil – Change 112

7.13.4 Engine oil – Sample extraction and analysis 114

7.14 Oil Filtration / Cooling 115

7.14.1 Automatic oil filter – Oil filter candles
replacement 115

7.14.2 Oil indicator filter – Cleaning and check 118

7.14.3 Centrifugal oil filter – Cleaning and filter­sleeve replacement 120

7.15 Coolant Circuit, General, High-Temperature
Circuit 122

7.15.1 Engine coolant – Level check 122

7.15.2 Engine coolant – Change 123

7.15.3 Draining engine coolant 124

7.15.4 Engine coolant – Filling 126

7.15.5 Engine coolant pump – Checking pressure
relief port 129

7.15.6 Engine coolant filter – Replacement 130

7.15.7 Engine coolant – Sample extraction and
analysis 131

7.16 Low-Temperature Circuit 132

7.16.1 Charge-air coolant – Level check 132

7.16.2 Charge-air coolant – Change 133

7.16.3 Draining charge-air coolant 134

7.16.4 Charge-air coolant – Filling 135

7.16.5 Charge-air coolant pump – Checking pressure
relief port 138

7.17 Belt Drive 139

7.17.1 Drive belt – Condition check 139

7.18 Battery-Charging Generator 140

7.18.1 Alternator – Removing and refitting 140

7.18.2 Battery-charging generator – Check 142

7.18.3 Battery-charging generator drive – Drive belt
tension adjustment 143

7.18.4 Battery-charging generator – Drive belt and
belt tensioner replacement 144

7.19 Fan Drive 146

7.19.1 Fan drive – Drive belt tension check /
adjustment 146

7.19.2 Fan drive – Drive belt replacement 148

7.20 Wiring (General) for Engine/Gearbox/Unit 149

7.20.1 Engine wiring – Check 149

7.21 Accessories for (Electronic) Engine
Governor / Control System 150

7.21.1 Engine governor and connectors – Cleaning 150

7.21.2 Engine governor plug connections – Check 151

8 Appendix A

8.1 Abbreviations 152

8.2 MTU contact persons/service partners 154

9 Appendix B

9.1 Special Tools 155

9.2 Index 162

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1 Safety

1.1 Important provisions for all products

Nameplate

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

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

General information

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

• Incorrect use

• Operation, maintenance and repair by unqualified personnel

• Modifications or conversions

• Noncompliance with the safety instructions and warning notices

Correct use

The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.

This means that the equipment must be operated:

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

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

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

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

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

• In accordance with the maintenance requirements over the entire service life of the product (→ Main­tenance Schedule)

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

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

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

Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation.The manufacturer will accept no liability for such damage.

Modifications or conversions

Unauthorized modifications to the product compromise safety.

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

Spare parts

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

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

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

Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe­ty-relevant instructions, in particular, must be read and understood.

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

Personnel requirements

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

• Training at the Training Center of the manufacturer

• 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 slip­ping 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, 10-60 Nm

F30452769 1

Torque wrench, 60-320 Nm

F30452768 1

Engine oil

Transport locking device

Note: The locking device on both ends protects the crankshaft bearings from shocks and vibration damage

during engine transport.

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

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

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

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

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

6. Attach these instructions, clearly visible, to the engine.

Fitting the transport locking de­vice on driving end (KS)

Note: Attach plate (6) only to the upper part of the openings.

1. Secure the two plates (6) with screws (4) and washers (5) 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) 250 Nm +25 Nm

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2. Screw locknut (2) onto screw (1) up to the end of the thread.

3. The long end of holder (3) must face downwards. Push holder (3) through the plate openings (6).

Note: The holders (3) must lock the flywheel only, not the ring gear.

4. Install screw (1) into the bore of holder (1) until the holder (1) is locked in position.

Note: Tighten screw (1) alternately on both sides of the flywheel housing.

5. Tighten screw (1) alternately to specified tightening torque.

Name Size Type Lubricant Value/Standard

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

6. Fit locknut (2) of screw (1) on plate (6) and secure.

Removing the transport locking
device from driving end (KS)

1. Release the locknut (2) on both sides of
the flywheel housing, remove screw (1) and
take off the two holders (3).

2. Unscrew screws (4) and remove together
with washers (5) and plate (6).

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

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1.5 Crankshaft transportation lock – For transport with flange­mounted generator

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 10-60 Nm

F30452769 1

Ratchet

F30027340 1

Engine oil

Transportation lock

Note: The transportation lock on the engine protects the crankshaft bearings from potential damage caused

by shocks and vibration when transporting the genset.

For installation and removal of the transportation lock, follow the instructions
below:

1. The transportation lock must remain in place on the engine for as long as possible during installation of
the genset in order to prevent damage.

2. The engine must never be started or cranked with the transportation lock in place. Make sure that the
transportation lock on the generator is also removed.

3. The transportation lock must always be refitted on the engine according to the instructions whenever
the genset is transported. The generator transportation lock should also be installed.

Removing transportation lock on
driving end (KS)

1. Unscrew screw (4) on both sides of the fly­wheel housing (5).

2. Remove retainer (2) and washer (3).

3. Remove guard plate from flywheel housing.

4. Store the removed parts safely so that they
are ready for reuse when required.

Installing the transportation lock on driving end (KS)

Note: Keep guard plate and screws on the engine. They must be refitted when the transportation lock has

been removed.

1. Remove guard plate from flywheel housing.

2. Install barring device (→ Page 78).

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3. Turn crankshaft to bring cylinder A1 to TDC
position.

4. Check the threads on both sides of the fly­wheel (1) for ease of movement.

5. Fit retainer (2) together with screw (4) and
washer (3) through the opening in the fly­wheel housing (5).

Note: Tighten screw (4) in three steps.

6. Tighten screw (4) on each side alternately to specified tightening torque.

Name Size Type Lubricant Value/Standard

Screw M10 Tightening torque (Engine oil) 50 Nm +5 Nm

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1.6 Safety regulations for startup and operation

Safety regulations for startup

Install the product correctly and carry out acceptance in accordance the manufacturer's specifications
before putting the product into service.

Before the product is put into operation for the first time, all official authorizations must be available
and commissioning preconditions met.

When putting the product 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 product into operation, make sure that all control and display instruments
as well as the 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 re­gard to present operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stop

The procedures for cases of emergency, in particular, emergency stop, must be practiced regularly.

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.

Operation

The following conditions must be fulfilled before starting the product:

• Wear ear protection.

• Ensure that the engine room is well ventilated.

• Do not inhale the exhaust gases of the product.

• 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, generator terminals or 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 or repair work carried out by qualified and authorized personnel only.

Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion
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 oil or working on the fuel system, ensure that the engine room is adequately venti­lated.

Never carry out maintenance and repair work with the product in operation.

Carry out function checks on a product in operation only if expressly permitted to do so.

Secure the product against unintentional starting, e.g. with start interlock.

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

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 product.

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
device as an additional measure.

Safety regulations during maintenance and repair work

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

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

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

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

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
contact 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 prop­erly 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 com­ponents or assemblies are placed on stable surfaces.

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Ensure particular cleanness during maintenance and repair work on the product. After completion of
maintenance and repair work, make sure that no loose objects are in/on the product (e.g. cloths and
cable ties)

Safety regulations after completion of maintenance and repair work

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

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

Welding work

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

Before starting welding work:

• Switch off the power supply master switch.

• Disconnect the battery.

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

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

Do not use product as ground terminal.

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

Remove parts (e.g. exhaust pipes) which are to be welded from the product 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 with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.

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

Do not allow electrolyte to come in contact with skin or clothing.

Wear protective clothing and protective gloves.

Never place tools on the battery.

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

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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 union nuts on connectors.

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

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack
defective electronic components and assemblies in a suitable manner when dispatched for repair, i.e.
protected, in particular, 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 (hazard due to heavi­ly focused radiation).

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, fluids and
lubricants, auxiliary materials

Fire prevention

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

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

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

Always 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 85dB (A).

Environmental protection and disposal

Modification or removal of any mechanical/electronic components or the installation of additional com­ponents as well as the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu­facturer. Noncompliance with these guidelines will lead to forfeiture of the operating permit issued by
the emission monitoring authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.

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

Within the EU, batteries can be returned free of charge to the manufacturer where they are subjected to
proper recycling procedures.

Auxiliary materials, fluids and lubricants

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera­tion, make sure that the latest version is used. The applicable version may be downloaded at: http://
www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.

Auxiliary materials, fluids and lubricants might be hazardous goods or toxic substances.When using flu­ids, lubricants, auxiliary materials 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 residue.

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 products 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,
ensure 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 specified containers (without fixed cov­ers).

• Avoid body contact (eyes, hands).

• Wear protective clothing, protective gloves, closed shoes and protective goggles.

• Make sure that working area is well ventilated.

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

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

• Observe the relevant safety data sheet for all materials.

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

• Do not inhale vapors.

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

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

• In case of skin contact, rinse 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 notices in the text

DANGER

In the event of immediate danger.

Consequences: Death, serious or permanent injury.

• Remedial action

WARNING

In the event of a situation involving potential danger.

Consequences: Death, serious or permanent injury.

• Remedial action

CAUTION

In the event of a situation involving potential danger.

Consequences: Minor or moderate injuries.

• Remedial action

NOTICE

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

Consequences: Material damage.

• Remedial action

• Additional product information

Safety notices

u This manual with all safety instructions and safety notices must be issued to all personnel involved in

operation, maintenance, repair or transportation.

18 | Safety | M015695/03E 2013-03

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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

M015695/03E 2013-03 | General Information | 19

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2.2 Engine layout

Illustration is valid for 16V 4000 Cxyz engines

1 Crankcase breather
2 Air intake
3 Exhaust turbocharger
4 Exhaust outlet
5 Air intake
6 Exhaust turbocharger
7 Exhaust outlet
8 Coolant system

9 Intercooler
10 Flywheel
11 Valve gear
12 Lifting eye
13 Cylinder head
14 Starter
15 Oil filler neck
16 Fuel filter head

17 Engine governor
18 HP fuel pump
19 Automatic oil filter
20 Engine mounting/support
21 Gear train
22 Vibration damper
23 Battery-charging generator
24 Fan drive

Engine model designation

Key to the engine model designation 12/16V 4000 Cxyz

12/16 Number of cylinders

V Cylinder arrangement: Vee engine

4000 Series

C Application

x Application segment (1,2 )

y Design index (3)

z R (reduced power / speed)

L (enhanced power / speed)

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2.3 Sensors and actuators – Overview

Illustration also applies to 16V 4000 Cx3 engines

1 B07 (lube oil temperature)
2 Sensors for cylinder ex-

haust temperature B4.1
through B4.8 (A-bank) (op­tional only for 16 V)

3 Injectors Y39.1 to Y39.6

(A-bank)

4 ADEC (ECU 7)
5 B34 (fuel pressure after fil-

ter)

6 B48 (fuel pressure in com-

mon rail)

7 M8 (HP fuel pump actua-

tor)

The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and neces­sary activities (→ Page 97).

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1 B50 (crankcase pressure)
2 B05.3 (lube oil pressure

before filter)

3 B05 (lube oil pressure af-

ter filter)

4 B33 (fuel temperature in

common rail)
5 B01 (camshaft speed)
6 B48 (fuel pressure in com-

mon rail)

7 B43 (charge-air coolant

pressure)

8 B26 (charge-air coolant

temperature)

9 B06 (engine coolant tem-

perature)

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1 Injectors Y39.11 to

Y39.16 (B-bank)

2 Sensors for cylinder ex-

haust temperature B4.11
through B4.18 (B-bank)
(optional only for 16 V)

3 B44 (turbocharger speed)

4 B03 (intake air tempera-

ture)
5 B16 (coolant pressure)
6 B10 (charge-air pressure)

7 B09 (charge-air tempera-

ture)

The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and neces­sary activities (→ Page 97).

M015695/03E 2013-03 | General Information | 23

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1 B13 (crankshaft speed)

24 | General Information | M015695/03E 2013-03

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3 Technical Data

3.1 12/16 V 4000 C13/13R/13L engine data: Application group
5A, optimized fuel consumption

Explanation:

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

A Design value
G Guaranteed value
R Guideline value

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

- Not applicable

X Applicable

REFERENCE CONDITIONS

Engine model 12V

4000C13

R

12V

4000C13

12V

4000C13L

16V

4000C13

R

16V

4000C13

16V

4000C13L

Application group 5A 5A 5A 5A 5A 5A

Intake air temper­ature

°C 25 25 25 25 25 25

Charge-air cool­ant temperature

°C 45 45 45 45 45 45

Raw-water inlet
temperature

°C - - - - - -

Barometric pres­sure

mbar 1000 1000 1000 1000 1000 1000

Site altitude
above sea level

m 100 100 100 100 100 100

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

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Rated engine
speed

A rpm 1800 1800 1800 1800 1800

1900

1800
1900

Net brake power
(w/o fan) (fuel
stop power ISO

3046)

A kW 1193 1343 1425 1492 1750 1865

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GENERAL CONDITIONS (for maximum power)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Intake depression
(new filter)

A mbar 30 30 30 30 30 30

Intake depres­sion, max.

L mbar 50 50 50 50 50 50

Exhaust overpres­sure

A mbar 65 65 65 65 65 65

Exhaust overpres­sure, max.

L mbar 85 85 85 85 85 85

Fuel temperature
at engine inlet
connection

R °C 25 25 25 25 25 25

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

L °C 60 60 60 60 60 60

CONSUMPTION

Number of cylin­ders

12V 12V 12V 16V 16V 16V

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

R % of B 0.3 0.3 0.3 0.3 0.3 0.3

MODEL-RELATED DATA (basic design)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Number of cylin­ders

12 12 12 16 16 16

Cylinder arrange­ment: V angle

degrees 90 90 90 90 90 90

Bore mm 170 170 170 170 170 170

Stroke mm 210 210 210 210 210 210

Cylinder displace­ment

Liters 4.77 4.77 4.77 4.77 4.77 4.77

Total displace­ment

Liters 57.2 57.2 57.2 76.3 76.3 76.3

Number of inlet
valves per cylin­der

2 2 2 2 2 2

Number of ex­haust valves per
cylinder

2 2 2 2 2 2

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COMBUSTION AIR / EXHAUST GAS

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Charge-air pres­sure before cylin­der

R bar abs 2.2 2.4 2.5 2.3 2.5

2.6

2.7

2.8

Exhaust tempera­ture after turbo­charger

R °C 440 440 440 390 395

390

400
380

COOLANT SYSTEM (HT circuit)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

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

A °C 100 100 100 100 100 100

Coolant tempera­ture after engine,
warning

R °C 102 102 102 102 102 102

Coolant tempera­ture after engine,
shutdown

L °C 104 104 104 104 104 104

Coolant antifreeze
content, max.

L % 50 50 50 50 50 50

Coolant pump: in­let pressure, max.

L bar 2.5 2.5 2.5 2.5 2.5 2.5

Thermostat:
Starts to open

R °C 79 79 79 79 79 79

Thermostat: Fully
open

R °C 92 92 92 92 92 92

COOLANT SYSTEM (LT circuit)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

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

R °C 51 52 53 53 55

52

56
55

Coolant tempera­ture difference af­ter/before inter­cooler, min.

L °C 4 5 6 6 8

10

9

11

Coolant tempera­ture difference af­ter/before inter­cooler, max.

L °C 12 13 14 14 16

18

17
19

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Number of cylin­ders

12V 12V 12V 16V 16V 16V

Coolant antifreeze
content, max.

L % 50 50 50 50 50 50

Charge-air tem­perature after in­tercooler, max.

L °C 80 80 80 80 80 80

Thermostat:
Starts to open

R °C 38 38 38 38 38 38

Thermostat: Fully
open

R °C 51 51 51 51 51 51

LUBE OIL SYSTEM

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Lube oil operating
temperature be­fore engine, from

R °C 92 92 92 92 92 92

Lube oil operating
temperature be­fore engine, to

R °C 95 95 95 95 95 95

Lube oil tempera­ture before en­gine, alarm

R °C 97 97 97 97 97 97

Lube oil tempera­ture before en­gine, shutdown

L °C 99 99 99 99 99 97

Lube oil operating
pressure before
engine (measure­ment block)

R bar 6.4 6.4 6.4 5.0 5.0 5.0

Lube oil operating
pressure (low
idle) (meas. point:
before engine)

R bar 2.6 2.6 2.6 2.0 2.0 2.0

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FUEL SYSTEM

Number of cylin­ders

12V 12V 12V 16V 16V 16V

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

L bar -0.1 -0.1 -0.1 -0.1 -0.1 -0.1

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

L bar -0.3 -0.3 -0.3 -0.3 -0.3 -0.3

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

L bar 1.5 1.5 1.5 1.5 1.5 1.5

GENERAL OPERATING DATA

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Coolant preheat­ing: preheating
temperature
(min.)

R °C 40 40 40 40 40 40

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

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

L degrees 15 15 15 15 15 15

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

L degrees 15 15 15 15 15 15

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

L degrees 15 15 15 15 15 15

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CAPACITIES

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Engine coolant,
engine side (with­out cooling equip­ment)

R Liters 212 212 212 260 260 260

Charge-air cool­ant, engine side

R Liters 47 47 47 50 50 50

Engine oil on ini­tial filling (stand­ard oil system)
(option: max. op­erating inclina­tions)

R Liters 245 245 245 300 300 300

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

L Liters 150 150 150 210 210 210

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

L Liters 190 190 190 240 240 240

WEIGHTS (basic design, dry engine)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Engine dry weight
(with attached
standard accesso­ries, without cou­pling)

R kg 7000 7000 7000 8100 8100 8100

ACOUSTICS

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Exhaust noise, un­silenced,BL, (free­field sound-pres­sure level Lp, 1m
distance, ISO

6798)

R dB(A) 106 106 107 108 109 110

Exhaust noise, un­silenced - BL
(sound power lev­el LW, ISO 6798)

R dB(A) 118 119 119 120 122 122

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Number of cylin­ders

12V 12V 12V 16V 16V 16V

Engine surface
noise with attenu­ated intake noise
(filter), BL, (free­field sound-pres­sure level Lp, 1m
distance, ISO

6798)

R dB(A) 103 104 105 105 108 108

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

R dB(A) 121 123 123 124 127 127

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3.2 12/16 V 4000 C13/13R/13L engine data: Application group
5A, optimized exhaust emissions (EPA Stage 2)

Explanation:

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

A Design value

G Guaranteed value

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

N Not yet defined value

- Not applicable

X Applicable

REFERENCE CONDITIONS

Engine model 12V

4000C13

R

12V

4000C13

12V

4000C13L

16V

4000C13

R

16V

4000C13

16V

4000C13L

Application group 5A 5A 5A 5A 5A 5A

Intake air temper­ature

°C 25 25 25 25 25 25

Charge-air cool­ant temperature

°C 45 45 45 45 45 45

Raw-water inlet
temperature

°C - - - - - -

Barometric pres­sure

mbar 1000 1000 1000 1000 1000 1000

Site altitude
above sea level

m 100 100 100 100 100 100

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

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Rated engine
speed

A rpm 1800 1800 1800 1800 1800 1800

1900

Net brake power
(w/o fan) (fuel
stop power ISO

3046)

A kW 1193 1343 1425 1492 1750 1865

GENERAL CONDITIONS (for maximum power)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Intake depression
(new filter)

A mbar 30 30 30 30 30 30

Intake depres­sion, max.

L mbar 50 50 50 50 50 50

Exhaust overpres­sure

A mbar 65 65 65 65 65 65

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Number of cylin­ders

12V 12V 12V 16V 16V 16V

Exhaust overpres­sure, max.

L mbar 85 85 85 85 85 85

Fuel temperature
at engine inlet
connection

R °C 25 25 25 25 25 25

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

L °C 60 60 60 60 60 60

CONSUMPTION

Number of cylin­ders

12V 12V 12V 16V 16V 16V

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

R % of B 0.3 0.3 0.3 0.3 0.3 0.3

MODEL-RELATED DATA (basic design)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Number of cylin­ders

12 12 12 16 16 16

Cylinder arrange­ment: V angle

degrees 90 90 90 90 90 90

Bore mm 170 170 170 170 170 170

Stroke mm 210 210 210 210 210 210

Cylinder displace­ment

Liters 4.77 4.77 4.77 4.77 4.77 4.77

Total displace­ment

Liters 57.2 57.2 57.2 76.3 76.3 76.3

Number of inlet
valves per cylin­der

2 2 2 2 2 2

Number of ex­haust valves per
cylinder

2 2 2 2 2 2

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COMBUSTION AIR / EXHAUST GAS

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Charge-air pres­sure before cylin­der

R bar abs 2.4 2.6 2.8 2.6 2.9 3.0

3.1

Exhaust tempera­ture after turbo­charger

R °C 440 440 450 390 400 405

380

COOLANT SYSTEM (HT circuit)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

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

A °C 100 100 100 100 100 100

Coolant tempera­ture after engine,
warning

R °C 102 102 102 102 102 102

Coolant tempera­ture after engine,
shutdown

L °C 104 104 104 104 104 104

Coolant antifreeze
content, max.

L % 50 50 50 50 50 50

Coolant pump: in­let pressure, max.

L bar 2.5 2.5 2.5 2.5 2.5 2.5

Thermostat:
Starts to open

R °C 79 79 79 79 79 79

Thermostat: Fully
open

R °C 92 92 92 92 92 92

COOLANT SYSTEM (LT circuit)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

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

R °C 53 54 55 55 57 57

56

Coolant tempera­ture difference af­ter/before inter­cooler, min.

L °C 6 7 8 8 10 10

8

Coolant tempera­ture difference af­ter/before inter­cooler, max.

L °C 14 15 16 16 18 18

16

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Number of cylin­ders

12V 12V 12V 16V 16V 16V

Coolant antifreeze
content, max.

L % 50 50 50 50 50 50

Charge-air tem­perature after in­tercooler, max.

L °C 80 80 80 80 80 80

Thermostat:
Starts to open

R °C 38 38 38 38 38 38

Thermostat: Fully
open

R °C 51 51 51 51 51 51

LUBE OIL SYSTEM

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Lube oil operating
temperature be­fore engine, from

R °C 92 92 92 92 92 92

Lube oil operating
temperature be­fore engine, to

R °C 95 95 95 95 95 95

Lube oil tempera­ture before en­gine, alarm

R °C 97 97 97 97 97 97

Lube oil tempera­ture before en­gine, shutdown

L °C 99 99 99 99 99 99

Lube oil operating
pressure before
engine (measure­ment block)

R bar 6.4 6.4 6.4 5.0 5.0 5.0

Lube oil operating
pressure (low
idle) (meas. point:
before engine)

R bar 2.6 2.6 2.6 2.0 2.0 2.0

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FUEL SYSTEM

Number of cylin­ders

12V 12V 12V 16V 16V 16V

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

L bar -0.1 -0.1 -0.1 -0.1 -0.1 -0.1

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

L bar -0.3 -0.3 -0.3 -0.3 -0.3 -0.3

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

L bar 1.5 1.5 1.5 1.5 1.5 1.5

GENERAL OPERATING DATA

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Coolant preheat­ing: preheating
temperature
(min.)

R °C 40 40 40 40 40 40

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

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

L degrees 15 15 15 15 15 15

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

L degrees 15 15 15 15 15 15

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

L degrees 15 15 15 15 15 15

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CAPACITIES

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Engine coolant,
engine side (with­out cooling equip­ment)

R Liters 212 212 212 260 260 260

Charge-air cool­ant, engine side

R Liters 47 47 47 50 50 50

Engine oil on ini­tial filling (stand­ard oil system)
(option: max. op­erating inclina­tions)

R Liters 245 245 245 300 300 300

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

L Liters 150 150 150 210 210 210

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

L Liters 190 190 190 240 240 240

WEIGHTS (basic design, dry engine)

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Engine dry weight
(with attached
standard accesso­ries, without cou­pling)

R kg 7000 7000 7000 8100 8100 8100

ACOUSTICS

Number of cylin­ders

12V 12V 12V 16V 16V 16V

Exhaust noise, un­silenced,BL, (free­field sound-pres­sure level Lp, 1m
distance, ISO

6798)

R dB(A) 106 107 108 108 109 110

Exhaust noise, un­silenced - BL
(sound power lev­el LW, ISO 6798)

R dB(A) 119 120 120 121 122 122

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Number of cylin­ders

12V 12V 12V 16V 16V 16V

Engine surface
noise with attenu­ated intake noise
(filter), BL, (free­field sound-pres­sure level Lp, 1m
distance, ISO

6798)

R dB(A) 103 105 106 107 106 109

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

R dB(A) 122 124 124 126 125 127

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3.3 12/16 V 4000 C23/23R engine data: Application group 5B,
optimized fuel consumption

Explanation:

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

A Design value
G Guaranteed value
R Guideline value

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

N Not yet defined value

- Not applicable

X Applicable

REFERENCE CONDITIONS

Engine model 12V

4000C23

R

12V

4000C23

16V

4000C23

R

16V

4000C23

Application group 5B 5B 5B 5B

Intake air temperature °C 25 25 25 25

Charge-air coolant temperature °C 45 45 45 45

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 as per ISO 3046)

Number of cylinders 12V 12V 16V 16V

Rated engine speed A rpm 1800 1800

1900

1800
1900

1800

Net brake power (w/o fan) (fuel stop pow­er ISO 3046)

A kW 1510 1680 2013 2240

GENERAL CONDITIONS (for maximum power)

Number of cylinders 12V 12V 16V 16V

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

Intake depression, max. L mbar 50 50 50 50

Exhaust overpressure A mbar 65 65 65 65

Exhaust overpressure, max. L mbar 85 85 85 85

Fuel temperature at engine inlet connec­tion

R °C 25 25 25 25

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

L °C 60 60 60 60

CONSUMPTION

Number of cylinders 12V 12V 16V 16V

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

R % of B 0.3 0.3 0.3 0.3

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MODEL-RELATED DATA (basic design)

Number of cylinders 12V 12V 16V 16V

Number of cylinders 12 12 16 16

Cylinder arrangement: V angle degrees 90 90 90 90

Bore mm 170 170 170 170

Stroke mm 210 210 210 210

Cylinder displacement Liters 4.77 4.77 4.77 4.77

Total displacement Liters 57.2 57.2 76.3 76.3

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 12V 12V 16V 16V

Charge-air pressure before cylinder R bar abs 2.7 2.9 2.9 3.2

Exhaust temperature after turbocharger R °C 440 440 410

380

410
380

COOLANT SYSTEM (HT circuit)

Number of cylinders 12V 12V 16V 16V

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

A °C 100 100 100 100

Coolant temperature after engine, warning R °C 102 102 102 102

Coolant temperature after engine, shut­down

L °C 104 104 104 104

Coolant antifreeze content, max. L % 50 50 50 50

Coolant pump: inlet pressure, max. L bar 2.5 2.5 2.5 2.5

Thermostat: Starts to open R °C 79 79 79 79

Thermostat: Fully open R °C 92 92 92 92

COOLANT SYSTEM (LT circuit)

Number of cylinders 12V 12V 16V 16V

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

R °C 54 56 57 60

Coolant temperature difference after/
before intercooler, min.

L °C 7 9 11 13

Coolant temperature difference after/
before intercooler, max.

L °C 15 17 19 21

Coolant antifreeze content, max. L % 50 50 50 50

Charge-air temperature after intercooler,
max.

L °C 80 80 80 80

Thermostat: Starts to open R °C 38 38 38 38

Thermostat: Fully open R °C 51 51 51 51

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LUBE OIL SYSTEM

Number of cylinders 12V 12V 16V 16V

Lube oil operating temperature before en­gine, from

R °C 92 92 92 92

Lube oil operating temperature before en­gine, to

R °C 95 95 95 95

Lube oil temperature before engine, alarm R °C 97 97 97 97

Lube oil temperature before engine, shut­down

L °C 99 99 99 99

Lube oil operating pressure before engine
(measurement block)

R bar 6.4 6.4 5.0 5.0

Lube oil operating pressure (low idle)
(meas. point: before engine)

R bar 2.6 2.6 2.0 2.0

FUEL SYSTEM

Number of cylinders 12V 12V 16V 16V

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

L bar -0.1 -0.1 -0.1 -0.1

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

L bar -0.3 -0.3 -0.3 -0.3

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

L bar 1.5 1.5 1.5 1.5

GENERAL OPERATING DATA

Number of cylinders 12V 12V 16V 16V

Coolant preheating: preheating tempera­ture (min.)

R °C 40 40 40 40

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders 12V 12V 16V 16V

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

L degrees 15 15 15 15

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

L degrees 15 15 15 15

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

L degrees 15 15 15 15

CAPACITIES

Number of cylinders 12V 12V 16V 16V

Engine coolant, engine side (without cool­ing equipment)

R Liters 212 212 260 260

Charge-air coolant, engine side R Liters 47 47 50 50

Engine oil on initial filling (standard oil sys­tem) (option: max. operating inclinations)

R Liters 245 245 300 300

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Number of cylinders 12V 12V 16V 16V

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

L Liters 150 150 210 210

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

L Liters 190 190 240 240

WEIGHTS (basic design, dry engine)

Number of cylinders 12V 12V 16V 16V

Engine dry weight (with attached standard
accessories, without coupling)

R kg 7000 7000 8100 8100

ACOUSTICS

Number of cylinders 12V 12V 16V 16V

Exhaust noise, unsilenced,BL, (free-field
sound-pressure level Lp, 1m distance, ISO

6798)

R dB(A) 107 108 110 111

Exhaust noise, unsilenced - BL (sound
power level LW, ISO 6798)

R dB(A) 120 121 122 123

Engine surface noise with attenuated in­take noise (filter), BL, (free-field sound­pressure level Lp, 1m distance, ISO 6798)

R dB(A) 105 108 109 109

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

R dB(A) 124 126 128 128

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3.4 12/16 V 4000 C23/23R engine data: Application group 5B,
optimized exhaust emissions (EPA Stage 2)

Explanation:

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

A Design value
G Guaranteed value
R Guideline value

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

N Not yet defined value

- Not applicable

X Applicable

REFERENCE CONDITIONS

Engine model 12V

4000C23

R

12V

4000C23

16V

4000C23

R

16V

4000C23

Application group 5B 5B 5B 5B

Intake air temperature °C 25 25 25 25

Charge-air coolant temperature °C 45 45 45 45

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 as per ISO 3046)

Number of cylinders 12V 12V 16V 16V

Rated engine speed A rpm 1800

1900

1800
1900

1800
1900

1800

Net brake power (w/o fan) (fuel stop pow­er ISO 3046)

A kW 1510 1680 2013 2240

GENERAL CONDITIONS (for maximum power)

Number of cylinders 12V 12V 16V 16V

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

Intake depression, max. L mbar 50 50 50 50

Exhaust overpressure A mbar 65 65 65 65

Exhaust overpressure, max. L mbar 85 85 85 85

Fuel temperature at engine inlet connec­tion

R °C 25 25 25 25

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

L °C 60 60 60 60

CONSUMPTION

Number of cylinders 12V 12V 16V 16V

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

R % of B 0.3 0.3 0.3 0.3

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MODEL-RELATED DATA (basic design)

Number of cylinders 12V 12V 16V 16V

Number of cylinders 12 12 16 16

Cylinder arrangement: V angle degrees 90 90 90 90

Bore mm 170 170 170 170

Stroke mm 210 210 210 210

Cylinder displacement Liters 4.77 4.77 4.77 4.77

Total displacement Liters 57.2 57.2 76.3 76.3

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 12V 12V 16V 16V

Charge-air pressure before cylinder R bar abs 2.9 3.2

3.4

3.2

3.3

3.4

Exhaust temperature after turbocharger R °C 440

425

440 410 410

COOLANT SYSTEM (HT circuit)

Number of cylinders 12V 12V 16V 16V

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

A °C 100 100 100 100

Coolant temperature after engine, warning R °C 102 102 102 102

Coolant temperature after engine, shut­down

L °C 104 104 104 104

Coolant antifreeze content, max. L % 50 50 50 50

Coolant pump: inlet pressure, max. L bar 2.5 2.5 2.5 2.5

Thermostat: Starts to open R °C 79 79 79 79

Thermostat: Fully open R °C 92 92 92 92

COOLANT SYSTEM (LT circuit)

Number of cylinders 12V 12V 16V 16V

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

R °C 56

55

58
57

59 62

Coolant temperature difference after/
before intercooler, min.

L °C 9

7

11

7

12 15

Coolant temperature difference after/
before intercooler, max.

L °C 17

15

19
15

20 23

Coolant antifreeze content, max. L % 50 50 50 50

Charge-air temperature after intercooler,
max.

L °C 80 80 80 80

Thermostat: Starts to open R °C 38 38 38 38

Thermostat: Fully open R °C 51 51 51 51

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LUBE OIL SYSTEM

Number of cylinders 12V 12V 16V 16V

Lube oil operating temperature before en­gine, from

R °C 92 92 92 92

Lube oil operating temperature before en­gine, to

R °C 95

96

95
96

95 95

Lube oil temperature before engine, alarm R °C 97

98

97
98

97 97

Lube oil temperature before engine, shut­down

L °C 99

100

99

100

99 99

Lube oil operating pressure before engine
(measurement block)

R bar 6.4

6.2

6.4

6.9

5.0 5.0

Lube oil operating pressure (low idle)
(meas. point: before engine)

R bar 2.6 2.6 2.0 2.0

FUEL SYSTEM

Number of cylinders 12V 12V 16V 16V

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

L bar -0.1 -0.1 -0.1 -0.1

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

L bar -0.3 -0.3 -0.3 -0.3

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

L bar 1.5 1.5 1.5 1.5

GENERAL OPERATING DATA

Number of cylinders 12V 12V 16V 16V

Coolant preheating: preheating tempera­ture (min.)

R °C 40 40 40 40

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Number of cylinders 12V 12V 16V 16V

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

L degrees 15 15 15 15

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

L degrees N N N N

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

L degrees 15 15 15 15

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

L degrees 15 15 15 15

M015695/03E 2013-03 | Technical Data | 45

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CAPACITIES

Number of cylinders 12V 12V 16V 16V

Engine coolant, engine side (without cool­ing equipment)

R Liters 212 212 260 260

Charge-air coolant, engine side R Liters 47 47 50 50

Engine oil on initial filling (standard oil sys­tem) (option: max. operating inclinations)

R Liters 245 245 300 300

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

L Liters 150 150 210 210

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

L Liters 190 190 240 240

WEIGHTS (basic design, dry engine)

Number of cylinders 12V 12V 16V 16V

Engine dry weight (with attached standard
accessories, without coupling)

R kg 7000 7000 8100 8100

ACOUSTICS

Number of cylinders 12V 12V 16V 16V

Exhaust noise, unsilenced,BL, (free-field
sound-pressure level Lp, 1m distance, ISO

6798)

R dB(A) 108 109 111 112

Exhaust noise, unsilenced - BL (sound
power level LW, ISO 6798)

R dB(A) 121 122 123 125

Engine surface noise with attenuated in­take noise (filter), BL, (free-field sound­pressure level Lp, 1m distance, ISO 6798)

R dB(A) 109 108 100 109

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

R dB(A) 125 126 128 128

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3.5 Firing order

Firing order

Num­ber of
cylin­ders

Firing order

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

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

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

M015695/03E 2013-03 | Technical Data | 47

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3.6 Main engine dimensions

Main engine dimensions

Length (A) 12V approx. 2810 mm

Length (A) 16V approx. 3280 mm

Width (B) 12V, 16V approx. 1585 mm

Height (C) 12V, 16V approx. 2027 mm

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4 Operation

4.1 Preparations for recommissioning the engine after extended
out-of-service periods (>3 months)

Preconditions

☑Engine shut down and secured against being restarted.

☑MTU Corrosion-proofing and Reproofing Regulations (A001070/..) are available.

Recommissioning after long out-of-service periods (>3 months)

Item Action

Engine Remove corrosion-proofing (→ MTU Corrosion-proofing and Reproofing Regu-

lations A001070/..).

Valve gear Lubricate valve gear every ≥ 6 months (→ Page 90).

Oil lubrication system Check engine oil level (→ Page 110).

Crank engine using starting system (→ Page 80).

Fuel prefilter Fill with fuel (if fitted).

Coolant system If engine has been out of service for more than 1 year, change engine cool-

ant (→ Page 123).
Change charge-air coolant (→ Page 133).

Coolant system Check engine coolant level (→ Page 122);

Check charge-air coolant level (→ Page 132).

Coolant system Preheat coolant with coolant preheating unit (if available).

Engine Control Unit Check electrical connections (→ Page 151).

High-pressure fuel pump Only on engines without oil priming pump

Fill HP fuel pump with fresh engine oil (→ Page 96).

M015695/03E 2013-03 | Operation | 49

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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 110).

Coolant circuit Check engine coolant level (→ Page 122);

Check charge-air coolant level (→ Page 132).

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, opera­tor station etc. (depending
on manufacturer).

1.

If no coolant preheater is fitted, make sure that the coolant tempera­ture 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 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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4.5 After shutting down the engine

Preconditions

☑MTU Corrosion-proofing and Reproofing Regulations (A001070/..) are available.

After shutting down the engine

Item Action

Coolant system Drain coolant (→ Page 124), (→ Page 134), 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;

•

coolant is not preheated;

•

antifreeze concentration is 50 % and outside temperature is below

-40 °C.

Engine control system Switch off.

Air intake and exhaust sys­tem

Out-of-service period > 1 week:
Seal off engine's intake and exhaust systems.
Out-of-service period > 1 month:
Corrosion-proof engine (→ MTU Corrosion-proofing and Reproofing Regula­tions A001070/..).

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4.6 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
protection).

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.

54 | Operation |

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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 oil level with dipstick.

Check oil level at sight glass.

(→ Page 110)
(→ Page 111)

W0501 Visually inspect engine for leaks and general condition. -

W0502 X Check intercooler drain(s). (→ Page 107)

W0503 Check signal ring position of service indicator on air fil-

ter.

(→ Page 108)

W0505 Check relief bores of coolant pump(s). (→ Page 129)

(→ Page 138)

W0506 Check engine for abnormal running noises, exhaust col-

or and vibrations.

(→ Page 56)

W0507 X Drain water and contaminants from fuel prefilter. (→ Page 105)

W0508 X Check reading on differential pressure gage of fuel pre-

filter.

-

W0525 Check battery-charging generator for contamination,

clean as necessary.

(→ Page 142)

W1001 Replace fuel filter or fuel filter element. (→ Page 104)

W1006 Replace fuel injectors. (→ Page 97)

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

replace filter sleeve, accomplish at every engine oil
change, at the latest.

(→ Page 120)

W1011 Perform endoscopic examination. (→ Page 81)

W1036 Replace coolant filter. (→ Page 130)

W1047 Check and clean oil indicator filter. (→ Page 118)

W1207 Check valve clearance, adjust as necessary. Attention!

First adjustment after 1,000 operating hours.

(→ Page 91)

W1209 Disassemble battery-charging generator and clean thor-

oughly with compressed air.

(→ Page 140)

W1241 Check condition of belt drive and replace if necessary;

adjust belt tension.

(→ Page 139)

W1697 X Check carbon brushes on flywheel, replace if necessary. (→ Page 87)

W1698 X Replace carbon brushes on flywheel. (→ Page 89)

W1713 Injector: Reset drift compensation (CDC) parameters. (→ Page 98)

Table 1: Maintenance task reference table [QL1]

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6 Troubleshooting

6.1 Troubleshooting

Engine does not turn over when starter is operated

Component Cause Action

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

documentation).

Cable connections defective Check if cable connections are properly

secured (see manufacturer's documen­tation).

Starter Engine wiring or starter faulty Check if cable connections are properly

secured, contact Service.

Engine wiring Faulty Check (→ Page 149).

Engine/alternator
control system

Assemblies or connectors possibly loose Perform visual inspection (see manufac-

turer's documentation).

Engine Control Unit Electrical connections may be loose Check electrical connections

(→ Page 151).

Engine Jammed (cannot be cranked by hand) Notify Service.

Engine turns over when started but does not fire

Component Cause Action

Starter Lacks power: battery discharged or de-

fective

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

Engine wiring Faulty Check (→ Page 149).

Fuel system Air in fuel system Bleed fuel system (→ Page 103).

Engine Control Unit Faulty Notify Service.

Engine fires unevenly

Component Cause Action

Fuel injection system Injector defective Replace (→ Page 97).

Engine wiring Faulty Check (→ Page 149).

Fuel system Air in fuel system Bleed fuel system (→ Page 103).

Engine Control Unit Faulty Notify Service.

Engine fails to reach rated speed

Component Cause Action

Fuel supply Fuel prefilter clogged Replace

Fuel filter clogged Replace (→ Page 104).

Air supply Air filter clogged Clean.

Fuel injection system Injector defective Replace (→ Page 97).

Engine wiring Faulty Check (→ Page 149).

Engine Overloaded Notify Service.

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Engine speed not steady

Component Cause Action

Fuel injection system Injector defective Replace (→ Page 97).

Speed sensor Defective Notify Service.

Fuel system Air in fuel system Bleed fuel system (→ Page 103).

Engine Control Unit Defective Notify Service.

Charge air temperature too high

Component Cause Action

Engine coolant Incorrect coolant concentration Check (MTU test kit).

Intercooler Dirty Notify Service.

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

pipes.

Charge-air pressure too low

Component Cause Action

Air supply Air filter clogged Clean.

Intercooler Dirty Notify Service.

Turbocharger Defective Notify Service.

Coolant leakage from intercooler

Component Cause Action

Intercooler Leaking, significant coolant loss Notify Service.

Black smoke from exhaust

Component Cause Action

Air supply Air filter clogged Clean.

Fuel injection system Injector defective Replace (→ Page 97).

Engine Overloaded Notify Service.

Blue smoke from exhaust

Component Cause Action

Engine oil Too much oil in engine Drain engine oil (→ Page 112).

Oil separator on crankcase venting sys­tem dirty

Replace (→ Page 85).

Turbocharger, cylinder
head, piston rings, cyl­inder liner

Defective Notify Service.

White smoke from exhaust

Component Cause Action

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

ture.

Fuel system Water in fuel Check fuel system at fuel prefilter

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Component Cause Action

Drain water from fuel prefilter.

Intercooler Leaking Notify Service.

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6.2 Fault messages of the engine governor ADEC (ECU 7) for
series 4000 C&I engines

The fault code numbers are generated by the Engine Control Unit an transmitted to the display.

The fault code (1) comprises three digits.

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

The table below lists possible fault codes:

Fault code No. Full designation Meaning Action

Related
parameter
No.

003 HI T-Fuel

Preliminary warning: Fuel
temperature too high. Contact Service.

2.0122.93
1

004 SS T-Fuel

Main warning: Fuel tempera­ture too high; engine shut­down. Contact Service.

2.0122.93
2

005 HI T-Charge Air

Preliminary warning: Charge­air temperature too high

1. Reduce power.

2. Check intercool­er.

2.0121.93
1

006 SS T-Charge Air

Main warning: Charge-air
temperature too high; engine
shutdown.

1. Reduce power.

2. Check intercool­er.

2.0121.93
2

009

AL L1 T-Coolant Inter­cooler

Charge-air coolant tempera­ture too high (1st limit val­ue). Reduce power.

2.0124.93
1

010

AL L2 T-Coolant Inter­cooler

Main warning: Charge-air
coolant temperature too
high; engine shutdown. Reduce power.

2.0124.93
2

015 LO P-Lube Oil

Oil pressure too low (1st lim­it value).

Check oil level, top
up as necessary
(→ Page 110).

2.0100.92
1

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Fault code No. Full designation Meaning Action

Related
parameter
No.

016 SS P-Lube Oil

Oil pressure too low
(2nd limit value), automatic
engine shutdown.

1. Check oil level,
top up as necessa­ry(→ Page 110).

2. Attempt to re­start engine
(→ Page 51).

2.0100.92
2

019 HI T-Exhaust A

Exhaust temperature bank A
to high (1st limit value).

1. Check ca­bling(→ Page 149) ;

2. Contact Service.

2.0126.93
1

020 SS T-Exhaust A

Exhaust temperature bank A
to high (2nd limit value).

1. Check ca­bling(→ Page 149) ;

2. Contact Service.

2.0126.93
2

021 HI T-Exhaust B

Exhaust temperature bank B
to high (1st limit value).

1. Check ca­bling(→ Page 149) ;

2. Contact Service.

2.0127.93
1

022 SS T-Exhaust B

Exhaust temperature bank B
to high (2nd limit value).

1. Check ca­bling(→ Page 149) ;

2. Contact Service.

2.0127.93
2

023 LO Coolant Level

Coolant level too low (1st
limit value).

Check coolant level
in expansion
tank(→ Page 122) .

2.0152.92
1

024 SS Coolant Level

Coolant level too low (2nd
limit value).

Check coolant level
in expansion
tank(→ Page 122) .

2.0152.91
2

025 HI P-Diff. Lube Oil

Oil filter differential pressure
too high (1st limit value).

Replace oil filter
candles
(→ Page 115).

2.0154.93
1

026 SS P-Diff. Lube Oil

Alarm configuration limit val­ue 1; prewarning: differential
pressure at oil filter too high.

Replace oil filter
candles
(→ Page 115).

2.0154.93
2

027 HI Leak Fuel Level Leak fuel (1st limit value).

1. Check fuel sys­tem.

2. Contact Service.

2.0151.93
1

029 HI ETC2 Speed ETC 2 idling speed too high Contact Service.

1.8004.20
6

030 SS Engine Overspeed

Engine overspeed; automatic
engine shutdown.

1. Acknowledge
alarm.

2. Attempt to re­start engine.

2.2510.93
2

031 HI ETC1 Overspeed

Alarm configuration limit val­ue 1; preliminary warning:
Speed of primary turbocharg­er too high. Contact Service.

2.3011.93
1

032 SS ETC1 Overspeed

ETC 1 – speed exceeded
(2nd limit value)

Automatic power
reduction by engine
control sys­tem.Check air filter.

2.3012.93
2

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Fault code No. Full designation Meaning Action

Related
parameter
No.

036 HI ETC2 Overspeed

Alarm configuration limit val­ue 1; preliminary warning:
Speed of secondary turbo­charger too high.

1. Reduce power.

2. Contact Service.

2.3013.93
1

037 SS ETC2 Overspeed

Alarm configuration limit val­ue 2; main warning: Speed of
secondary turbocharger too
high. Fuel limitation to a
fixed value.

1. Reduce power.

2. Contact Service.

2.3013.91
2

038 AL ETC Synchro Fault

Synchronization error be­tween exhaust turbocharger
1 and 2.

1. Reduce power.

2. Contact Service.

1.8004.20
5

039 AL ETC2 Cut-in Failure ETC2 failed to cut in.

1. Reduce power.

2. Contact Service.

1.8004.20
4

044

L1 Coolant Level Inter­cooler

Charge air coolant level too
high/low (1st limit value not
attained).

Check coolant level
(→ Page 132).

2.0153.92
1

051 HI T-Lube Oil

Oil temperature too high
(1st limit value). Reduce power.

2.0125.93
1

052 SS T-Lube Oil

Lube oil temperature too
high (2nd limit value).

1. Reduce power.

2. Check engine oil
level (→ Page 110).

2.0125.93
2

057 LO P-Coolant

Coolant pressure too low
(1st limit value).

Check coolant cir­cuit.

2.0101.92
1

058 SS P-Coolant

Coolant pressure too low
(2nd limit value).

Automatic engine
shutdown.Check
coolant level
(→ Page 122).

2.0101.92
2

063 HI P-Crankcase

Preliminary warning: Crank­case pressure too high.

1. Reduce power.

2. Replace filter el­ement of oil separa­tor (→ Page 85).

2.0106.93
1

064 SS P-Crankcase

Main warning: Crankcase
pressure too high; engine
shutdown.

1. Contact Service.

2. Replace filter el­ement of oil separa­tor (→ Page 85).

2.0106.93
2

065 LO P-Fuel

Fuel supply pressure too low
(1st limit value).

Check fuel lines for
leaks.
Clean fuel prefil­ter.Flush fuel prefil­ter.
Replace fuel prefil­ter filter element.
Replace fuel filter
(→ Page 104).

2.0102.92
1

066 SS P-Fuel

Fuel supply pressure too low
(2nd limit value).

Check fuel lines for
leaks.
Clean fuel prefilter.

2.0102.92
2

M015695/03E 2013-03 | Troubleshooting | 61

TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

Flush fuel prefil­ter.Replace fuel
prefilter filter ele­ment.
Replace fuel filter
(→ Page 104).

067 HI T-Coolant

Coolant temperature too
high (1st limit value). Reduce power.

2.0120.93
1

068 SS T-Coolant

Coolant temperature too
high (2nd limit value), auto­matic engine shutdown.

1. Allow the engine
to cool down;

2. Contact Service.

3.
Check engine cool­ant cooler, clean if
dirty.

4. Restart engine
(→ Page 51).

2.0120.93
2

081 AL System Leaky

Pressure gradient in rail is
too low during starting or too
high during stopping; (HP
system leaky, air in system). Contact Service.

1.8004.04
6

082 HI P-Fuel (Common Rail)

Rail pressure > reference val­ue; DBR fuel limitation, start
of injection readjusted to­wards late; (suction restrictor
of HP fuel block jamming or
HP fuel control block wiring
faulty) Contact Service.

2.0104.93
1

083

LO P-Fuel (Common
Rail)

Rail pressure <reference val­ue; DBR fuel limitation; (suc­tion restrictor of HP fuel con­trol block defective or leak­age in HP fuel system) Contact Service.

2.0104.92
1

085 HI T-Recirculation

Preliminary warning: Recircu­lation temperature too high. Reduce power.

2.0128.93
1

086 HII T-Recirculation

Main warning: Recirculation
temperature too high. Reduce power.

2.0128.93
2

089 AL Stalling Engine

Engine speed did not attain
200 rpm. A stop is activated.

Note further mes­sages.

2.2500.03
0

090 SS No Idling Speed

Alarm configuration limit val­ue; Idling speed was not at­tained. Contact Service.

2.1090.92
5

091 SS No Runup Speed

Alarm configuration limit val­ue; Runup speed was not at­tained. Contact Service.

2.1090.92
4

62 | Troubleshooting | M015695/03E 2013-03

TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

092 SS No Starter Speed

Alarm configuration limit val­ue; Starter speed was not at­tained; Termination of start­ing sequence; Starter rotates
too slowly or does not rotate
at all. Contact Service.

2.1090.92
3

093 SS T-Preheat

Alarm configuration limit val­ue 2; Main warning: Preheat­ing temperature too low;
coolant temperature too low
for engine start; engine start
interlock active. Check preheater.

2.1090.92
2

094 LO T-Preheat

Alarm configuration limit val­ue 1; Preheating temperature
too low; coolant temperature
too low for engine start. Check preheater.

2.1090.92
1

095 AL Oil Priming Fail

Alarm configuration; oil pri­ming failure.

Check oil priming
system.

2.1090.92
0

102

AL Consumption Meter
Faulty

Invalid fuel consumption dis­play, checksum error in
EDM/EEPROM 1 (redundant
data record 1). Contact Service.

1.8004.62
4

104

AL Eng Hours Counter
Defect

Checksum error of the hour
meter in the EDM/
EEPROM 1. Contact Service. 18004.623

118 LO ECU Supply Voltage

Supply voltage too low (1st
limit value).

Check ECU supply
voltage.
Contact Service.

2.0140.92
1

119

LOLO ECU Supply Volt­age

Supply voltage too low (2nd
limit value).

Check ECU supply
voltage.
Contact Service.

2.0140.92
2

120 HI ECU Supply Voltage

Supply voltage too high (1st
limit value).

Check ECU supply
voltage.
Contact Service.

2.0140.93
1

121

HIHI ECU Supply Volt­age

Supply voltage too high (2nd
limit value); automatic engine
shutoff (dependent on appli­cation engineering).

Check ECU supply
voltage.
Contact Service.

2.0140.93
2

122 HI T-ECU

Temperature in the ECU
housing too high (1st limit
value).

1. Improve engine
room ventilation.

2. Reduce power.

2.0132.92
1

134 15V POS ECU DEFECT

Internal voltage (-15 V DC)
defective; automatic engine
shutdown. Replace ECU. -

136 15V NEG ECU DEFECT

Internal voltage (-15 V DC)
missing; automatic engine
shutdown. Contact Service. -

M015695/03E 2013-03 | Troubleshooting | 63

TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

139 L1 TE BUFFER TEST

Supply voltage of tempera­ture sensors faulty.

Contact Serv­ice.Check sen­sors;Replace ECU. -

140 TE BUF. ECU DEFECT

Supply voltage of tempera­ture sensors faulty.

Contact Serv­ice.Check sen­sors;Replace ECU. -

142 BANK1 ECU DEFECT

Power output stage for sole­noid valve activation on
bank 1 faulty; engine does
not start. Replace ECU. -

144 BANK2 ECU DEFECT

Power output stage for sole­noid valve activation on
bank 2 faulty; engine does
not start. Replace ECU. -

145

15V_GOOD ECU DE­FECT

Voltage supply is defective;
automatic engine shutdown. Replace ECU. -

146 L1 AD-TEST1 SUPPLY

Supply voltage of A/D con­verter too low. Replace ECU. -

147 AD-TEST1 ECU DEFECT

Electronic fault; automatic
engine shutdown. Replace ECU. -

148 L1 AD-TEST2 SUPPLY

Supply voltage of A/D con­verter too low. Replace ECU. -

149 AD-TEST2 ECU DEFECT

Internal electronic fault; au­tomatic engine shutdown. Replace ECU. -

150 L1 AD-TEST3 SUPPLY

Internal electronic fault; au­tomatic engine shutdown. Replace ECU. -

151 AD-TEST3 ECU DEFECT

Internal electronic fault; au­tomatic engine shutdown. Replace ECU. -

176 AL LifeData Not Avail

Alarm configuration; No (ap­propriate) LifeData backup
system available, ECU reset
after expiration of time-out
period. Contact Service.

2.4000.00
4

177

AL LifeData Restore In­complete

Alarm configuration; This er­ror message is generated if a
CRC is faulty during a data
upload to ADEC (indicated
for each indiv. module). Contact Service.

2.4000.00
6

180 AL CAN1 Node Failure

Alarm configuration; Connec­tion to one node on CAN bus
1 failed. Contact Service.

2.0500.68
0

181 AL CAN2 Node Failure

Alarm configuration; Connec­tion to one node on CAN bus
2 failed. Contact Service.

2.0500.68
1

182

AL CAN Incorr. Parame­triz.

Alarm configuration; Incor­rect parameter values en­tered in data record. Contact Service.

2.0500.68
2

64 | Troubleshooting | M015695/03E 2013-03

TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

183 AL CAN No PU-Data

Alarm configuration; The se­lected CAN mode initializes
communication by means of
the PU data module. Howev­er, the necessary PU data
module is not present or is
invalid. Contact Service.

2.0500.68
3

184

AL CAN PU Data Flash
Error

Alarm configuration; A pro­gramming error occurred
when attempting to copy a
received PU data module in­to the Flash module. Contact Service.

2.0500.68
4

186 AL CAN1 Bus Off

CAN 1 in Bus-Off state: Ei­ther short circuit on bus. Or
massive magnetic fields dis­rupting the bus.

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

2.0500.68
6

187 AL CAN1 Error Passive

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

Contact Serv­ice.Check that at
least one CAN sta­tion is available.
Check cabling as
necessary.Check
shielding, improve
shielding as neces­sary.

2.0500.68
7

188 AL CAN2 Bus Off

CAN 2 in Bus-Off state: Ei­ther short circuit on bus. Or
massive magnetic fields dis­rupting the bus.

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

2.0500.68
8

189 AL CAN2 Error Passive

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

Contact Serv­ice.Check that at
least one CAN sta­tion is available.
Check cabling as
necessary.Check
shielding, improve
shielding as neces­sary.

2.0500.68
9

190

AL EMU Parameter Not
Supported

Alarm configuration; EMU pa­rameters are not supported. Contact Service.

2.0500.69
0

201 SD T-Coolant

Sensor B06 defective (cool­ant temperature).

1. Check cabling.

2. Replace if neces­sary.

1.8004.57
0

M015695/03E 2013-03 | Troubleshooting | 65

TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

202 SD T-Fuel

Sensor B33 defective (fuel
temperature).

1. Check cabling.

2. Replace if neces­sary.

1.8004.57
2

203 SD T-Charge Air

Sensor B09 faulty (charge-air
temperature) A side.

1. Check cabling.

2. Replace if neces­sary.

1.8004.57
1

204 SD T-Coolant Intercooler

Sensor defective B26
(charge air coolant tempera­ture).

1. Check cabling.

2. Replace if neces­sary.

1.8004.57
4

205 SD T-Exhaust A

Sensor B4.21 faulty (exhaust
temperature) engine A side.

1. Check cabling

2. Replace if neces­sary.

1.8004.57
6

206 SD T-Exhaust B

Sensor B4.22 faulty (exhaust
temperature) engine B side.

1. Check cabling.

2. Replace if neces­sary.

1.8004.57
7

208 SD P-Charge Air

SD alarm configuration,
charge-air pressure sensor
(B10) faulty, short circuit or
wire break.

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

1.8004.56
6

211 SD P-Lube Oil

Sensor B05 defective (lube
oil pressure).

1. Check cabling.

2. Replace if neces­sary.

1.8004.56
3

212 SD P-Coolant

Sensor B16 defective (cool­ant pressure).

1. Check cabling.

2. Replace if neces­sary.

1.8004.56
4

213

SD P-Coolant Intercool-erSensor B43 faulty (intercool-

er coolant pressure).

1. Check cabling.

2. Replace if neces­sary.

1.8004.56
9

214 SD P-CrankCase

Sensor B50 faulty (crankcase
pressure).

1. Check cabling.

2. Replace if neces­sary.

1.8004.56
8

215 SD P-HD

Sensor B48 faulty (rail pres­sure, HP regulator); emer­gency mode active.

1. Check cabling.

2. Replace if neces­sary.

1.8004.56
7

216 SD T-Lube Oil

Sensor B07 faulty (lube oil
temperature).

1. Check cabling.

2. Replace if neces­sary.

1.8004.57
5

219 SD T-Intake Air

Sensor B03 faulty (intake air
temperature).

1. Check cabling.

2. Replace if neces­sary.

1.8004.57
3

220 SD Coolant Level

Sensor F33 faulty (coolant
level 1).

1. Switch system
OFF and ON again;

2. Check error mes­sage;

3. Check cabling

4. Contact Service.

5. Check sensor.

1.8004.58
4

66 | Troubleshooting | M015695/03E 2013-03

TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

221 SD Diff Lube Oil

Sensor F25 faulty (lube oil
differential pressure).

1. Check sensor
and wiring.

2. Replace if neces­sary.
Error cleared after
restarting the en­gine.

1.8004.58
5

222 SD Leak-Fuel Level Sensor F46 faulty (leak fuel).

1. Check sensor
and wiring.

2. Replace if neces­sary.

3. Contact Service.

1.8004.58
2

223

SD Intercooler Coolant
Level

Sensor F57 defective (charge
air coolant level).

1. Check sensor
and wiring.

2. Contact Service.

1.8004.58
3

227 SD P-Oil bef. Filter

SD alarm configuration; Sen­sor B5.3 (lube oil pressure
before filter) faulty; short cir­cuit or wire break.

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

1.8004.62
0

229

AL Stop Sensor Defect
Camshaft

Crankshaft and camshaft
speed sensor faulty.

1. Check cabling.

2. Contact Service.;
Check sensor.

1.8004.56
2

230 SD crankshaft

Sensor B13 faulty (crank­shaft speed).

1. Check sensor
and wiring.

2. Contact Service.

1.8004.49
8

231 SD camshaft

Sensor B1 faulty (camshaft
speed).

1. Check sensor
and wiring.

2. Contact Service.

1.8004.49
9

232 SD ETC Speed 1

Sensor B44 faulty (turbo­charger speed 1).

1. Check sensor
and wiring.

2. Contact Service.

1.3011.12
8

233 SD ETC Speed 2

Sensor B44.2 faulty (turbo­charger speed 2).

1. Check sensor
and wiring.

2. Contact Service.

1.3011.12
9

240 SD P-Fuel

Sensor B34 faulty (fuel pres­sure).

1. Check sensor
and wiring.

2. Contact Service.

1.8004.56
5

241 SD T-Recirculation

Sensor B49 faulty (recircula­tion temperature).

1. Check sensor
and wiring.

2. Contact Service.

1.8004.58
1

242 SD T-Coolant Redundant

Redundant coolant tempera­ture sensor faulty.

1. Check sensor
and wiring.

2. Contact Service.

1.8004.62
2

244 SD Oil Press. Redundant

SD alarm configuration; Re­dundant lube oil pressure
sensor faulty; Short circuit or
wire break

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

1.8004.62
1

M015695/03E 2013-03 | Troubleshooting | 67

TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

245 SD ECU Supply Voltage

Sensor fault (ECU operating
voltage). Replace ECU. 2.8006589

266 SD Speed Setting External speed setting faulty.

1. Check cabling.

2. Check speed set­ting.

2.8006.58
6

269 SD Loadp. Analog Filt.

SD alarm configuration; Fil­tered analog signal of load
pulse missing; short circuit
or wire break.

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

2.8006.58
8

270 SD Frequency Input

Frequency setting sensor
faulty.

1. Check cabling.

2. Contact Service.;
Check setpoint
speed transmitter.

2.8006.59
0

301

TIMING CYLINDER(A1­A10)

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

Replace injector
concerned if the
fault message ap­pears frequently
(→ Page 97).

1.8004.50
0

302 - - -

1.8004.50
1

303 - - -

1.8004.50
2

304 - - -

1.8004.50
3

305 - - -

1.8004.50
4

306 - - -

1.8004.50
5

307 - - -

1.8004.50
6

308 - - -

1.8004.50
7

309 - - -

1.8004.50
8

310 - - -

1.8004.50
9

311

TIMING CYLINDER(B1­B10)

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

Replace injector
concerned if the
fault message ap­pears frequently
(→ Page 97).

1.8004.51
0

312 - - -

1.8004.51
1

313 - - -

1.8004.51
2

314 - - -

1.8004.51
3

68 | Troubleshooting | M015695/03E 2013-03

TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

315 - - -

1.8004.51
4

316 - - -

1.8004.51
5

317 - - -

1.8004.51
6

318 - - -

1.8004.51
7

319 - - -

1.8004.51
8

320 - - -

1.8004.51
9

321

WIRING CYLINDER(A1­A10)

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

1. Check solenoid
valve.

2. Contact Service.

1.8004.52
0

322 - - -

1.8004.52
1

323 - - -

1.8004.52
2

324 - - -

1.8004.52
3

325 - - -

1.8004.52
4

326 - - -

1.8004.52
5

327 - - -

1.8004.52
6

328 - - -

1.8004.52
7

329 - - -

1.8004.52
8

330 - - -

1.8004.52
9

331

WIRING CYLINDER(B1­B10)

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

1. Check solenoid
valve.

2. Contact Service.

1.8004.53
0

332 - - -

1.8004.53
1

333 - - -

1.8004.53
2

334 - - -

1.8004.53
3

335 - - -

1.8004.53
4

336 - - -

1.8004.53
5

M015695/03E 2013-03 | Troubleshooting | 69

TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

337 - - -

1.8004.53
6

338 - - -

1.8004.53
7

339 - - -

1.8004.53
8

340 - - -

1.8004.53
9

341

OPEN_LOAD CYL.(A1­A10)

Open Load Bank 1 (solenoid
valve 1) ... Open Load Bank 1
(solenoid valve 10)

1. Check solenoid
valve.

2. Contact Service.

1.8004.54
0

342 - - -

1.8004.54
1

343 - - -

1.8004.54
2

344 - - -

1.8004.54
3

345 - - -

1.8004.54
4

346 - - -

1.8004.54
5

347 - - -

1.8004.54
6

348 - - -

1.8004.54
7

349 - - -

1.8004.54
8

350 - - -

1.8004.54
9

351

OPEN_LOAD CYL.(B1­B10)

Open Load Bank 2 (solenoid
valve 1) ... Open Load Bank 2
(solenoid valve 10)

1. Check solenoid
valve.

2. Contact Service.

1.8004.55
0

352 - - -

1.8004.55
1

353 - - -

1.8004.55
2

354 - - -

1.8004.55
3

355 - - -

1.8004.55
4

356 - - -

1.8004.55
5

357 - - -

1.8004.55
6

358 - - -

1.8004.55
7

70 | Troubleshooting | M015695/03E 2013-03

TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

359 - - -

1.8004.55
8

360 - - -

1.8004.55
9

361

AL Injector Power Stage
Low

Alarm configuration; Internal
electronic fault (electronics
possibly faulty: start
ITS).Check additional mes­sages if ITS indicates diagno­sis "Electronics OK" (e.g. ca­bling faulty).

1. Check solenoid
valve cabling.

2. Replace ECU.

1.8004.49
6

362

AL Injector Power Stage
High

Alarm configuration; Internal
electronic fault (electronics
possibly faulty: start
ITS).Check additional mes­sages if ITS indicates diagno­sis "Electronics OK" (e.g. ca­bling faulty).

1. Check solenoid
valve cabling.

2. Replace ECU.

1.8004.49
7

363

AL Stop Injector Power
Stage

Alarm configuration; Internal
electronic fault (electronics
possibly faulty: start ITS).

1. Check cabling.

2. Attempt to re­start engine.

1.8004.56
0

365

AL Stop Solenoid Valve
Grounding

Alarm configuration; Injector
cabling faulty. If bit
"1.1020.021" (Power Stage
Failure: Stop Engine) is set,
engine will be shut down as
additional measure. 1. Short
circuit of positive connection
of one or more injectors to
ground 2. Short circuit of
negative connection of one
or more injectors to ground .

1. Check cabling.

2. Attempt to re­start engine.

1.8004.56
1

371 AL Wiring TO 1

Alarm configuration; Short
circuit or wire break on tran­sistor output 1 (TO 1).

1. Check turbo­charger valve/
cabling, repair as
necessary

2. Replace ECU.

1.8004.63
4

372 AL Wiring TO 2

Alarm configuration; Short
circuit or wire break on tran­sistor output 2 (TO 2).

1. Check recircula­tion valve/cabling,
repair as necessary

2. Replace ECU.

1.8004.63
5

373 AL Wiring TO 3

Alarm configuration; Short
circuit or wire break on tran­sistor output 3 (TO 3). -

1.8004.63
6

374 AL Wiring TO 4

Alarm configuration; Short
circuit or wire break on tran­sistor output 4 (TO 4). -

1.8004.63
7

381 AL Wiring TOP 1

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

Check cabling to
plant.

2.8006.63
8

M015695/03E 2013-03 | Troubleshooting | 71

TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

382 AL Wiring TOP 2

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

Check cabling to
plant.

2.8006.63
9

383 AL Wiring TOP 3

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

Check cabling to
plant.

2.8006.64
0

384 AL Wiring TOP 4

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

Check cabling to
plant.

2.8006.64
1

390 AL MCR exceeded

Alarm configuration;
DBR/MCR function: MCR ex­ceeded.

1. If alarm is only
temporary, no ac­tion required;

2. <if alarm is con­tinuously active,
contact Service.

1.1085.00
9

392 HI T-Coolant Redundant

Alarm configuration limit val­ue 1; Preliminary warning:
Redundant coolant tempera­ture reading too high.

1. Check cabling.

2. Contact Service.

2.0129.93
1

393 SS T-Coolant Redundant

Alarm configuration limit val­ue 1; Main warning: Redun­dant coolant temperature
reading too high; engine
shutdown.

1. Check sensor
and wiring.

2. Contact Service.

2.0129.93
2

394

LO P-Lube Oil Redun­dant

Alarm configuration limit val­ue 1; Preliminary warning:
Redundant lube oil pressure
reading too low.

1. Check sensor
and wiring.

2. Contact Service.

2.0112.92
1

395

SS P-Lube Oil Redun­dant

Alarm configuration limit val­ue 2; Main warning: Redun­dant lube oil pressure read­ing too low.

1. Check sensor
and wiring.

2. Contact Service.

2.0112.92
2

396

AL T-Coolant Max Devia­tion

Alarm configuration; Maxi­mum coolant temperature
deviation.

1. Check sensor
and wiring.

2. Contact Service.

1.8004.62
6

397 AL P-Oil Max Deviation

Alarm configuration; Maxi­mum lube oil pressure devia­tion.

1. Check sensor
and wiring.

2. Contact Service.

1.8004.62
5

400

AL Open Load Digital In­put 1

Alarm configuration; Line dis­ruption on digital input 1; Ca­bling faulty or no resistance
over switch.

1. Check cabling.

2. Contact Service.;

3. Check input of
target device.

2.8006.62
5

401

AL Open Load Digital In­put 2

Alarm configuration; Line dis­ruption on digital input 2; Ca­bling faulty or no resistance
over switch.

1. Check cabling.

2. Contact Service.;
Check input of tar­get device.

2.8006.62
6

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TIM-ID: 0000033662 - 001

Fault code No. Full designation Meaning Action

Related
parameter
No.

402

AL Open Load Digital In­put 3

Alarm configuration; Line dis­ruption on digital input 3; Ca­bling faulty or no resistance
over switch.

1. Check cabling.

2. Contact Service.;
Check input of tar­get device.

2.8006.62
7

403

AL Open Load Digital In­put 4

Alarm configuration; Line dis­ruption on digital input 4; Ca­bling faulty or no resistance
over switch.

1. Check cabling.

2. Contact Service.;
Check input of tar­get device.

2.8006.62
8

404

AL Open Load Digital In­put 5

Alarm configuration; Line dis­ruption on digital input 5; Ca­bling faulty or no resistance
over switch.

1. Check cabling.

2. Contact Service.;
Check input of tar­get device.

2.8006.62
9

405

AL Open Load Digital In­put 6

Alarm configuration; Line dis­ruption on digital input 6; Ca­bling faulty or no resistance
over switch.

1. Check cabling.

2. Contact Service.;
Check input of tar­get device.

2.8006.63
0

406

AL Open Load Digital In­put 7

Alarm configuration; Line dis­ruption on digital input 7; Ca­bling faulty or no resistance
over switch.

1. Check cabling.

2. Contact Service.;
Check input of tar­get device.

2.8006.63
1

407

AL Open Load Digital In­put 8

Alarm configuration; Line dis­ruption on digital input 8;
wiring defective or no resist­ance through the switch.

1. Check cabling.

2. Contact Service.;
Check input of tar­get device.

2.8006.63
2

408

AL Open Load Em. Stop
Input ESI

Alarm configuration; Line dis­ruption on the input for
emergency stop; Cabling
faulty or no resistance over
switch.

1. Check cabling.

2. Contact Service.;
Check input of tar­get device.

2.8006.63
3

410 LO U-PDU

Alarm configuration limit val­ue 1; Preliminary warning: In­jector voltage too low.

1. Check cabling.

2. Check power
supply.

3. Contact Service.

2.0141.92
1

411 LOLO U-PDU

Alarm configuration limit val­ue 2; Main warning: Injector
voltage too low.

1. Check cabling.

2. Check power
supply.

3. Contact Service.

2.0141.92
2

412 HI U-PDU

Alarm configuration limit val­ue 1; Preliminary warning: In­jector voltage too high.

1. Check cabling.

2. Check power
supply.

3. Contact Service.

2.0141.93
1

413 HIHI U-PDU

Alarm configuration limit val­ue; Main warning: Injector
voltage too high.

1. Check cabling.

2. Check power
supply.

3. Contact Service.

2.0141.93
2

414

HI Water Level Fuel Pre­filter

Alarm configuration limit val­ue 1; Warning: water level in
fuel prefilter too high. Drain water.

2.0156.93
1

M015695/03E 2013-03 | Troubleshooting | 73

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Fault code No. Full designation Meaning Action

Related
parameter
No.

415 LO P-Coolant Intercooler

Alarm configuration limit val­ue 1; Preliminary warning:
Coolant pressure in inter­cooler too low.

Top up coolant
(→ Page 135).

2.0107.92
1

416 SS P-Coolant Intercooler

Alarm configuration limit val­ue 2; Main warning: Coolant
pressure in intercooler too
low. engine shutdown.

Top up coolant
(→ Page 135).

2.0107.92
2

417

SD Water Level Fuel
Prefilter

SD alarm configuration; Sen­sor for water level in fuel pre­filter faulty; short circuit or
wire break.

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

1.8004.59
4

420 L1 Aux 1

Alarm configuration limit val­ue 1; Input signal of Aux 1
has exceeded/not attained
limit value 1, depending on
configuration.

Determine cause of
limit value violation
and rectify fault.

2.0160.92
1

421 L2 Aux 1

Alarm configuration limit val­ue 1; Input signal of Aux 1
has exceeded/not attained
limit value 2, depending on
configuration.

Determine cause of
limit value violation
and rectify fault.

2.0160.92
2

428 L1 T-Aux 1

Alarm configuration limit val­ue 1; Preliminary warning:
Temperature signal of Aux 1
has exceeded / not attained
limit value 1, depending on
configuration.

Determine cause of
limit value violation
and rectify fault.

2.0130.92
1

440 L1 P-Aux 1

Alarm configuration limit val­ue 1; Preliminary warning:
Pressure signal of Aux 1 has
exceeded / not attained limit
value 1, depending on config­uration.

Determine cause of
limit value violation
and rectify fault.

2.0110.92
1

442 L2 P-Aux 1

Alarm configuration limit val­ue 2; Preliminary warning:
Pressure signal of Aux 1 has
exceeded / not attained limit
value 2, depending on config­uration.

Determine cause of
limit value violation
and rectify fault.

2.0110.93
1

444 SD U-PDU

SD alarm configuration; In­jector power stage sensor
defect; Internal fault in
ECU7.

Replace ADEC (ECU

7).

1.8004.57
8

445 SD P-Ambient Air

SD alarm configuration; Am­bient air pressure sensor
faulty. Replace ECU.

1.8004.58
0

448 HI P-Charge Air

Alarm configuration limit val­ue 1; Preliminary warning:
Charge-air pressure too high. Contact Service.

2.0103.93
1

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Fault code No. Full designation Meaning Action

Related
parameter
No.

449 SS P-Charge Air

Alarm configuration limit val­ue 2; Main warning: Charge­air pressure too high. Contact Service.

2.0103.93
2

450 SD Feed Signal Percent

SD alarm configuration; Input
signal for initial/final torque
faulty; Short circuit or wire
break

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

2.8006.59
2

454

SS Power Reduction Ac­tive

Alarm configuration; Power
reduction is active.

1. Note further fault
messages.

2. Determine and
rectify reason for
power reduction.

2.7000.01
1

455 AL Aux 1 Plant L1

Alarm configuration limit val­ue 1; Input signal of Aux 1
(plant side) has
exceeded/not attained limit
value 1, depending on config­uration.

Determine cause of
limit value violation
and rectify fault.

2.8006.65
0

456 AL Aux 1 Plant L2

Alarm configuration limit val­ue 2; Input signal of Aux 1
(plant side) has
exceeded/not attained limit
value 2, depending on config­uration.

Determine cause of
limit value violation
and rectify fault.

2.8006.65
1

460 AL Exhaust EMU High

Alarm configuration limit val­ue; EMU exhaust gas temper­ature value too high.

1. Check cabling.

2. Contact Service.

2.8006.65
2

461 AL Exhaust EMU Low

Alarm configuration limit val­ue; EMU exhaust gas temper­ature value too low.

1. Check cabling.

2. Contact Service.

2.8006.65
3

462 AL Coolant EMU L1

Alarm configuration limit val­ue; EMU coolant temperature
value too high / low.

Check configura­tion with DiaSys.

2.8006.65
4

463 SD AUX 2

SD alarm configuration; Ana­log input signal for Aux 2
faulty; Short circuit or wire
break

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

1.8004.59
1

464 SD P-AUX 1

SD alarm configuration; Ana­log input signal for Aux 1
pressure faulty; Short circuit
or wire break

Check pressure
sensor and cabling.
Error cleared after
restarting the en­gine.

1.8004.58
9

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Fault code No. Full designation Meaning Action

Related
parameter
No.

465 SD P-AUX 2

SD alarm configuration; Ana­log input signal for Aux 2
pressure faulty; Short circuit
or wire break

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

1.8004.58
8

466 SD T-AUX 2

SD alarm configuration; Ana­log input signal for Aux 2
temperature faulty; Short cir­cuit or wire break

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

1.8004.58
6

467 L2 T-Aux 1

Alarm configuration limit val­ue 2; Preliminary warning:
Temperature signal of Aux 1
has exceeded / not attained
limit value 2, depending on
configuration.

Determine cause of
limit value violation
and rectify fault.

2.0130.92
2

468 SD T-AUX 1

SD alarm configuration; Ana­log input for Aux 1 tempera­ture faulty. Replace ECU. 1.8004579

469 SD AUX 1

SD alarm configuration; Ana­log input signal for Aux 1
faulty; Short circuit or wire
break

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

1.8004.59
0

470 SD T-ECU

SD alarm configuration; Tem­perature sensor for ECU faul­ty; Short circuit or wire break

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

1.8004.58
7

471

SD HP Fuel Control
Block

SD alarm configuration; Con­trol of HP fuel control block
faulty; Short circuit or wire
break

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

1.8004.59
2

472 AL Stop SD

Alarm configuration; Engine
shutdown, since all shut­down channels have “sensor
faulty”.

1. Check cabling.

2. Contact Service.

2.8006.59
3

473 AL Cabling PWM_CM2

Alarm configuration; Cable
break or short circuit on
channel PWM_CM2.

1. Check cabling.

2. Contact Service.

1.8004.59
3

474 AL Cabling FO

Alarm configuration; Cable
break or short circuit on
channel FO.

1. Check cabling.

2. Contact Service.

2.8006.65
5

475

AL CR Engine Shutdown
Trigger

Alarm configuration; activat­ed when crash recorder trig­gered by an engine shutdown

Determine and rec­tify cause of trig­gering / engine
shutdown.

1.8010.00
9

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Fault code No. Full designation Meaning Action

Related
parameter
No.

476 AL Crash Rec. Init. Error

Alarm configuration; Initiali­zation error of crash record­er.

Check settings with
DiaSys.

1.8010.00
7

478

AL Comb. Alarm Yellow
(Plant)

Alarm configuration; Com­bined alarm YELLOW from
plant.

Note further fault
messages.

2.8006.00
1

479

AL Comb. Alarm Red
(Plant)

Alarm configuration; Com­bined alarm RED from plant.

Note further fault
messages.

2.8006.00
2

480 AL Lim Ext. Plant Bin

Alarm configuration limit val­ue; input signal has exceed­ed / not attained limit, de­pending on configuration.

Determine cause of
limit value violation
and rectify fault.

2.0291.92
1

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7 Task Description

7.1 Engine

7.1.1 Cranking engine manually

Preconditions

☑Engine shut down and secured against being restarted.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Cranking tool

F6555766 1

Cranking tool

F6783293 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.

Cranking engine manually (tool
mounted on side)

1. Remove guard plate.

2. Engage cranking tool (2) in ring gear (3)
and mount on flywheel housing.

• Use cranking tool F6555766.

3. Fit ratchet (1) onto cranking tool (2).

4. Rotate crankshaft in normal direction of en­gine rotation; apart from the normal com­pression resistance, there should be no re­sistance.

5. Cranking tool is removed by same proce­dure in reverse.

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Cranking engine manually (tool
mounted underneath)

1. Remove grounding device or guard plate.

2. Engage cranking tool (2) in ring gear (1)
and mount on flywheel housing.

• For 12/16V engines, use cranking

tool F6555766 with adapter F6558528.

• For 20V engines, use cranking

tool F6783293.

3. Fit ratchet (3) onto cranking tool (2).

4. Rotate crankshaft in normal direction of en­gine rotation; apart from the normal com­pression resistance, there should be no re­sistance.

5. Cranking tool is removed by same proce­dure in reverse.

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

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

Engine – Barring with starting system

1. Release latch of connector X4.

2. Remove connector from engine governor.

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

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

5. Engine start is automatically interrupted when specified starting period has passed. If necessary, re­start the engine after approx. 20 seconds.

6. Connect connector X4 to engine governor and latch in position.

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7.2 Cylinder Liner

7.2.1 Cylinder liner – Endoscopic examination

Preconditions

☑Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Barring device

F6555766 1

Ratchet with extension

F30006212 1

Endoscope

Y20097353 1

Preparatory steps

1. Remove cylinder head cover (→ Page 95).

2. Remove injector (→ Page 98).

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 cir­cumference cannot be faulted

•

Piston rings cannot be faulted

Further endoscopic examina­tion required as part of mainte­nance 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
damage

•

Heat discoloration of piston rings

Cylinder liner must be replaced;
Service must be contacted.

M015695/03E 2013-03 | Task Description | 81

TIM-ID: 0000003304 - 004

1. Compile endoscopy report using the table.

2. Use technical terms for description of the liner surface (→ Page 83).

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 98).

2. Install cylinder head cover (→ Page 95).

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

Terms used for endoscopic examination

Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex­amination 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 scoring
on the running surface under endoscope magnification. Cannot be felt with the
fingernail.
Findings not critical.

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

and cross through the 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 anoth-

er. 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 hon-

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

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

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 temper-

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

Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves in

the overlap (open) position. They are clearly visible due to the dark color of the
honing groove bottom.
This corrosion is not critical unless there is corrosion pitting.

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

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

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 pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.

M015695/03E 2013-03 | Task Description | 83

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Findings Measure

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
investigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid
unnecessary disassembly work, it is recommended that another inspection be carried out after further
operation of the engine.

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7.3 Crankcase Breather

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

Preconditions

☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 6-50 Nm

F30027336 1

Ratchet

F30027340 1

Engine oil

Filter element

(→ Spare Parts Catalog)

Diaphragm

(→ Spare Parts Catalog)

Gasket

(→ Spare Parts Catalog)

WARNING

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

Risk of injury and poisoning!

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

• Avoid contact with skin.

• Do not inhale oil vapor.

Replacing oil separator element

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

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

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

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

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

Name Size Type Lubricant Value/Standard

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

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

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| Task Description | 85

TIM-ID: 0000000017 - 008

Checking diaphragm

1. Remove cover (4).

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

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

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

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

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

Name Size Type Lubricant Value/Standard

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

7. Check diaphragms in further oil separators in the same way.

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7.4 Running Gear

7.4.1 Grounding device – Carbon brush check

Preconditions

☑Engine is stopped 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.

NOTICE

Unsuitable cleaning tools.

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).

Checking grounding device

Item Findings Action

Carbon brush Damaged

Wear limit 45 mm (new condition
60 mm)

Fit new part(→ Page 89)
Fit new part(→ Page 89)

Press carbon brush against spring
pressure
Spring broken, damaged Fit new part(→ Page 89)

Running surface on adapter contaminated, corroded Clean

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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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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 de­vice (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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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 95).

2. Fill oil chambers of valve bridges with oil.

3. Fill oil chambers of rocker arms and adjust­ing screws with oil.

4. Install cylinder head covers (→ Page 95).

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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, 60-320 Nm

F30452768 1

Box wrench socket, 24 mm

F30039526 1

Engine oil

Preparatory steps

1. Remove cylinder head cover (→ Page 95).

2. Install barring device (→ Page 78).

3. The OT (TDC) marking (1) (if fitted) on the
flywheel must not be used for reference.

M015695/03E 2013-03 | Task Description | 91

TIM-ID: 0000000922 - 010

4. Rotate crankshaft with barring device in di­rection of engine rotation until the "OT-A1"
marking and pointer are aligned.

Diagram for 8V engines (two
crankshaft positions)

Diagram for 12V engines (two
crankshaft positions)

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TIM-ID: 0000000922 - 010

Diagram for 16V engines (two
crankshaft positions)

Diagram for 20V engines (two
crankshaft positions)

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 (long rocker arm) = 0.2 mm ±0.05 mm

• Exhaust (short rocker arm) = 0.5 mm ±0.05 mm

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

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

I Inlet valve

X Exhaust valve

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

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

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Adjusting valve clearance

1. Release locknut (1).

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

3. Use Allen key to set adjusting screw (2) so
that the specified valve clearance is estab­lished.

4. Feeler gauge (3) must just pass through
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

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

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

7. Check valve clearance.

Final steps

1. Remove barring device (→ Page 78).

2. Install cylinder head cover (→ Page 95).

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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.

Grease (Kluthe Hakuform 30-10/Emulgier)

X00029933 1

O-ring

(→ Spare Parts Catalog)

Removing cylinder head cover

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

2. Remove screws (3, 4) with washers (2, 5).

3. Take off cylinder head cover (1) with O­ring (6) from cylinder head (7).

Installing cylinder head cover

1. Clean mounting surface.

2. Check O-ring (6) for damage, replace if necessary.

3. Coat O-ring (6) with grease.

4. Position O-ring (6) in groove of cylinder head cover (1).

5. Fit cylinder head cover (1) on cylinder head (7).

6. Install cylinder head cover (1) with screws (3, 4) and washers (2, 5).

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7.6 Injection Pump / HP Pump

7.6.1 HP pump – Filling with engine oil

Preconditions

☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Engine oil

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

Oils/oil vapors are combustible/explosive.

Risk of fire and explosion!

• Avoid open flames, electric sparks and ignition sources.

• Do not smoke.

NOTICE

HP fuel pump not filled with engine oil.

Damage to components, major material damage!

• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.

Filling HP pump

1. Remove plug screw (1).

2. Use pump oiler to fill HP pump with engine
oil until engine oil emerges.

3. Install plug screw (1).

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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 98).

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7.7.2 Injector – Removal and installation

Preconditions

☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Installation/removal tool

F6789889 1

Milling cutter

F30452739 1

Torque wrench, 0.5-5 Nm

0015384230 1

Torque wrench, 10-60 Nm

F30452769 1

Ratchet

F30027340 1

Torque wrench, 60-320 Nm

F30452768 1

Ratchet

F30027341 1

Assembly paste (Optimoly Paste White T)

40477 1

Grease (Kluthe Hakuform 30-10/Emulgier)

X00029933 1

Engine oil

O-ring

(→ Spare Parts Catalog)

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Preparatory steps

1. Shut off fuel supply to engine.

2. Remove cylinder head cover (→ Page 95).

Removing injector

1. Disconnect cable connector on injector.

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2. Remove HP fuel line (4).

3. Remove return line (5).

Note: The injector accumulator will be emptied

when removing the adapter.

4. Remove adapter (3).

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

6. Install installation/removal tool on cylinder
head.

7. Remove injector with installation/removal
tool.

8. Remove installation/removal tool.

9. Remove sealing ring (4) from injector or
use a self-made hook to take it out of the
cylinder head.

10. Remove O-rings (3), O-ring (2) and damper
ring (1) from injector.

11. Clean all mating and sealing surfaces.

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

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Installing injector

1. Remove plug before installing the injec­tor. (Do not remove the plug from the HP
line before installing the adapter.)

2. Coat injector with assembly paste at the
seat of the nozzle clamping nut.

3. Fit new sealing ring (included in the scope
of supply of the injector) with grease on in­jector, observe installation position of seal­ing ring.

4. Fit new O-rings (3) (included in the scope
of supply of the injector), O-ring (2) and
damping ring (1) onto the injector and coat
with grease.

5. Remove oil carbon from sealing face on cyl­inder head and protective sleeve with mill­ing cutter.

6. Insert injector into cylinder head, ensuring
that the HP line adapter is correctly
aligned.

7. Use installation/removal tool to press in in­jector.

8. Remove installation/removal tool.

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