MTU M015710/04E Operating Instructions Manual

Operating Instructions

Diesel engine
12 V 4000 G23, G43, G63, G83
16 V 4000 G23, G43, G63, G83, G83L

M015710/04E

Table of Contents

1 Safety

1.1 General conditions 5

1.2 Personnel and organizational requirements 6

1.3 Transport 7

1.4 Crankshaft transport locking device 8

1.5 Safety regulations for startup and operation 11

1.6 Explosion hazard when removing
inspection port cover on engine 12

1.7 Safety regulations for maintenance and
repair work 13

1.8 Auxiliary materials, fluids and lubricants,
fire prevention and environmental
protection 16

1.9 Conventions for safety instructions in the
text 18

2 General Information

2.1 Engine side and cylinder designations 19

2.2 Engine layout 20

2.3 Sensors, actuators and injectors –
Overview 21

3 Technical Data

3.1 16 V 4000 Gx3 engine data: Continuous
operation 3A, optimized fuel consumption 25

3.2 12 V 4000 Gx3 engine data: Continuous
operation, variable 3B, optimized fuel
consumption 28

3.3 12 V 4000 Gx3 engine data: Continuous
operation, variable 3B, optimized exhaust
emissions (TA-Luft) 32

3.4 16 V 4000 Gx3 engine data: Continuous
operation, variable 3B, optimized fuel
consumption 36

3.5 12/16 V 4000 Gx3 engine data: Continuous
operation, variable 3B, optimized exhaust
emissions (EPA stage 2) 40

3.6 12V 4000 Gx3 engine data: Standby

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operation 3D, optimized fuel consumption 44

3.7 16 V 4000 Gx3 engine data: Standby
operation 3D, optimized fuel consumption 48

3.8 12/16 V 4000 Gx3 engine data: Standby
operation 3D, optimized exhaust emissions
(EPA stage 2) 52

3.9 16 V 4000 G83L engine data: Standby
operation 3D, optimized fuel consumption 56

3.10 16 V 4000 G83L engine data: Standby
operation 3D, optimized exhaust emissions
(EPA stage 2) 60

3.11 Final compression pressure 64

3.12 Firing order 65

3.13 Engine – Main dimensions 66

4 Operation

4.1 Putting the engine into operation after
extended out-of-service periods (>3
months) 67

4.2 Putting the engine into operation after
scheduled out-of-service-period 68

4.3 Start engine in manual mode (testing
mode) 69

4.4 Safety system – Override 70

4.5 Starting the engine in emergency situations
(override mode) 71

4.6 Operational checks 72

4.7 Stop engine in manual mode (testing
mode) 73

4.8 Emergency stop 74

4.9 After stopping the engine – Engine remains
ready for operation 75

4.10 After stopping the engine – putting the
engine out of service 76

4.11 Plant cleaning 77

5 Maintenance

5.1 Maintenance task reference table [QL1] 78

6 Troubleshooting

6.1 Troubleshooting 79

6.2 Engine governor ADEC (ECU 7) for Series
4000 genset engines – Fault messages 82

7 Task Description

7.1 Engine 131

7.1.1 Engine – Barring manually 131

7.1.2 Engine – Barring with starting system 132

7.1.3 Engine – Test run 133

M015710/04E 2012-09 | Table of Contents | 3

7.2 Cylinder Liner 134

7.2.1 Cylinder liner – Endoscopic examination 134

7.2.2 Instructions and comments on endoscopic
and visual examination of cylinder liners 136

7.3 Crankcase Breather 138

7.3.1 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 138

7.4 Valve Drive 140

7.4.1 Valve gear – Lubrication 140

7.4.2 Valve clearance – Check and adjustment 141

7.4.3 Cylinder head cover – Removal and
installation 144

7.5 Injection Pump / HP Pump 145

7.5.1 HP pump – Filling with engine oil 145

7.6 Injection Valve / Injector 146

7.6.1 Injector – Replacement 146

7.6.2 Injector – Removal and installation 147

7.14.3 Centrifugal oil filter – Cleaning and filter
sleeve replacement 174

7.15 Coolant Circuit, General, High­Temperature Circuit 176

7.15.1 Engine coolant – Level check 176

7.15.2 Engine coolant – Change 177

7.15.3 Engine coolant – Draining 178

7.15.4 Engine coolant – Filling 179

7.15.5 Engine coolant pump – Relief bore check 182

7.15.6 Engine coolant – Sample extraction and
analysis 183

7.16 Low-Temperature Circuit 184

7.16.1 Charge-air coolant – Level check 184

7.16.2 Charge-air coolant – Change 185

7.16.3 Charge-air coolant – Draining 186

7.16.4 Charge-air coolant – Filling 187

7.16.5 Charge-air coolant pump – Relief bore check 190

7.17 Belt Drive 191

7.17.1 Drive belt – Condition check 191

7.7 Fuel System 152

7.7.1 Fuel system – Venting 152

7.8 Fuel Filter 153

7.8.1 Fuel filter – Replacement 153

7.8.2 Fuel prefilter cleaning 154

7.8.3 Fuel prefilter – Differential pressure gauge
check and adjustment 155

7.8.4 Fuel prefilter – Draining 156

7.8.5 Fuel prefilter – Flushing 157

7.8.6 Fuel prefilter – Filter element replacement 159

7.9 Charge-Air Cooling 161

7.9.1 Intercooler – Checking condensate drain for
coolant discharge and obstructions 161

7.10 Air Filter 162

7.10.1 Air filter – Replacement 162

7.10.2 Air filter – Check 163

7.10.3 Air filter – Removal and installation 164

7.11 Air Intake 165

7.11.1 Service indicator – Signal ring position check
(optional) 165

7.12 Starting Equipment 166

7.12.1 Air starter – Manual operation 166

7.18 Battery-Charging Generator 192

7.18.1 Battery-charging generator drive – Drive belt
tension adjustment 192

7.18.2 Battery-charging generator drive – Drive belt
replacement 193

7.19 Engine Mounting / Support 194

7.19.1 Engine mounting – Check 194

7.20 Wiring (General) for Engine/Gearbox/Unit 195

7.20.1 Engine wiring – Check 195

7.21 Accessories for (Electronic) Engine
Governor / Control System 196

7.21.1 Engine governor and connectors – Cleaning 196

7.21.2 Engine governor – Checking plug-in
connections 197

7.21.3 ECU 7 engine governor – Removal and
installation 198

8 Appendix A

8.1 Abbreviations 199

8.2 MTU contact persons/service partners 202

7.13 Lube Oil System, Lube Oil Circuit 167

7.13.1 Engine oil – Change 167

7.13.2 Engine oil – Level check 169

7.13.3 Engine oil – Sample extraction and analysis 170

7.14 Oil Filtration / Cooling 171

7.14.1 Engine oil filter – Replacement 171

7.14.2 Oil indicator filter – Check 172

4 | Table of Contents | M015710/04E 2012-09

9 Appendix B

9.1 Special Tools 203

9.2 Index 209

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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.

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1 Left engine side
2 KGS = Free end

3 Right engine side
4 KS = Driving end

M015710/04E 2012-09 | General Information | 19

2.2 Engine layout

Illustration applies in the same way to 12 V 4000 Gx3.

1 Exhaust gas outlet con‐

nection
2 Air filter
3 Exhaust turbocharger
4 Intercooler
5 Cylinder head
6 Flywheel
7 Lifting eye

8 Charge-air pipe

9 Starter
10 Engine mounting
11 Oil pan
12 Crankcase
13 Engine oil filter
14 Fuel filter

15 HP fuel pump
16 Battery-charging gener‐

ator
17 Centrifugal oil filter
18 Oil heat exchanger
19 Crankcase breather

Engine model designation

Key to the engine model designations 12/16V 4000 Gx3(L)

12/16 Number of cylinders

V Cylinder arrangement: V engine

4000 Series

G Application

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

3 Design index

L L (enhanced power / speed)

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20 | General Information | M015710/04E 2012-09

2.3 Sensors, actuators and injectors – Overview

Illustrations are also valid for 12 V 4000 Gx3 engines.

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1 Temperature sensors

for cylinder exhaust gas
B4.1 to B4.8 (engine
side A)

The injectors (Y39.1 to Y39.8, engine side A) are underneath the cylinder head covers of the cylinder.
Injector replacement and necessary activities (→ Page 146).

2 Sensor B34 (fuel pres‐

sure after filter)

3 M8 (HP fuel pump ac‐

tuator)

M015710/04E 2012-09 | General Information | 21

1 B50 (crankcase pres‐

sure)

2 B05.3 (lube oil pressure

before filter)

3 B05 (lube oil pressure

after filter)

4 B33 (fuel temperature in

common rail)

5 B07 (lube oil tempera‐

ture)
6 B01 (camshaft speed)
7 B48 (fuel pressure in

common rail)
8 B43 (charge-air coolant

pressure)

9 B26 (charge-air coolant

temperature)

10 B06 (engine coolant

temperature)

22 | General Information | M015710/04E 2012-09

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1 Temperature sensors

for cylinder exhaust gas
B4.11 to B4.18 (engine
side B)

3 B10 (charge-air pres‐

sure)

4 B09 (charge-air temper‐

ature)

2 B16 (coolant pressure)

The injectors (Y39.11 to Y39.18, engine side B) are underneath the cylinder head covers of the cylinder.
Injector replacement and required procedure (→ Page 146)

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M015710/04E 2012-09 | General Information | 23

1 B13 (crankshaft speed)

24 | General Information | M015710/04E 2012-09

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3 Technical Data

3.1 16 V 4000 Gx3 engine data: Continuous operation 3A,
optimized fuel consumption

Explanation

Abbrevia‐
tion

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 set‐

N Not yet defined value

Meaning

tings).

Reference conditions

Engine model 16V

4000G43

Application group 3A 3A 3A

Intake air temperature °C 25 25 25

Charge-air coolant temperature °C 55 55 55

Barometric pressure mbar 1000 1000 1000

Site altitude above sea level m 100 100 100

16V

4000G63

16V

4000G83

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

Number of cylinders 16 16 16

Rated engine speed A rpm 1800 1500 1800

Continuous power as per ISO 3046 A kW 1560 1635 1710

General conditions (for maximum power)

Number of cylinders 16 16 16

Intake depression (new filter) A mbar 15 15 15

Intake depression, max. L mbar 50 50 50

Exhaust overpressure A mbar 30 30 30

Exhaust overpressure, max. L mbar 85 85 85

M015710/04E 2012-09 | Technical Data | 25

Model related data (basic design)

Number of cylinders 16 16 16

Number of cylinders 16 16 16

Cylinder arrangement: V-angle Degrees

(°)

Bore mm 170 170 170

Stroke mm 210 210 210

Cylinder displacement Liters 4.77 4.77 4.77

Total displacement Liters 76.3 76.3 76.3

Compression ratio 16.5 16.5 16.5

Inlet valves per cylinder 2 2 2

Exhaust valves per cylinder 2 2 2

90 90 90

Combustion air / Exhaust gas

Number of cylinders 16 16 16

Charge-air pressure before cylinder - BL R bar abs 2.7 2.6 2.9

Coolant system (HT circuit)

Number of cylinders 16 16 16

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

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

Coolant temperature after engine, shutdown L °C 104 104 104

Coolant antifreeze content, max. L % 50 50 50

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

A °C 100 100 100

Coolant system (LT circuit)

Number of cylinders 16 16 16

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

Coolant antifreeze content, max. L % 50 50 50

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

A °C 55 55 55

Lube oil system

Number of cylinders 16 16 16

Lube-oil operating temperature before engine, from R °C 90 89 88

Lube-oil operating temperature before engine, to R °C 96 95 95

Lube-oil temperature before engine, warning R °C 97 97 97

Lube-oil temperature before engine, shutdown L °C 99 99 99

Lube-oil operating pressure before engine, from R bar 4.7 4.2 4.7

Lube-oil operating pressure before engine, to R bar 6.5 5.5 6.5

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26 | Technical Data | M015710/04E 2012-09

Fuel system

Number of cylinders 16 16 16

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

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

L bar -0.1 -0.1 -0.1

L bar 1.5 1.5 1.5

General operating data

Number of cylinders 16 16 16

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

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

Firing speed, from R rpm 80 80 80

Firing speed, to R rpm 120 120 120

R °C 10 10 10

Capacities

Number of cylinders 16 16 16

Engine coolant capacity, engine side (without cool‐
ing equipment)

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

Engine oil, total, for initial filling (standard oil system)
(option: max. operating inclinations)

Oil change quantity, max. (standard oil system) (op‐
tion: max. operating inclinations)

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

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

R Liters 175 175 175

R Liters 300 300 300

R Liters 240 240 240

L Liters 210 210 210

L Liters 240 240 240

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Weights / main dimensions

Number of cylinders 16 16 16

Engine dry weight (basic engine configuration ac‐
cording to scope of delivery specifications)

R kg 7700 7700 7700

Acoustics

Number of cylinders 16 16 16

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

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

R dB(A) 126 124 127

R dB(A) 124 124 124

M015710/04E 2012-09 | Technical Data | 27

3.2 12 V 4000 Gx3 engine data: Continuous operation, variable
3B, optimized fuel consumption

Explanation

Abbrevia‐
tion

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 set‐

N Not yet defined value

- Not applicable

X Applicable

Meaning

tings).

Reference conditions

Engine model 12V4000

Application group 3B 3B 3B 3B 3B

Intake air temperature °C 25 25 25 25 25

Charge-air coolant tempera‐
ture

Raw water inlet temperature °C - - - - -

Barometric pressure mbar 1000 1000 1000 1000 1000

Site altitude above sea level m 100 100 100 100 100

°C 55 55 55 55 55

G23

12V4000

G23R

12V4000

G43

12V4000

G63

12V4000

G83

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

Number of cylinders 12 12 12 12 12

Rated engine speed A rpm 1500 1500 1800 1500 1800

Continuous power ISO 3046
(10% overload capability, de‐
sign power DIN 6280, ISO

8528)

General conditions (for maximum power)

Number of cylinders 12 12 12 12 12

Intake depression (new filter) A mbar 15 15 15 15 15

Intake depression, max. L mbar 50 50 50 50 50

Exhaust overpressure A mbar 30 30 30 30 30

Exhaust overpressure, max. L mbar 85 85 85 85 85

28 | Technical Data | M015710/04E 2012-09

A kW 1420 1205 1520 1575 1736

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Model related data (basic design)

Number of cylinders 12 12 12 12 12

Engine with exhaust turbo‐
charging (ETC) and charge­air cooling (CAC)

Uncooled exhaust lines X X X X X

Operating method: Four­stroke cycle, diesel, single­action

Combustion method: direct
fuel injection

Cooling method: Treated wa‐
ter

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

Number of cylinders 12 12 12 12 12

Cylinder arrangement: V-an‐
gle

Degrees
(°)

Bore mm 170 170 170 170 170

Stroke mm 210 210 210 210 210

Cylinder displacement Liters 4.77 4.77 4.77 4.77 4.77

Total displacement Liters 57.2 57.2 57.2 57.2 57.2

Compression ratio 16.5 16.5 16.5 16.5 16.5

Cylinder heads: individual
cylinder heads

Cylinder liners: wet, replace‐
able

Inlet valves per cylinder 2 2 2 2 2

Exhaust valves per cylinder 2 2 2 2 2

Standard housing connect‐

SAE 00 00 00 00 00
ing flange (engine main
PTO)

Flywheel interface DISC 21 21 21 21 21

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

90 90 90 90 90

X X X X X

X X X X X

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Combustion air / Exhaust gas

Number of cylinders 12 12 12 12 12

Charge air pressure before

R bar abs 2.6 2.4 2.9 2.9 3.2

cylinder - DL

Coolant system (HT circuit)

Number of cylinders 12 12 12 12 12

Coolant temperature (at en‐
gine connection: outlet to
cooling equipment)

Coolant temperature after
engine, warning

A °C 100 100 100 100 100

R °C 102 102 102 102 102

M015710/04E 2012-09 | Technical Data | 29

Number of cylinders 12 12 12 12 12

Coolant temperature after

L °C 104 104 104 104 104

engine, shutdown

Coolant antifreeze content,

L % 50 50 50 50 50

max.

Pressure loss in off-engine

L bar 0.7 0.7 0.7 0.7 0.7

cooling system, max.

Coolant system (LT circuit)

Number of cylinders 12 12 12 12 12

Coolant temperature before

A °C 55 55 55 55 55
intercooler (at engine con‐
nection: from cooling equip‐
ment)

Coolant antifreeze content,

L % 50 50 50 50 50
max.

Pressure loss in off-engine

L bar 0.7 0.7 0.7 0.7 0.7
cooling system, max.

Lube oil system

Number of cylinders 12 12 12 12 12

Lube-oil operating tempera‐

R °C 88 88 88 88 88
ture before engine, from

Lube-oil operating tempera‐

R °C 98 98 98 98 98
ture before engine, to

Lube-oil temperature before

R °C 99 99 99 99 99
engine, warning

Lube-oil temperature before

L °C 101 101 101 101 101
engine, shutdown

Lube-oil operating pressure

R bar 5.0 5.0 5.0 5.0 5.0
before engine, from

Lube-oil operating pressure

R bar 6.0 7.0 7.0 7.0 7.0
before engine, to

Lube-oil operating pressure

R bar -- -- -- -- -­before engine, warning

Lube-oil operating pressure

L bar -- -- -- -- -­before engine, shutdown

Fuel system

Number of cylinders 12 12 12 12 12

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

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

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

L bar 1.5 1.5 1.5 1.5 1.5

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30 | Technical Data | M015710/04E 2012-09

General operating data

Number of cylinders 12 12 12 12 12

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

Coolant preheating: preheat‐
ing temperature (min.)

Firing speed, from R rpm 80 80 80 80 80

Firing speed, to R rpm 120 120 120 120 120

R °C 10 10 10 10 10

R °C 32 32 32 32 32

Capacities

Number of cylinders 12 12 12 12 12

Engine coolant capacity, en‐
gine side (without cooling
equipment)

Charge-air coolant, engine
side

Engine oil, total, for initial fill‐
ing (standard oil system)
(option: max. operating incli‐
nations)

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

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

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

R Liters 160 160 160 160 160

R Liters 40 40 40 40 40

R Liters 260 260 260 260 260

R Liters 260 260 260 260 260

L Liters 160 160 160 160 160

L Liters 200 200 200 200 200

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Weights / main dimensions

Number of cylinders 12 12 12 12 12

Engine dry weight (basic en‐
gine configuration according
to scope of delivery specifi‐
cations)

R kg 6200* 6200* 6200* 6200* 6200*

Acoustics

Number of cylinders 12 12 12 12 12

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

Engine surface noise with at‐
tenuated intake noise filter) ­DL (sound power level LW,
ISO 6798)

R dB(A) 124 124 125 125 127

R dB(A) 120 120 122 121 123

M015710/04E 2012-09 | Technical Data | 31

3.3 12 V 4000 Gx3 engine data: Continuous operation, variable
3B, optimized exhaust emissions (TA-Luft)

Explanation

Abbrevia‐
tion

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 set‐

N Not yet defined value

- Not applicable

X Applicable

Meaning

tings).

Reference conditions

Engine model 12V4000

Application group 3B 3B 3B

Intake air temperature °C 25 25 25

Charge-air coolant temperature °C 55 55 55

Raw water inlet temperature °C - - -

Barometric pressure mbar 1000 1000 1000

Site altitude above sea level m 100 100 100

G23

12V4000

G23R

12V4000

G63

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

Number of cylinders 12 12 12

Rated engine speed A rpm 1500 1500 1500

Continuous power ISO 3046 (10% overload capabil‐
ity, design power DIN 6280, ISO 8528)

General conditions (for maximum power)

Number of cylinders 12 12 12

Intake depression (new filter) A mbar 15 15 15

Intake depression, max. L mbar 50 50 50

Exhaust overpressure A mbar 30 30 30

Exhaust overpressure, max. L mbar 85 85 85

32 | Technical Data | M015710/04E 2012-09

A kW 1420 1205 1575

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Model related data (basic design)

Number of cylinders 12 12 12

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

Uncooled exhaust lines X X X

Operating method: Four-stroke cycle, diesel, single­action

Combustion method: direct fuel injection X X X

Cooling method: Treated water X X X

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

Number of cylinders 12 12 12

Cylinder arrangement: V-angle Degrees

(°)

Bore mm 170 170 170

Stroke mm 210 210 210

Cylinder displacement Liters 4.77 4.77 4.77

Total displacement Liters 57.2 57.2 57.2

Compression ratio 16.5 16.5 16.5

Cylinder heads: individual cylinder heads X X X

Cylinder liners: wet, replaceable X X X

Inlet valves per cylinder 2 2 2

Exhaust valves per cylinder 2 2 2

Standard housing connecting flange (engine main

SAE 00 00 00

PTO)

Flywheel interface DISC 21 21 21

X X X

X X X

90 90 90

TIM-ID: 0000003032 - 002

Combustion air / Exhaust gas

Number of cylinders 12 12 12

Charge air pressure before cylinder - DL R bar abs 3.2 2.9 3.5

Coolant system (HT circuit)

Number of cylinders 12 12 12

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

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

Coolant temperature after engine, shutdown L °C 104 104 104

Coolant antifreeze content, max. L % 50 50 50

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

A °C 100 100 100

M015710/04E 2012-09 | Technical Data | 33

Coolant system (LT circuit)

Number of cylinders 12 12 12

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

Coolant antifreeze content, max. L % 50 50 50

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

A °C 55 55 55

Lube oil system

Number of cylinders 12 12 12

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

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

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

Lube-oil temperature before engine, shutdown L °C 101 101 101

Lube-oil operating pressure before engine, from R bar 5.0 5.0 5.0

Lube-oil operating pressure before engine, to R bar 7.0 7.0 7.0

Lube-oil operating pressure before engine, warning R bar -- -- --

Lube-oil operating pressure before engine, shut‐
down

L bar -- -- --

Fuel system

Number of cylinders 12 12 12

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

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

L bar -0.1 -0.1 -0.1

L bar 1.5 1.5 1.5

General operating data

Number of cylinders 12 12 12

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

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

Firing speed, from R rpm 80 80 80

Firing speed, to R rpm 120 120 120

R °C 10 10 10

Capacities

Number of cylinders 12 12 12

Engine coolant capacity, engine side (without cool‐
ing equipment)

Charge-air coolant, engine side R Liters 40 40 40

Engine oil, total, for initial filling (standard oil system)
(option: max. operating inclinations)

Oil change quantity, max. (standard oil system) (op‐
tion: max. operating inclinations)

R Liters 160 160 160

R Liters 260 260 260

R Liters 260 260 260

TIM-ID: 0000003032 - 002

34 | Technical Data | M015710/04E 2012-09

Number of cylinders 12 12 12

Oil pan capacity at dipstick mark “min.” (standard oil

L Liters 160 160 160

system) (option: max. operating inclinations)

Oil pan capacity at dipstick mark “max.” (standard oil

L Liters 200 200 200

system) (option: max. operating inclinations)

Weights / main dimensions

Number of cylinders 12 12 12

Engine dry weight (basic engine configuration ac‐

R kg 6200* 6200* 6200*

cording to scope of delivery specifications)

Acoustics

Number of cylinders 12 12 12

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

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

R dB(A) 126 126 127

R dB(A) 122 122 122

TIM-ID: 0000003032 - 002

M015710/04E 2012-09 | Technical Data | 35

3.4 16 V 4000 Gx3 engine data: Continuous operation, variable
3B, optimized fuel consumption

Explanation

Abbrevia‐
tion

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 set‐

N Not yet defined value

- Not applicable

X Applicable

Meaning

tings).

Reference conditions

Engine model 16V

4000G23

Application group 3B 3B 3B 3B

Intake air temperature °C 25 25 25 25

Charge-air coolant temperature °C 55 55 55 55

Raw-water inlet temperature °C - - - -

Barometric pressure mbar 1000 1000 1000 1000

Site altitude above sea level m 100 100 100 100

16V

4000G43

16V

4000G63

16V

4000G83

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

Number of cylinders 16 16 16 16

Rated engine speed A rpm 1500 1800 1500 1800

Continuous power ISO 3046 (10% over‐
load capability, design power DIN 6280,
ISO 8528)

General conditions (for maximum power)

Number of cylinders 16 16 16 16

Intake depression (new filter) A mbar 15 15 15 15

Intake depression, max. L mbar 50 50 50 50

Exhaust overpressure A mbar 30 30 30 30

Exhaust overpressure, max. L mbar 85 85 85 85

36 | Technical Data | M015710/04E 2012-09

A kW 1798 2020 1965 2280

TIM-ID: 0000003003 - 002

Model related data (basic design)

Number of cylinders 16 16 16 16

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

Uncooled exhaust lines X X X X

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

Combustion method: direct fuel injection X X X X

Cooling method: Treated water X X X X

Direction of rotation: c.c.w. (facing driv‐
ing end)

Number of cylinders 16 16 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 76.3 76.3 76.3 76.3

Compression ratio 16.5 16.5 16.5 16.5

Cylinder heads: individual cylinder
heads

Cylinder liners: wet, replaceable X X X X

Inlet valves per cylinder 2 2 2 2

Exhaust valves per cylinder 2 2 2 2

Standard housing connecting flange (en‐

SAE 00 00 00 00

gine main PTO)

Flywheel interface DISC 21 21 21 21

X X X X

X X X X

X X X X

X X X X

TIM-ID: 0000003003 - 002

Combustion air / Exhaust gas

Number of cylinders 16 16 16 16

Charge air pressure before cylinder - DL R bar abs 2.6 2.9 2.8 3.1

Coolant system (HT circuit)

Number of cylinders 16 16 16 16

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

Coolant temperature after engine, warn‐
ing

Coolant temperature after engine, shut‐
down

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

Pressure loss in off-engine cooling sys‐
tem, max.

A °C 100 100 100 100

R °C 102 102 102 102

L °C 104 104 104 104

L bar 0.7 0.7 0.7 0.7

M015710/04E 2012-09 | Technical Data | 37

Coolant system (LT circuit)

Number of cylinders 16 16 16 16

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

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

Pressure loss in off-engine cooling sys‐
tem, max.

A °C 55 55 55 55

L bar 0.7 0.7 0.7 0.7

Lube oil system

Number of cylinders 16 16 16 16

Lube-oil operating temperature before
engine, from

Lube-oil operating temperature before
engine, to

Lube-oil temperature before engine,
warning

Lube-oil temperature before engine,
shutdown

Lube-oil operating pressure before en‐
gine, from

Lube-oil operating pressure before en‐
gine, to

Lube-oil operating pressure before en‐
gine, warning

Lube-oil operating pressure before en‐
gine, shutdown

R °C 89 90 89 88

R °C 95 96 95 95

R °C 97 97 97 97

L °C 99 99 99 99

R bar 4.2 4.7 4.2 4.7

R bar 5.5 6.5 5.5 6.5

R bar -- -- -- --

L bar -- -- -- --

Fuel system

Number of cylinders 16 16 16 16

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

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

L bar -0.1 -0.1 -0.1 -0.1

L bar 1.5 1.5 1.5 1.5

General operating data

Number of cylinders 16 16 16 16

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

Coolant preheating: preheating tempera‐
ture (min.)

Firing speed, from R rpm 80 80 80 80

Firing speed, to R rpm 120 120 120 120

R °C 10 10 10 10

R °C 32 32 32 32

TIM-ID: 0000003003 - 002

38 | Technical Data | M015710/04E 2012-09

Capacities

Number of cylinders 16 16 16 16

Engine coolant capacity, engine side

R Liters 260 260 260 260

(without cooling equipment)

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

Engine oil, total, for initial filling (stand‐

R Liters 300 300 300 300
ard oil system) (option: max. operating
inclinations)

Oil change quantity, max. (standard oil

R Liters 240 240 240 240
system) (option: max. operating inclina‐
tions)

Oil pan capacity at dipstick mark “min.”

L Liters 210 210 210 210
(standard oil system) (option: max. oper‐
ating inclinations)

Oil pan capacity at dipstick mark “max.”

L Liters 240 240 240 240
(standard oil system) (option: max. oper‐
ating inclinations)

Weights / main dimensions

Number of cylinders 16 16 16 16

Engine dry weight (basic engine configu‐
ration according to scope of delivery
specifications)

R kg 7700 7700 7700 7700

TIM-ID: 0000003003 - 002

Acoustics

Number of cylinders 16 16 16 16

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

Engine surface noise with attenuated in‐
take noise filter) - DL (sound power level
LW, ISO 6798)

R dB(A) 125 127 126 129

R dB(A) 126 125 128 125

M015710/04E 2012-09 | Technical Data | 39

3.5 12/16 V 4000 Gx3 engine data: Continuous operation,
variable 3B, optimized exhaust emissions (EPA stage 2)

Explanation

Abbrevia‐
tion

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 set‐

N Not yet defined value

- Not applicable

X Applicable

Meaning

tings).

Reference conditions

Engine model 12V

4000G43

Application group 3B 3B 3B 3B

Intake air temperature °C 25 25 25 25

Charge-air coolant temperature °C 45 45 45 45

Raw-water inlet temperature °C - - - -

Barometric pressure mbar 1000 1000 1000 1000

Site altitude above sea level m 100 100 100 100

12V

4000G83

16V

4000G43

16V

4000G83

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

Number of cylinders 12 12 16 16

Rated engine speed A rpm 1800 1800 1800 1800

Continuous power ISO 3046 (10% over‐
load capability, design power DIN 6280,
ISO 8528)

General conditions (for maximum power)

Number of cylinders 12 12 16 16

Intake depression (new filter) A mbar 15 15 15 15

Intake depression, max. L mbar 50 50 50 50

Exhaust overpressure A mbar 30 30 30 30

Exhaust overpressure, max. L mbar 85 85 85 85

40 | Technical Data | M015710/04E 2012-09

A kW 1520 1736 2020 2280

TIM-ID: 0000003018 - 002

Model related data (basic design)

Number of cylinders 12 12 16 16

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

Uncooled exhaust lines X X X X

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

Combustion method: direct fuel injection X X X X

Cooling method: Treated water X X X X

Direction of rotation: c.c.w. (facing driv‐
ing end)

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

Compression ratio 16.5 16.5 16.5 16.5

Cylinder heads: individual cylinder
heads

Cylinder liners: wet, replaceable X X X X

Inlet valves per cylinder 2 2 2 2

Exhaust valves per cylinder 2 2 2 2

Standard housing connecting flange (en‐

SAE 00 00 00 00

gine main PTO)

Flywheel interface DISC 21 21 21 21

X X X X

X X X X

X X X X

X X X X

TIM-ID: 0000003018 - 002

Combustion air / Exhaust gas

Number of cylinders 12 12 16 16

Charge air pressure before cylinder - DL R bar abs 3.0 3.1 3.0 3.2

Coolant system (HT circuit)

Number of cylinders 12 12 16 16

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

Coolant temperature after engine, warn‐
ing

Coolant temperature after engine, shut‐
down

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

Pressure loss in off-engine cooling sys‐
tem, max.

A °C 100 100 100 100

R °C 102 102 102 102

L °C 104 104 104 104

L bar 0.7 0.7 0.7 0.7

M015710/04E 2012-09 | Technical Data | 41

Coolant system (LT circuit)

Number of cylinders 12 12 16 16

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

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

Pressure loss in off-engine cooling sys‐
tem, max.

A °C 45 45 45 45

L bar 0.7 0.7 0.7 0.7

Lube oil system

Number of cylinders 12 12 16 16

Lube-oil operating temperature before
engine, from

Lube-oil operating temperature before
engine, to

Lube-oil temperature before engine,
warning

Lube-oil temperature before engine,
shutdown

Lube-oil operating pressure before en‐
gine, from

Lube-oil operating pressure before en‐
gine, to

Lube-oil operating pressure before en‐
gine, warning

Lube-oil operating pressure before en‐
gine, shutdown

R °C 88 88 90 88

R °C 98 98 96 94

R °C 99 99 97 97

L °C 101 101 99 99

R bar 5.0 5.0 4.7 4.7

R bar 7.0 7.0 6.5 6.5

R bar -- -- -- --

L bar -- -- -- --

Fuel system

Number of cylinders 12 12 16 16

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

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

L bar -0.1 -0.1 -0.1 -0.1

L bar 1.5 1.5 1.5 1.5

General operating data

Number of cylinders 12 12 16 16

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

Coolant preheating: preheating tempera‐
ture (min.)

Firing speed, from R rpm 80 80 80 80

Firing speed, to R rpm 120 120 120 120

R °C 10 10 10 10

R °C 32 32 32 32

TIM-ID: 0000003018 - 002

42 | Technical Data | M015710/04E 2012-09

Capacities

Number of cylinders 12 12 16 16

Engine coolant capacity, engine side

R Liters 160 160 260 260

(without cooling equipment)

Charge-air coolant, engine side R Liters 40 40 50 50

Engine oil, total, for initial filling (stand‐

R Liters 260 260 300 300
ard oil system) (option: max. operating
inclinations)

Oil change quantity, max. (standard oil

R Liters 240 240
system) (option: max. operating inclina‐
tions)

Oil pan capacity at dipstick mark “min.”

L Liters 160 160 210 210
(standard oil system) (option: max. oper‐
ating inclinations)

Oil pan capacity at dipstick mark “max.”

L Liters 200 200 240 240
(standard oil system) (option: max. oper‐
ating inclinations)

Weights / main dimensions

Number of cylinders 12 12 16 16

Engine dry weight (basic engine configu‐
ration according to scope of delivery
specifications)

R kg 6200* 6200* 7700 7700

TIM-ID: 0000003018 - 002

Acoustics

Number of cylinders 12 12 16 16

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

Engine surface noise with attenuated in‐
take noise filter) - DL (sound power level
LW, ISO 6798)

R dB(A) 125 127 127 129

R dB(A) 122 123 125 125

M015710/04E 2012-09 | Technical Data | 43

3.6 12V 4000 Gx3 engine data: Standby operation 3D, optimized
fuel consumption

Explanation

Abbrevia‐
tion

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 set‐

N Not yet defined value

- Not applicable

X Applicable

Meaning

tings).

Reference conditions

Engine model 12V

4000G23

Application group 3D 3D 3D 3D

Intake air temperature °C 25 25 25 25

Charge-air coolant temperature °C 55 55 55 55

Raw-water inlet temperature °C - - - -

Barometric pressure mbar 1000 1000 1000 1000

Site altitude above sea level m 100 100 100 100

12V

4000G43

12V

4000G63

12V

4000G83

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

Number of cylinders 12 12 12 12

Rated engine speed A rpm 1500 1800 1500 1800

Fuel stop power ISO 3046 A kW 1575 1736 1750 1910

General conditions (for maximum power)

Number of cylinders 12 12 12 12

Intake depression (new filter) A mbar 15 15 15 15

Intake depression, max. L mbar 50 50 50 50

Exhaust overpressure A mbar 30 30 30 30

Exhaust overpressure, max. L mbar 85 85 85 85

44 | Technical Data | M015710/04E 2012-09

TIM-ID: 0000002873 - 002

Model related data (basic design)

Number of cylinders 12 12 12 12

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

Uncooled exhaust lines X X X X

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

Combustion method: direct fuel injection X X X X

Cooling method: Treated water X X X X

Direction of rotation: c.c.w. (facing driv‐
ing end)

Number of cylinders 12 12 12 12

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 57.2 57.2

Compression ratio 16.5 16.5 16.5 16.5

Cylinder heads: individual cylinder
heads

Cylinder liners: wet, replaceable X X X X

Inlet valves per cylinder 2 2 2 2

Exhaust valves per cylinder 2 2 2 2

Standard housing connecting flange (en‐

SAE 00 00 00 00

gine main PTO)

Flywheel interface DISC 21 21 21 21

X X X X

X X X X

X X X X

X X X X

TIM-ID: 0000002873 - 002

Combustion air / Exhaust gas

Number of cylinders 12 12 12 12

Charge-air pressure before cylinder - BL R bar abs 2.9 3.2 3.2 3.4

Coolant system (HT circuit)

Number of cylinders 12 12 12 12

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

Coolant temperature after engine, warn‐
ing

Coolant temperature after engine, shut‐
down

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

Pressure loss in off-engine cooling sys‐
tem, max.

A °C 100 100 100 100

R °C 102 102 102 102

L °C 104 104 104 104

L bar 0.7 0.7 0.7 0.7

M015710/04E 2012-09 | Technical Data | 45

Coolant system (LT circuit)

Number of cylinders 12 12 12 12

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

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

Pressure loss in off-engine cooling sys‐
tem, max.

A °C 55 55 55 55

L bar 0.7 0.7 0.7 0.7

Lube oil system

Number of cylinders 12 12 12 12

Lube-oil operating temperature before
engine, from

Lube-oil operating temperature before
engine, to

Lube-oil temperature before engine,
warning

Lube-oil temperature before engine,
shutdown

Lube-oil operating pressure before en‐
gine, from

Lube-oil operating pressure before en‐
gine, to

Lube-oil operating pressure before en‐
gine, warning

Lube-oil operating pressure before en‐
gine, shutdown

R °C 88 88 88 88

R °C 98 98 98 98

R °C 99 99 99 99

L °C 101 101 101 101

R bar 5.0 5.0 5.0 5.0

R bar 7.0 7.0 7.0 7.0

R bar -- -- -- --

L bar -- -- -- --

Fuel system

Number of cylinders 12 12 12 12

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

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

L bar -0.1 -0.1 -0.1 -0.1

L bar 1.5 1.5 1.5 1.5

General operating data

Number of cylinders 12 12 12 12

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

Coolant preheating: preheating tempera‐
ture (min.)

Firing speed, from R rpm 80 80 80 80

Firing speed, to R rpm 120 120 120 120

R °C 10 10 10 10

R °C 32 32 32 32

TIM-ID: 0000002873 - 002

46 | Technical Data | M015710/04E 2012-09

Capacities

Number of cylinders 12 12 12 12

Engine coolant capacity, engine side

R Liters 160 160 160 160

(without cooling equipment)

Charge-air coolant, engine side R Liters 40 40 40 40

Engine oil, total, for initial filling (stand‐

R Liters 260 260 260 260
ard oil system) (option: max. operating
inclinations)

Oil change quantity, max. (standard oil

R Liters
system) (option: max. operating inclina‐
tions)

Oil pan capacity at dipstick mark “min.”

L Liters 160 160 160 160
(standard oil system) (option: max. oper‐
ating inclinations)

Oil pan capacity at dipstick mark “max.”

L Liters 200 200 200 200
(standard oil system) (option: max. oper‐
ating inclinations)

Weights / main dimensions

Number of cylinders 12 12 12 12

Engine dry weight (basic engine configu‐
ration according to scope of delivery
specifications)

R kg 6200* 6200* 6200* 6200*

TIM-ID: 0000002873 - 002

Acoustics

Number of cylinders 12 12 12 12

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

Engine surface noise with attenuated in‐
take noise (filter) - BL (sound power lev‐
el LW, ISO 6798)

R dB(A) 125 127 126 129

R dB(A) 121 123 122 124

M015710/04E 2012-09 | Technical Data | 47

3.7 16 V 4000 Gx3 engine data: Standby operation 3D,
optimized fuel consumption

Explanation

Abbrevia‐
tion

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 set‐

N Not yet defined value

- Not applicable

X Applicable

Meaning

tings).

Reference conditions

Engine model 16V

4000G23

Application group 3D 3D 3D 3D

Intake air temperature °C 25 25 25 25

Charge-air coolant temperature °C 55 55 55 55

Raw-water inlet temperature °C - - - -

Barometric pressure mbar 1000 1000 1000 1000

Site altitude above sea level m 100 100 100 100

16V

4000G43

16V

4000G63

16V

4000G83

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

Number of cylinders 16 16 16 16

Rated engine speed A rpm 1500 1800 1500 1800

Fuel stop power ISO 3046 A kW 1965 2280 2185 2500

General conditions (for maximum power)

Number of cylinders 16 16 16 16

Intake depression (new filter) A mbar 15 15 15 15

Intake depression, max. L mbar 50 50 50 50

Exhaust overpressure A mbar 30 30 30 30

Exhaust overpressure, max. L mbar 85 85 85 85

48 | Technical Data | M015710/04E 2012-09

TIM-ID: 0000002922 - 002

Model related data (basic design)

Number of cylinders 16 16 16 16

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

Uncooled exhaust lines X X X X

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

Combustion method: direct fuel injection X X X X

Cooling method: Treated water X X X X

Direction of rotation: c.c.w. (facing driv‐
ing end)

Number of cylinders 16 16 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 76.3 76.3 76.3 76.3

Compression ratio 16.5 16.5 16.5 16.5

Cylinder heads: individual cylinder
heads

Cylinder liners: wet, replaceable X X X X

Inlet valves per cylinder 2 2 2 2

Exhaust valves per cylinder 2 2 2 2

Standard housing connecting flange (en‐

SAE 00 00 00 00

gine main PTO)

Flywheel interface DISC 21 21 21 21

X X X X

X X X X

X X X X

X X X X

TIM-ID: 0000002922 - 002

Combustion air / Exhaust gas

Number of cylinders 16 16 16 16

Charge-air pressure before cylinder - BL R bar abs 2.8 3.1 3.1 3.3

Coolant system (HT circuit)

Number of cylinders 16 16 16 16

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

Coolant temperature after engine, warn‐
ing

Coolant temperature after engine, shut‐
down

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

Pressure loss in off-engine cooling sys‐
tem, max.

A °C 100 100 100 100

R °C 102 102 102 102

L °C 104 104 104 104

L bar 0.7 0.7 0.7 0.7

M015710/04E 2012-09 | Technical Data | 49

Coolant system (LT circuit)

Number of cylinders 16 16 16 16

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

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

Pressure loss in off-engine cooling sys‐
tem, max.

A °C 55 55 55 55

L bar 0.7 0.7 0.7 0.7

Lube oil system

Number of cylinders 16 16 16 16

Lube-oil operating temperature before
engine, from

Lube-oil operating temperature before
engine, to

Lube-oil temperature before engine,
warning

Lube-oil temperature before engine,
shutdown

Lube-oil operating pressure before en‐
gine, from

Lube-oil operating pressure before en‐
gine, to

Lube-oil operating pressure before en‐
gine, warning

Lube-oil operating pressure before en‐
gine, shutdown

R °C 89 88 88 88

R °C 95 95 94 94

R °C 97 97 97 97

L °C 99 99 99 99

R bar 4.2 4.7 4.2 4.7

R bar 5.5 6.5 5.5 6.5

R bar -- -- -- --

L bar -- -- -- --

Fuel system

Number of cylinders 16 16 16 16

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

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

L bar -0.1 -0.1 -0.1 -0.1

L bar 1.5 1.5 1.5 1.5

General operating data

Number of cylinders 16 16 16 16

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

Coolant preheating: preheating tempera‐
ture (min.)

Firing speed, from R rpm 80 80 80 80

Firing speed, to R rpm 120 120 120 120

R °C 10 10 10 10

R °C 32 32 32 32

TIM-ID: 0000002922 - 002

50 | Technical Data | M015710/04E 2012-09

Capacities

Number of cylinders 16 16 16 16

Engine coolant capacity, engine side

R Liters 260 260 260 260

(without cooling equipment)

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

Engine oil, total, for initial filling (stand‐

R Liters 300 300 300 300
ard oil system) (option: max. operating
inclinations)

Oil change quantity, max. (standard oil

R Liters 240 240 240 240
system) (option: max. operating inclina‐
tions)

Oil pan capacity at dipstick mark “min.”

L Liters 210 210 210 210
(standard oil system) (option: max. oper‐
ating inclinations)

Oil pan capacity at dipstick mark “max.”

L Liters 240 240 240 240
(standard oil system) (option: max. oper‐
ating inclinations)

Weights / main dimensions

Number of cylinders 16 16 16 16

Engine dry weight (basic engine configu‐
ration according to scope of delivery
specifications)

R kg 7700 7700 7700 7700

TIM-ID: 0000002922 - 002

Acoustics

Number of cylinders 16 16 16 16

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

Engine surface noise with attenuated in‐
take noise (filter) - BL (sound power lev‐
el LW, ISO 6798)

R dB(A) 126 129 128 130

R dB(A) 128 125 125 126

M015710/04E 2012-09 | Technical Data | 51

3.8 12/16 V 4000 Gx3 engine data: Standby operation 3D,
optimized exhaust emissions (EPA stage 2)

Explanation

Abbrevia‐
tion

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 set‐

N Not yet defined value

- Not applicable

X Applicable

Meaning

tings).

Reference conditions

Engine model 12V

4000G43

Application group 3D 3D 3D 3D

Intake air temperature °C 25 25 25 25

Charge-air coolant temperature °C 45 45 45 45

Raw-water inlet temperature °C - - - -

Barometric pressure mbar 1000 1000 1000 1000

Site altitude above sea level m 100 100 100 100

12V

4000G83

16V

4000G43

16V

4000G83

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

Number of cylinders 12 12 16 16

Rated engine speed A rpm 1800 1800 1800 1800

Fuel stop power ISO 3046 A kW 1736 1910 2280 2500

General conditions (for maximum power)

Number of cylinders 12 12 16 16

Intake depression (new filter) A mbar 15 15 15 15

Intake depression, max. L mbar 50 50 50 50

Exhaust overpressure A mbar 30 30 30 30

Exhaust overpressure, max. L mbar 85 85 85 85

52 | Technical Data | M015710/04E 2012-09

TIM-ID: 0000002955 - 002

Model related data (basic design)

Number of cylinders 12 12 16 16

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

Uncooled exhaust lines X X X X

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

Combustion method: direct fuel injection X X X X

Cooling method: Treated water X X X X

Direction of rotation: c.c.w. (facing driv‐
ing end)

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

Compression ratio 16.5 16.5 16.5 16.5

Cylinder heads: individual cylinder
heads

Cylinder liners: wet, replaceable X X X X

Inlet valves per cylinder 2 2 2 2

Exhaust valves per cylinder 2 2 2 2

Standard housing connecting flange (en‐

SAE 00 00 00 00

gine main PTO)

Flywheel interface DISC 21 21 21 21

X X X X

X X X X

X X X X

X X X X

TIM-ID: 0000002955 - 002

Combustion air / Exhaust gas

Number of cylinders 12 12 16 16

Charge-air pressure before cylinder - BL R bar abs 3.2 3.3 3.2 3.3

Coolant system (HT circuit)

Number of cylinders 12 12 16 16

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

Coolant temperature after engine, warn‐
ing

Coolant temperature after engine, shut‐
down

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

Pressure loss in off-engine cooling sys‐
tem, max.

A °C 100 100 100 100

R °C 102 102 102 102

L °C 104 104 104 104

L bar 0.7 0.7 0.7 0.7

M015710/04E 2012-09 | Technical Data | 53

Coolant system (LT circuit)

Number of cylinders 12 12 16 16

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

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

Pressure loss in off-engine cooling sys‐
tem, max.

A °C 45 45 45 45

L bar 0.7 0.7 0.7 0.7

Lube oil system

Number of cylinders 12 12 16 16

Lube-oil operating temperature before
engine, from

Lube-oil operating temperature before
engine, to

Lube-oil temperature before engine,
warning

Lube-oil temperature before engine,
shutdown

Lube-oil operating pressure before en‐
gine, from

Lube-oil operating pressure before en‐
gine, to

Lube-oil operating pressure before en‐
gine, warning

Lube-oil operating pressure before en‐
gine, shutdown

R °C 88 88 88 88

R °C 98 98 94 94

R °C 99 99 97 97

L °C 101 101 99 99

R bar 5.0 5.0 4.7 4.7

R bar 7.0 7.0 6.5 6.5

R bar -- -- -- --

L bar -- -- -- --

Fuel system

Number of cylinders 12 12 16 16

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

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

L bar -0.1 -0.1 -0.1 -0.1

L bar 1.5 1.5 1.5 1.5

General operating data

Number of cylinders 12 12 16 16

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

Coolant preheating: preheating tempera‐
ture (min.)

Firing speed, from R rpm 80 80 80 80

Firing speed, to R rpm 120 120 120 120

R °C 10 10 10 10

R °C 32 32 32 32

TIM-ID: 0000002955 - 002

54 | Technical Data | M015710/04E 2012-09

Capacities

Number of cylinders 12 12 16 16

Engine coolant capacity, engine side

R Liters 160 160 260 260

(without cooling equipment)

Charge-air coolant, engine side R Liters 40 40 50 50

Engine oil, total, for initial filling (stand‐

R Liters 260 260 300 300
ard oil system) (option: max. operating
inclinations)

Oil change quantity, max. (standard oil

R Liters 240 240
system) (option: max. operating inclina‐
tions)

Oil pan capacity at dipstick mark “min.”

L Liters 160 160 210 210
(standard oil system) (option: max. oper‐
ating inclinations)

Oil pan capacity at dipstick mark “max.”

L Liters 200 200 240 240
(standard oil system) (option: max. oper‐
ating inclinations)

Weights / main dimensions

Number of cylinders 12 12 16 16

Engine dry weight (basic engine configu‐
ration according to scope of delivery
specifications)

R kg 6200* 6200* 7700 7700

TIM-ID: 0000002955 - 002

Acoustics

Number of cylinders 12 12 16 16

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

Engine surface noise with attenuated in‐
take noise (filter) - BL (sound power lev‐
el LW, ISO 6798)

R dB(A) 127 129 129 130

R dB(A) 123 124 125 126

M015710/04E 2012-09 | Technical Data | 55

3.9 16 V 4000 G83L engine data: Standby operation 3D,
optimized fuel consumption

Explanation

Abbrevia‐
tion

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 set‐

N Not yet defined value

- Not applicable

X Applicable

Meaning

tings).

Reference conditions

Engine model 16V

4000G83L

Application group 3D

Intake air temperature °C 25

Charge-air coolant temperature °C 45

Raw water inlet temperature °C -

Barometric pressure mbar 1000

Site altitude above sea level m 100

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

Number of cylinders 16

Rated engine speed A rpm 1800

Fuel stop power ISO 3046 A kW 2740

General conditions (for maximum power)

Number of cylinders 16

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

Exhaust overpressure A mbar 30

Exhaust overpressure, max. L mbar 85

56 | Technical Data | M015710/04E 2012-09

TIM-ID: 0000039902 - 001

Model related data (basic design)

Number of cylinders 16

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

Uncooled exhaust lines X

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

Combustion method: direct fuel injection X

Cooling method: Treated water X

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

Number of cylinders 16

Cylinder arrangement: V-angle Degrees

(°)

Bore mm 170

Stroke mm 210

Cylinder displacement Liters 4.77

Total displacement Liters 76.3

Compression ratio 16.4

Inlet valves per cylinder 2

Cylinder heads: individual cylinder heads X

Cylinder liners: wet, replaceable X

Exhaust valves per cylinder 2

Standard housing connecting flange (engine main PTO) SAE 00

Flywheel interface (DISC) 21

90

TIM-ID: 0000039902 - 001

Combustion air / Exhaust gas

Number of cylinders 16

Charge-air pressure before cylinder - BL R bar abs 3.7

Coolant system (HT circuit)

Number of cylinders 16

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

Coolant temperature after engine, warning R °C 102

Coolant temperature after engine, shutdown L °C 104

Coolant antifreeze content, max. L % 50

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

Coolant system (LT circuit)

Number of cylinders 16

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

Coolant antifreeze content, max. L % 50

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

A °C 45

M015710/04E 2012-09 | Technical Data | 57

Lube oil system

Number of cylinders 16

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

Lube-oil operating temperature before engine, to R °C 94

Lube-oil temperature before engine, warning R °C 97

Lube-oil temperature before engine, shutdown L °C 99

Lube-oil operating pressure before engine, from R bar 4.7

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

Lube-oil operating pressure before engine, warning R bar -

Lube-oil operating pressure before engine, shutdown L bar -

Fuel system

Number of cylinders 16

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.1

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 1.5

General operating data

Number of cylinders 16

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

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

Firing speed, from R rpm 80

Firing speed, to R rpm 120

R °C 10

Capacities

Number of cylinders 16

Engine coolant capacity, engine side (without cooling equipment) R Liters 175

Charge-air coolant, engine side R Liters 50

Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐
ing inclinations)

Oil change quantity, max. (standard oil system) (Option: max. operating in‐
clinations)

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

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

R Liters 300

R Liters 240

L Liters 210

L Liters 240

Weights / main dimensions

Number of cylinders 16

Engine dry weight (basic engine configuration according to scope of deliv‐
ery specifications)

R kg 7700

TIM-ID: 0000039902 - 001

58 | Technical Data | M015710/04E 2012-09

Acoustics

Number of cylinders 16

Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798+3) R dB(A) 130

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

R dB(A) 126

TIM-ID: 0000039902 - 001

M015710/04E 2012-09 | Technical Data | 59

3.10 16 V 4000 G83L engine data: Standby operation 3D,
optimized exhaust emissions (EPA stage 2)

Explanation

Abbrevia‐
tion

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 set‐

N Not yet defined value

- Not applicable

X Applicable

Meaning

tings).

Reference conditions

Engine model 16V

4000G83L

Application group 3D

Intake air temperature °C 25

Charge-air coolant temperature °C 45

Raw water inlet temperature °C -

Barometric pressure mbar 1000

Site altitude above sea level m 100

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

Number of cylinders 16

Rated engine speed A rpm 1800

Fuel stop power ISO 3046 A kW 2740

General conditions (for maximum power)

Number of cylinders 16

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

Exhaust overpressure A mbar 30

Exhaust overpressure, max. L mbar 85

60 | Technical Data | M015710/04E 2012-09

TIM-ID: 0000039906 - 001

Model related data (basic design)

Number of cylinders 16

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

Uncooled exhaust lines X

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

Combustion method: direct fuel injection X

Cooling method: Treated water X

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

Number of cylinders 16

Cylinder arrangement: V-angle Degrees

(°)

Bore mm 170

Stroke mm 210

Cylinder displacement Liters 4.77

Total displacement Liters 76.3

Compression ratio 16.4

Inlet valves per cylinder 2

Cylinder heads: individual cylinder heads X

Cylinder liners: wet, replaceable X

Exhaust valves per cylinder 2

Standard housing connecting flange (engine main PTO) SAE 00

Flywheel interface (DISC) 21

90

TIM-ID: 0000039906 - 001

Combustion air / Exhaust gas

Number of cylinders 16

Charge-air pressure before cylinder - BL R bar abs 3,7

Coolant system (HT circuit)

Number of cylinders 16

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

Coolant temperature after engine, warning R °C 102

Coolant temperature after engine, shutdown L °C 104

Coolant antifreeze content, max. L % 50

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

Coolant system (LT circuit)

Number of cylinders 16

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

Coolant antifreeze content, max. L % 50

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

A °C 45

M015710/04E 2012-09 | Technical Data | 61

Lube oil system

Number of cylinders 16

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

Lube-oil operating temperature before engine, to R °C 94

Lube-oil temperature before engine, warning R °C 97

Lube-oil temperature before engine, shutdown L °C 99

Lube-oil operating pressure before engine, from R bar 4.7

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

Lube-oil operating pressure before engine, warning R bar -

Lube-oil operating pressure before engine, shutdown L bar -

Fuel system

Number of cylinders 16

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.1

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 1.5

General operating data

Number of cylinders 16

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

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

Firing speed, from R rpm 80

Firing speed, to R rpm 120

R °C 10

Capacities

Number of cylinders 16

Engine coolant capacity, engine side (without cooling equipment) R Liters 175

Charge-air coolant, engine side R Liters 50

Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐
ing inclinations)

Oil change quantity, max. (standard oil system) (Option: max. operating in‐
clinations)

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

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

R Liters 300

R Liters 240

L Liters 210

L Liters 240

Weights / main dimensions

Number of cylinders 16

Engine dry weight (basic engine configuration according to scope of deliv‐
ery specifications)

R kg 7700

TIM-ID: 0000039906 - 001

62 | Technical Data | M015710/04E 2012-09

Acoustics

Number of cylinders 16

Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798+3) R dB(A) 130

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

R dB(A) 126

TIM-ID: 0000039906 - 001

M015710/04E 2012-09 | Technical Data | 63

3.11 Final compression pressure

Final compression pressure

Final compression pressure at 120 rpm 24 bar to 28 bar

64 | Technical Data | M015710/04E 2012-09

TIM-ID: 0000002820 - 001

3.12 Firing order

Firing order

Num‐
ber of
cylin‐
ders

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

Firing order

TIM-ID: 0000002796 - 003

M015710/04E 2012-09 | Technical Data | 65

3.13 Engine – Main dimensions

Also valid for 12 V and 16 V engines.

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

12 V 4000 Gx3 approx. 2520 mm approx. 1660 mm approx. 2160 mm

16 V 4000 Gx3 approx. 2990 mm approx. 1660 mm approx. 2160 mm

TIM-ID: 0000002133 - 002

66 | Technical Data | M015710/04E 2012-09

4 Operation

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

Preconditions

☑ Engine is stopped and starting disabled.

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

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

Item Action

Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001070/..).

Valve gear Lubricate valve gear every ≥ 6 months (→ Page 140).

Lube oil system Check engine oil level (→ Page 169).

Fuel prefilter Fill with fuel (→ Page 159).

Fuel prefilter, pressure
gauge

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

Align adjustable pointer with position of pressure indicator (→ Page 155).

(→ Page 177).

TIM-ID: 0000002195 - 002

Change charge-air coolant (→ Page 185).

Coolant circuit Check engine coolant level (→ Page 176);

Check charge-air coolant level (→ Page 184).

Coolant circuit Heat engine coolant with coolant preheating unit.

Engine governor Check plug-in connections (→ Page 197).

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

Engine/generator control
system

HP fuel pump Only for engines without oil priming pump

Switch ON;

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

Fill HP fuel pump with new engine oil (→ Page 145).

M015710/04E 2012-09 | Operation | 67

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

Preconditions

☑ Engine is stopped and starting disabled.

Putting the engine into operation

Item Task

Lube oil system Check oil level (→ Page 169);

Cooling system Check engine coolant level (→ Page 176);

Check charge-air coolant level (→ Page 184).

Cooling system Preheat coolant with preheating unit.

Fuel prefilter Drain (→ Page 156).

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

Engine/generator control
system

Switch ON;

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

68 | Operation | M015710/04E 2012-09

TIM-ID: 0000002677 - 001

4.3 Start engine in manual mode (testing mode)

Preconditions

☑ Generator (if provided) not connected to network.

☑ External start interlock is not activated.

DANGER

WARNING

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.

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

• Wear ear protectors.

Preparation

Item Task

Operating mode selector
switch (if provided)

Preheating pump (if provid‐
ed)

Change to manual mode.

Switch ON.

Starting the engine

Item Task

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

If coolant temperature is

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

• > 5 °C (without preheating equipment):

TIM-ID: 0000002226 - 002

Press start button.

• Automatic starting sequence is performed;

• Engine speed display instrument indicates increasing crankshaft speed;

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

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

Item Task

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

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

Close the generator circuit breaker.

ant temperature approx. 75 °C).

M015710/04E 2012-09 | Operation | 69

4.4 Safety system – Override

CAUTION

CAUTION

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

• Initiate emergency start only in emergency situations.

Inadmissible operational condition.
Major material damage!

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

Preparation

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

Bypassing the safety system (Override)

Item Action

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

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

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

Activate pushbutton for Override input of the ECU.

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

Actuate start button, for further starting sequence, refer to engine start
(→ Page 69).

ture, pressures).

Constantly monitor plant limit values.

TIM-ID: 0000000984 - 002

70 | Operation | M015710/04E 2012-09

4.5 Starting the engine in emergency situations (override mode)

CAUTION

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

• Initiate emergency start only in emergency situations.

Preparation

Item Task

Operating mode switch Set to emergency mode.

Starting the engine in emergency situations

Item Task

Control cabinet Actuate switch/button for ECU override input.

Control cabinet • Automatic starting procedure is performed; any safety functions and

alarms leading to engine shutdown are disregarded;

• Tachometer indicates increasing crankshaft speed;

• Engine is running at rated speed when the starting sequence is com‐
pleted.

Connecting the generator (if fitted) to mains

TIM-ID: 0000010665 - 001

Item Task

Control cabinet If generator is not connected to mains: Close generator circuit breaker.

Engine Operate engine at rated power.

M015710/04E 2012-09 | Operation | 71

4.6 Operational checks

DANGER

WARNING

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

• Take special care when working on a running engine.

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

• Wear ear protectors.

Operational checks

Item Measure

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

Engine oil Check engine oil level (→ Page 169)

Engine under load

Engine at nominal speed

Fuel prefilter Check reading on differential pressure gauge to ensure that maximum

Exhaust system Check exhaust color (→ Page 79).

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

Air filter Check signal ring position of contamination indicator (→ Page 165).

Check engine/plant and piping for leaks, repair leaky pipes with the engine
stopped (exhaust lines and turbocharger turbine housings may be red-hot.
If the maximum exhaust temperatures are not exceeded, no restrictions in
engine operation are required)

Check for abnormal running noises and vibration.

permissible value is not exceeded (→ Page 155).

(→ Page 161).

Replace air filter (→ Page 162) if the signal ring is completely visible in the
contamination indicator control window.

Engine coolant pump Check relief bore (→ Page 182).

Charge-air coolant pump Check relief bore (→ Page 190).

Compressed-air system (if
installed)

Check operating pressure on pressure gauge;

Always fill compressed-air tank to max. pressure;

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

TIM-ID: 0000002258 - 003

72 | Operation | M015710/04E 2012-09

4.7 Stop engine in manual mode (testing mode)

Preconditions

☑ Generator (if provided) not connected to network.

☑ Engine is running in manual mode.

CAUTION

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

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

Preparing the generator drive (only with generator breaker)

Item Task

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

load for approx. 5 minutes.

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

Item Task

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

serve natural resonance of engine (installation-dependent)!

Stopping the engine

Item Task

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

Press stop button.

• Automatic stopping sequence is performed;

• Engine is stopped.

TIM-ID: 0000002285 - 001

After stopping the engine

Item Task

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

M015710/04E 2012-09 | Operation | 73

4.8 Emergency stop

CAUTION

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

• Initiate emergency stop only in emergency situations.

Emergency stop from LOP

Item Task

EMERGENCY STOP but‐
ton

Press.

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

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

After emergency stop from LOP

Item Task

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

Press button for alarm acknowledgement.

• Audible and visual signalization stops.

74 | Operation | M015710/04E 2012-09

TIM-ID: 0000002305 - 002

4.9 After stopping the engine – Engine remains ready for
operation

After stopping the engine

Item Action

Engine/generator/pump
control

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

TIM-ID: 0000000983 - 002

M015710/04E 2012-09 | Operation | 75

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

Preconditions

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

After stopping the engine

Item Task

Cooling system Drain engine coolant (→ Page 178);

Drain charge-air coolant (→ Page 186) if:

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

• the engine room is not heated;

• the coolant is not maintained at a suitable temperature;

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

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

-40°C.

Engine/generator/pump
controller

Air intake and exhaust sys‐
tem

Switch OFF.

If the engine is to remain out of service for more than 1 week, seal the
engine's air and exhaust sides. If the engine is to remain out of service for
more than 1 month, preserve engine (→ MTU-Preservation and Represer‐
vation Specifications A001070/..).

76 | Operation | M015710/04E 2012-09

TIM-ID: 0000002706 - 002

4.11 Plant cleaning

Preconditions

☑ Engine is stopped and starting disabled.

☑ Operating voltage is not present.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

WARNING

WARNING

CAUTION

NOTICE

Steam jet cleaner

Cleaner (Hakupur 312)

Compressed air
Risk of injury!

• Do not direct compressed-air jet at persons.

• Wear protective goggles / safety mask and ear protectors.

Water jet.
Risk of injury and scalding!

• Do not direct water jet at persons.

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

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

• Observe manufacturer's instructions.

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

Dry with compressed air.
Damage to component!

• Never aim compressed air directly at electronic components.

- 1

30390 1

TIM-ID: 0000010171 - 024

Note: Never aim compressed air directly at electronic components.

Plant cleaning

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

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

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

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

5. Carry out external cleaning as follows:

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

e) Dry engine.

M015710/04E 2012-09 | Operation | 77

5 Maintenance

5.1 Maintenance task reference table [QL1]

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

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

Task Option Maintenance tasks

W0500 Check engine oil level. (→ Page 169)

W0501 Visually inspect engine for leaks and general condition. (→ Page 72)

W0502 X Check intercooler drain(s). (→ Page 161)

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

ter.

W0505 Check relief bores of water pump(s). (→ Page 182)

W0506 Check engine for abnormal running noises, exhaust col‐

or and vibrations.

W0507 X Drain water and contaminants from fuel prefilter. (→ Page 72)

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

filter.

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

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

W1001 Replace fuel filter or fuel filter element. (→ Page 153)

W1005 Replace air filter. (→ Page 162)

W1006 Replace fuel injectors. (→ Page 146)

W1008 Replace engine oil filter when changing engine oil, or

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

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

replace filter sleeve.

W1011 Perform endoscopic examination. (→ Page 134)

W1046 Crankcase breather: Replace filter or filter element. (→ Page 138)

W1207 Check and adjust valve clearance. Attention!First adjust‐

ment after 1,000 operating hours.

W1241 Check condition of belt drive and replace if necessary;

adjust belt tension.

W1463 Check general condition of engine mounting (visual in‐

spection).

W1714 X Check and clean oil indicator filter. (→ Page 172)

Table 1: Maintenance task reference table [QL1]

(→ Page 165)

(→ Page 72)

(→ Page 72)

(→ Page 133)

(→ Page 171)

(→ Page 174)

(→ Page 141)

(→ Page 191)

(→ Page 194)

TIM-ID: 0000022705 - 003

78 | Maintenance | M015710/04E 2012-09

6 Troubleshooting

6.1 Troubleshooting

Engine does not turn when starter is actuated

Component Probable cause Task

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

Cable connections defective Check if cable connections are proper‐

Starter (electric) Engine wiring or starter defective Check cable connections for secure

Starter (compressed
air)

Engine wiring Defective Check (→ Page 195).

Engine/generator
control system

Engine Governor Plug-in connections are loose Check plug connections (→ Page 197).

Engine Running gear blocked (engine cannot

Cabling on starting valve or starter de‐
fective

Secure seating of assemblies or con‐
nectors not provided

be barred manually)

documentation).

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

seating,

Contact Service.

Check cable connections for secure
seating,

Contact Service.

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

Contact Service.

TIM-ID: 0000002537 - 001

Engine turns but does not fire

Component Probable cause Task

Starter (electric) Poor rotation by starter: Battery low or

defective

Starter (compressed
air)

Engine wiring Defective Check (→ Page 195).

Fuel system Not vented Vent fuel system (→ Page 152).

Engine Governor Defective Contact Service.

Poor rotation by starter: Air pressure
too low

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

Check compressed air system.

Engine fires unevenly

Component Probable cause Task

Fuel injection equip‐
ment

Engine wiring Defective Check (→ Page 195).

Fuel system Not vented Vent fuel system (→ Page 152).

Engine Governor Defective Contact Service.

Injector defective Replace (→ Page 146).

M015710/04E 2012-09 | Troubleshooting | 79

Engine does not reach nominal speed

Component Probable cause Task

Fuel supply Fuel prefilter clogged Replace (→ Page 159).

Easy-change fuel filter clogged Replace (→ Page 153).

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

dicator (→ Page 165).

Fuel injection equip‐
ment

Engine wiring Defective Check (→ Page 195).

Engine Overloaded Contact Service.

Injector defective Replace (→ Page 146).

Engine speed not steady

Component Probable cause Task

Fuel injection equip‐
ment

Speed sensor Defective Contact Service.

Fuel system Not vented Vent fuel system (→ Page 152).

Engine Governor Defective Contact Service.

Injector defective Replace (→ Page 146).

Charge-air temperature too high

Component Probable cause Task

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

Intercooler Contaminated Contact Service.

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

ducts.

Charge air pressure too low

Component Probable cause Task

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

dicator (→ Page 165).

Intercooler Contaminated Contact Service.

Exhaust turbocharger Defective Contact Service.

Coolant leaks on intercooler

Component Probable cause Task

Intercooler Leaking, major coolant discharge Contact Service.

Exhaust gas black

Component Probable cause Task

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

Fuel injection equip‐
ment

Engine Overloaded Contact Service.

80 | Troubleshooting | M015710/04E 2012-09

Injector defective Replace (→ Page 146).

TIM-ID: 0000002537 - 001

dicator (→ Page 165).

Exhaust gas blue

Component Probable cause Task

Engine oil Too much engine oil in the engine Drain engine oil (→ Page 167).

Oil separator of crankcase breather

Replace (→ Page 138).

contaminated

Exhaust turbocharg‐

Defective Contact Service.
er, cylinder head, pis‐
ton rings, cylinder lin‐
er

Exhaust gas white

Component Probable cause Task

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

ature.

Fuel system Water in fuel Check fuel system on fuel prefilter.

Drain fuel prefilter (→ Page 156).

Intercooler Leaking Contact Service.

TIM-ID: 0000002537 - 001

M015710/04E 2012-09 | Troubleshooting | 81

6.2 Engine governor ADEC (ECU 7) for Series 4000 genset
engines – Fault messages

003 – HI T-Fuel

ZKP-Number: 2.0122.931

Limit value 1

Cause Corrective action

Fuel temperature too high. u Contact Service.

004 – SS T-Fuel

ZKP-Number: 2.0122.932

Limit value 2

Cause Corrective action

Fuel temperature too high;
Engine stop.

u Contact Service.

005 – HI T-Charge Air

ZKP-Number: 2.0121.931

Limit value 1

Cause Corrective action

Charge-air temperature too high. 1. Reduce power.

2. Check intercooler.

006 – SS T-Charge Air

ZKP-Number: 2.0121.932

Limit value 2

Cause Corrective action

Charge-air temperature too high
Engine stop.

1. Reduce power.

2. Check intercooler.

009 – HI T-Coolant Intercooler

Limit value 1

Cause Corrective action

Coolant temperature in
intercooler too high.

82 | Troubleshooting | M015710/04E 2012-09

ZKP-Number: 2.0124.931

u Reduce power.

TIM-ID: 0000008506 - 002

010 – SS T-Coolant Intercooler

ZKP-Number: 2.0124.932

Limit value 2

Cause Corrective action

Coolant temperature in
intercooler too high;Engine stop.

u Reduce power.

015 – LO P-Lube Oil

ZKP-Number: 2.0100.921

Limit value 1

Cause Corrective action

Lube oil pressure too low. u Check oil level, top up as necessary (→ Page 169).

016 – SS P-Lube Oil

ZKP-Number: 2.0100.922

Limit value 2

Cause Corrective action

Lube oil pressure too
low;Automatic engine shutdown.

u Engine must not be started (risk of engine failure), contact

Service.

019 – HI T-Exhaust A

ZKP-Number: 2.0126.931

TIM-ID: 0000008506 - 002

Limit value 1

Cause Corrective action

Exhaust gas temperature (A­side) too high.

1. Check wiring (→ Page 195).

2. Contact Service.

020 – SS T-Exhaust A

ZKP-Number: 2.0126.932

Limit value 2

Cause Corrective action

Exhaust gas temperature (A­side) too high;Engine stop.

1. Check wiring (→ Page 195).

2. Contact Service.

021 – HI T-Exhaust B

ZKP-Number: 2.0127.931

Limit value 1

Cause Corrective action

Exhaust gas temperature (B­side) too high.

1. Check wiring (→ Page 195).

2. Contact Service.

M015710/04E 2012-09 | Troubleshooting | 83

022 – SS T-Exhaust B

ZKP-Number: 2.0127.932

Limit value 2

Cause Corrective action

Exhaust gas temperature (B­side) too high;Engine stop.

1. Check wiring (→ Page 195).

2. Contact Service.

023 – LO Coolant Level

ZKP-Number: 2.0152.921

Limit value 1

Cause Corrective action

Coolant level too low. u Check coolant level in expansion tank(→ Page 176) .

025 – HI P-Diff. Lube Oil

ZKP-Number: 2.0154.931

Limit value 1

Cause Corrective action

Oil filter differential pressure too
high.

u Replace oil filter (→ Page 171).

026 – SS P-Diff. Lube Oil

ZKP-Number: 2.0154.932

Limit value 2

Cause Corrective action

Oil filter differential pressure too
high.

u Replace oil filter (→ Page 171).

027 – HI Level Leakage Fuel

ZKP-Number: 2.0151.931

Limit value 1

Cause Corrective action

Leak-fuel level too high. 1. Check fuel system.

2. Contact Service.

029 – HI ETC 2 Idle Speed too High

ZKP-Number: 1.8004.206

Cause Corrective action

Idle speed of ETC 2 too high. u Contact Service.

TIM-ID: 0000008506 - 002

84 | Troubleshooting | M015710/04E 2012-09

030 – SS Engine Overspeed

ZKP-Number: 2.2510.932

Limit value 2

Cause Corrective action

Reduced fuel injection. 1. Acknowledge alarm.

2. Attempt to restart engine.

031 – HI ETC 1 Overspeed

ZKP-Number: 2.3011.931

Limit value 1

Cause Corrective action

Speed of primary turbocharger
too high.

u Contact Service.

032 – SS ETC 1 Overspeed

ZKP-Number: 2.3012.932

Limit value 2

Cause Corrective action

Speed of primary turbocharger
too high.

1. Automatic power reduction by engine control system.

2. Check air filters (→ Page 163).

33 – HI P-Diff-Fuel

ZKP-Number: 20.114.931

Limit value 1

Cause Corrective action

Fuel filter differential pressure
too high.

u Replace fuel filter (→ Page 153).

34 – SS P-Diff-Fuel

TIM-ID: 0000008506 - 002

ZKP-Number: 20.114.932

Limit value 2

Cause Corrective action

Fuel filter differential pressure
too high.

u Replace fuel filter (→ Page 153).

036 – HI ETC 2 Overspeed

ZKP-Number: 2.3013.931

Limit value 1

Cause Corrective action

Speed of first secondary
turbocharger too high.

1. Reduce power.

2. Contact Service.

M015710/04E 2012-09 | Troubleshooting | 85

037 – SS ETC 2 Overspeed

ZKP-Number: 2.3013.912

Limit value 2

Cause Corrective action

Speed of first secondary
turbocharger too high.

1. Reduce power.

2. Contact Service.

038 – AL ETC Speed Deviation

ZKP-Number: 1.8004.205

Cause Corrective action

Synchro fault between primary
turbocharger and one of the
secondary turbochargers.

1. Reduce power.

2. Contact Service.

039 – AL ETC 2 Cutin Failure

ZKP-Number: 1.8004.204

Cause Corrective action

Cut-in of turbocharger ETC 2
failed.

1. Reduce power.

2. Contact Service.

044 – LO Coolant Level Intercooler

ZKP-Number: 2.0153.921

Limit value 1

Cause Corrective action

Intercooler coolant level too low. u Check coolant level (→ Page 184).

051 – HI T-Lube Oil

ZKP-Number: 2.0125.931

Limit value 1

Cause Corrective action

Lube oil temperature too high. u Reduce power.

052 – SS T-Lube Oil

ZKP-Number: 2.0125.932

Limit value 2

Cause Corrective action

Lube oil temperature too high.
Engine stop.

1. Reduce power.

2. Check engine oil level (→ Page 169).

TIM-ID: 0000008506 - 002

86 | Troubleshooting | M015710/04E 2012-09

057 – LO P-Coolant

ZKP-Number: 2.0101.921

Limit value 1

Cause Corrective action

Coolant pressure too low. u Check coolant circuit.

058 – SS P-Coolant

ZKP-Number: 2.0101.922

Limit value 2

Cause Corrective action

Coolant pressure too low;
Engine stop or reduced fuel
injection.

1. Automatic engine shutdown.

2. Check coolant level (→ Page 176).

59 – SS T-Coolant L3

ZKP-Number: 20.120.933

Limit value 3

Cause Corrective action

Coolant temperature too high/
low

1. Allow engine to cool down.

2. Check engine coolant cooler, clean if dirty.

3. Contact Service.

60 – SS T-Coolant L4

ZKP-Number: 20.120.934

Limit value 4

Cause Corrective action

Coolant temperature too high/
low

1. Allow engine to cool down.

2. Check engine coolant cooler, clean if dirty.

3. Contact Service.

TIM-ID: 0000008506 - 002

063 – HI P-Crankcase

ZKP-Number: 2.0106.931

Limit value 1

Cause Corrective action

Crankcase pressure too high. 1. Reduce power.

2. Replace oil separator element (→ Page 138).

M015710/04E 2012-09 | Troubleshooting | 87

064 – SS P-Crankcase

ZKP-Number: 2.0106.932

Limit value 2

Cause Corrective action

Crankcase pressure too high;
Automatic engine shutdown.

u Engine must not be started (risk of engine failure), contact

Service.

065 – LO P-Fuel

ZKP-Number: 2.0102.921

Limit value 1

Cause Corrective action

Fuel supply pressure too low. 1. Check fuel lines for leakage.

2. Clean fuel prefilter (→ Page 154).

3. Flush fuel prefilter (→ Page 157).

4. Replace filter element of fuel prefilter (→ Page 159).

5. Replace fuel filter (→ Page 153).

066 – SS P-Fuel

ZKP-Number: 2.0102.922

Limit value 2

Cause Corrective action

Fuel supply pressure too
low;Engine stop.

1. Check fuel lines for leakage.

2. Clean fuel prefilter (→ Page 154).

3. Flush fuel prefilter (→ Page 157).

4. Replace filter element of fuel prefilter (→ Page 159).

5. Replace fuel filter (→ Page 153).

067 – HI T-Coolant

Limit value 1

Cause Corrective action

Coolant temperature too high. u Reduce power.

068 – SS T-Coolant

Limit value 2

Cause Corrective action

Coolant temperature too high;
Engine stop.

88 | Troubleshooting | M015710/04E 2012-09

ZKP-Number: 2.0120.931

ZKP-Number: 2.0120.932

TIM-ID: 0000008506 - 002

1. Allow engine to cool down.

2. Check engine coolant cooler, clean if dirty.

3. Restart engine (→ Page 69).

4. Contact Service.

081 – AL Rail Leakage

ZKP-Number: 1.8004.046

Cause Corrective action

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

u Contact Service.

082 – HI P-Fuel (Common Rail)

ZKP-Number: 2.0104.931

Cause Corrective action

Rail pressure > set value;
Speed-sensitive fuel limiter
reduction, start of injection
moved towards late; Suction
restrictor of HP fuel block
jamming or HP fuel control block
wiring faulty.

u Contact Service.

083 – LO P-Fuel (Common Rail)

ZKP-Number: 2.0104.921

Cause Corrective action

Rail pressure < set value;
Speed-sensitive fuel limiter
reduction; Suction restrictor of
HP fuel control block faulty or
leakage in HP fuel system.

u Contact Service.

TIM-ID: 0000008506 - 002

085 – HI T-Umblasen

ZKP-Number: 2.0128.931

Limit value 1

Cause Corrective action

Recirculation temperature too
high.

u Reduce power.

086 – SS T-Umblasen

ZKP-Number: 2.0128.932

Limit value 2

Cause Corrective action

Recirculation temperature too
high.

u Reduce power.

M015710/04E 2012-09 | Troubleshooting | 89

089 – SS Engine Speed too Low

ZKP-Number: 2.2500.030

Cause Corrective action

Engine speed too low. u Check for additional messages.

090 – SS Idle Speed Not Reached

ZKP-Number: 2.1090.925

Cause Corrective action

Idling speed was not attained. u Contact Service.

091 – SS Release Speed Not Reached

ZKP-Number: 2.1090.924

Cause Corrective action

Runup speed was not attained. u Contact Service.

092 – SS Starter Speed Not Reached

ZKP-Number: 2.1090.923

Cause Corrective action

Starter speed was not attained;
Termination of starting
sequence; Starter rotates too
slowly or does not rotate at all.

u Contact Service.

093 – SS T-Preheat

ZKP-Number: 2.1090.922

Limit value 2

Cause Corrective action

Preheating temperature too low;
coolant temperature too low for
engine start; engine start
interlock active.

u Check preheater.

094 – LO T-Preheat

ZKP-Number: 2.1090.921

Limit value 1

Cause Corrective action

Preheating temperature too low;
coolant temperature too low for
engine start.

90 | Troubleshooting | M015710/04E 2012-09

TIM-ID: 0000008506 - 002

u Check preheater.

095 – AL Prelubrication Fault

ZKP-Number: 2.1090.920

Cause Corrective action

Oil priming fault. u Check oil priming system.

102 – AL Fuel Cons. Counter Defect

ZKP-Number: 1.8004.624

Cause Corrective action

Consumption meter faulty. u Contact Service.

104 – AL Eng Hours Counter Defect

ZKP-Number: 1.8004.623

Cause Corrective action

Hour meter faulty. u Contact Service.

118 – LO ECU Power Supply Voltage

ZKP-Number: 2.0140.921

Limit value 1

Cause Corrective action

Supply voltage too low. 1. Check ECU supply voltage.

2. Contact Service.

119 – LOLO ECU Power Supply Voltage

ZKP-Number: 2.0140.922

Limit value 2

Cause Corrective action

Supply voltage too low. 1. Check ECU supply voltage.

2. Contact Service.

120 – HI ECU Power Supply Voltage

ZKP-Number: 2.0140.931

Limit value 1

Cause Corrective action

TIM-ID: 0000008506 - 002

Supply voltage too high. 1. Check ECU supply voltage.

2. Contact Service.

M015710/04E 2012-09 | Troubleshooting | 91

121 – HIHI ECU Power Supply Voltage

ZKP-Number: 2.0140.932

Limit value 2

Cause Corrective action

Supply voltage too high. 1. Check ECU supply voltage.

2. Contact Service.

122 – HI T-ECU

ZKP-Number: 2.0132.921

Limit value 1

Cause Corrective action

Electronic unit temperature too
high.

1. Reduce power.

2. Improve engine room ventilation.

141 – AL Power too high

ZKP-Number: 11.088.007

Cause Corrective action

Alarm is triggered if the mean
value of the power has exceeded
the maximum value stipulated by
PR1.1088.001 within the last 24
hours.

u Reduce power.

142 – AL MCR exceeded 1 hour

ZKP-Number: 1.1088.006

Cause Corrective action

the alarm is triggered if the MCR
has been exceeded for more
than 1 hour within the last 12
hours.

u Reduce power.

176 – AL LifeData not available

Cause Corrective action

No (appropriate) LifeData
backup system available, ECU
reset after expiration of time-out
period.

92 | Troubleshooting | M015710/04E 2012-09

ZKP-Number: 2.4000.004

u Contact Service.

TIM-ID: 0000008506 - 002

177 – AL LifeData restore incomplete

ZKP-Number: 2.4000.006

Cause Corrective action

this error message is generated
if a CRC is faulty during a data
upload to ADEC (indicated for
each individual module).

u Contact Service.

180 – AL CAN1 Node Lost

ZKP-Number: 2.0500.680

Cause Corrective action

Connection to a node on CAN
bus 1 failed.

u Contact Service.

181 – AL CAN2 Node Lost

ZKP-Number: 2.0500.681

Cause Corrective action

Connection to a node on CAN
bus 2 failed.

u Contact Service.

182 – AL CAN Wrong Parameters

ZKP-Number: 2.0500.682

TIM-ID: 0000008506 - 002

Cause Corrective action

Incorrect parameter values
entered in data record.

u Contact Service.

183 – AL CAN No PU-Data

ZKP-Number: 2.0500.683

Cause Corrective action

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.

u Contact Service.

184 – AL CAN PU-Data Flash Error

ZKP-Number: 2.0500.684

Cause Corrective action

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

u Contact Service.

M015710/04E 2012-09 | Troubleshooting | 93

186 – AL CAN1 Bus Off

ZKP-Number: 2.0500.686

Cause Corrective action

CAN controller 1 is in "Bus-Off"
status.

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

2. Check shielding, improve shielding as necessary.

3. Contact Service.

187 – AL CAN1 Error Passive

ZKP-Number: 2.0500.687

Cause Corrective action

CAN controller 1 has indicated a
warning.

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

2. Check shielding, improve shielding as necessary.

3. Contact Service.

188 – AL CAN2 Bus Off

ZKP-Number: 2.0500.688

Cause Corrective action

CAN controller 2 is in "Bus-Off"
status. => automatic changeover
to CAN 1.Short circuit, massive
interference or Baud rate
incompatibility.

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

2. Check shielding, improve shielding as necessary.

3. Contact Service.

189 – AL CAN2 Error Passive

ZKP-Number: 2.0500.689

Cause Corrective action

CAN controller 2 has indicated a
warning.

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

2. Check shielding, improve shielding as necessary.

3. Contact Service.

190 – AL EMU Parameter Not Supported

ZKP-Number: 2.0500.690

Cause Corrective action

EMU parameters are not
supported.

u Contact Service.

TIM-ID: 0000008506 - 002

94 | Troubleshooting | M015710/04E 2012-09

201 – SD T-Coolant

ZKP-Number: 1.8004.570

Cause Corrective action

Coolant temperature sensor
faulty; short circuit or wire break.

u Check sensor and cabling (B6), replace as necessary.

Error cleared after restarting the engine.

202 – SD T-Fuel

ZKP-Number: 1.8004.572

Cause Corrective action

Fuel temperature sensor faulty;
short circuit or wire break.

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

Error cleared after restarting the engine.

203 – SD T-Charge Air

ZKP-Number: 1.8004.571

Cause Corrective action

Charge-air temperature sensor
faulty; short circuit or wire break.

u Check sensor and cabling (B9), replace as necessary.

Error cleared after restarting the engine.

204 – SD Level Lube Oil

ZKP-Number: 1.8004.602

TIM-ID: 0000008506 - 002

Cause Corrective action

Lube oil level sensor defective;
short circuit or wire break.

u Check sensor and cabling, replace as necessary.

205 – SD T-Coolant Intercooler

ZKP-Number: 1.8004.574

Cause Corrective action

Intercooler coolant temperature
sensor faulty; short circuit or wire
break.

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

Error cleared after restarting the engine.

206 – SD T-Exhaust A

ZKP-Number: 1.8004.576

Cause Corrective action

Exhaust temperature sensor on
A-side faulty; short circuit or wire
break.

u Check sensor and cabling (B4.21), replace if necessary.

Error cleared after restarting the engine.

M015710/04E 2012-09 | Troubleshooting | 95

207 – SD T-Exhaust B

ZKP-Number: 18.004.577

Cause Corrective action

Exhaust temperature sensor on
B-side faulty. short circuit or wire
break.

u Check sensor and cabling (B4.22), replace as necessary.

208 – SD P-Charge Air

ZKP-Number: 1.8004.566

Cause Corrective action

Charge-air pressure sensor
faulty; short circuit or wire break.

u Check sensor and cabling (B10), replace as necessary.

Error cleared after restarting the engine.

211 – SD P-Lube Oil

ZKP-Number: 1.8004.563

Cause Corrective action

Lube oil pressure sensor faulty;
short circuit or wire break.

u Check sensor and cabling (B5), replace as necessary.

Error cleared after restarting the engine.

212 – SD P-Coolant

ZKP-Number: 1.8004.564

Cause Corrective action

Coolant pressure sensor faulty;
short circuit or wire break.

u Check sensor and cabling (B16), replace as necessary.

Error cleared after restarting the engine.

213 – SD P-Coolant Intercooler

ZKP-Number: 1.8004.569

Cause Corrective action

Intercooler coolant pressure
sensor faulty; short circuit or wire
break.

u Check sensor and cabling (B43), replace as necessary.

Error cleared after restarting the engine.

214 – SD P-Crankcase

ZKP-Number: 1.8004.568

Cause Corrective action

Crankcase pressure sensor
faulty; short circuit or wire break.

u Check sensor and cabling (B50), replace as necessary.

Error cleared after restarting the engine.

TIM-ID: 0000008506 - 002

96 | Troubleshooting | M015710/04E 2012-09

215 – SD P-HD

ZKP-Number: 1.8004.567

Cause Corrective action

Rail pressure sensor faulty;
High-pressure regulator in
emergency mode ==> Short
circuit or wire break.

u Check sensor and cabling (B48), replace as necessary.

Error cleared after restarting the engine.

216 – SD T-Lube Oil

ZKP-Number: 1.8004.575

Cause Corrective action

Lube oil temperature sensor
faulty; short circuit or wire break.

u Check sensor and cabling (B7), replace as necessary.

Error cleared after restarting the engine.

219 – SD T-Intake Air

ZKP-Number: 1.8004.573

Cause Corrective action

Intake air temperature sensor
faulty; short circuit or wire break.

u Check sensor and cabling (B3), replace as necessary.

Error cleared after restarting the engine.

220 – SD Level Coolant Water

TIM-ID: 0000008506 - 002

ZKP-Number: 1.8004.584

Cause Corrective action

Coolant level sensor faulty; short
circuit or wire break.

u Check sensor and cabling (F33), replace as necessary.

Error cleared after restarting the engine.

221 – SD P-Diff Lube Oil

ZKP-Number: 1.8004.585

Cause Corrective action

Lube oil pressure differential
sensor faulty; short circuit or wire
break.

u Check sensor and cabling (F25), replace as necessary.

Error cleared after restarting the engine.

222 – SD Level Leakage Fuel

ZKP-Number: 1.8004.582

Cause Corrective action

Leak-off fuel level sensor faulty;
short circuit or wire break.

u Check sensor and cabling (F46), replace as necessary.

Error cleared after restarting the engine.

M015710/04E 2012-09 | Troubleshooting | 97

223 – SD Level Coolant Intercooler

ZKP-Number: 1.8004.583

Cause Corrective action

Sensor for intercooler coolant
level faulty; short circuit or wire
break.

u Check sensor and cabling (F57), replace as necessary.

Error cleared after restarting the engine.

227 – SD P-Lube Oil before Filter

ZKP-Number: 1.8004.620

Cause Corrective action

Sensor for lube oil pressure
before filter faulty; short circuit or
wire break.

u Check sensor and cabling (B5.3), replace as necessary.

Error cleared after restarting the engine.

228 – SD P-Fuel before Filter

ZKP-Number: 18.004.595

Cause Corrective action

Fuel pressure sensor faulty.
short circuit or wire break.

u Check sensor and cabling (B5.3), replace as necessary.

229 – AL Stop Camshaft Sensor Defect

ZKP-Number: 1.8004.562

Cause Corrective action

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

u Check sensor and cabling to connector B1, replace as

necessary.

Error cleared after restarting the engine.

230 – SD Crankshaft Speed

ZKP-Number: 1.8004.498

Cause Corrective action

Crankshaft sensor faulty; short
circuit or wire break.

u Check sensor and cabling (B13), replace as necessary.

Error cleared after restarting the engine.

231 – SD Crankshaft Speed

ZKP-Number: 1.8004.499

Cause Corrective action

Camshaft sensor faulty; short
circuit or wire break.

u Check sensor and cabling (B13), replace as necessary.

Error cleared after restarting the engine.

TIM-ID: 0000008506 - 002

98 | Troubleshooting | M015710/04E 2012-09

232 – SD Charger 1 Speed

ZKP-Number: 1.3011.128

Cause Corrective action

Speed sensor of primary
turbocharger faulty; short circuit
or wire break.

u Check sensor and cabling (B44.1), replace as necessary.

Error cleared after restarting the engine.

233 – SD Charger 2 Speed

ZKP-Number: 1.3011.129

Cause Corrective action

Speed sensor of secondary
turbocharger faulty; short circuit
or wire break.

u Check sensor and cabling (B44.2), replace as necessary.

Error cleared after restarting the engine.

239 – SD P-Diff Fuel

ZKP-Number: 18.004.598

Cause Corrective action

Fuel differential pressure sensor
faulty.
This alarm occurs only in
combination with the alarm SD
P-Fuel before Filter or SD P-Fuel
after Filter.

u Check for additional message.

TIM-ID: 0000008506 - 002

240 – SD P-Fuel

ZKP-Number: 1.8004.565

Cause Corrective action

Fuel pressure sensor faulty;
short circuit or wire break.

u Check sensor and cabling (B34), replace as necessary.

Error cleared after restarting the engine.

241 – SD T-Umblasen

ZKP-Number: 1.8004.581

Cause Corrective action

Recirculation sensor faulty; short
circuit or wire break.

u Check sensor and cabling (B49), replace as necessary.

Error cleared after restarting the engine.

242 – SD T-Coolant (R)

ZKP-Number: 1.8004.622

Cause Corrective action

Redundant coolant pressure
sensor faulty; short circuit or wire
break.

u Check sensor and cabling, replace as necessary.

Error cleared after restarting the engine.

M015710/04E 2012-09 | Troubleshooting | 99

244 – SD P-Lube Oil (R)

ZKP-Number: 1.8004.621

Cause Corrective action

Redundant lube oil pressure
sensor faulty; short circuit or wire
break.

u Check sensor and cabling, replace as necessary.

Error cleared after restarting the engine.

245 – SD ECU Power Supply Voltage

ZKP-Number: 2.8006.589

Cause Corrective action

Internal ECU fault; Electronics
faulty.

u Replace Engine Control Unit.

266 – SD Speed Demand

ZKP-Number: 2.8006.586

Cause Corrective action

Analog speed setting faulty;
short circuit or wire break.

1. Check cabling.

2. Check speed demand.

268 – SD Spinning Value

ZKP-Number: 28.006.591

Cause Corrective action

Analog wheel slip signal faulty;
short circuit or wire break.

u Check sensor and cabling, replace as necessary.

269 – SD Loadp.Analog filt.

ZKP-Number: 2.8006.588

Cause Corrective action

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

u Check cabling, replace as necessary.

Error cleared after restarting the engine.

270 – SD Frequency Input

ZKP-Number: 2.8006.590

Cause Corrective action

Frequency input faulty; short
circuit or wire break.

1. Check cabling.

2. Check speed demand transmitter.

3. Contact Service.

TIM-ID: 0000008506 - 002

100 | Troubleshooting | M015710/04E 2012-09

301 – AL Timing Cylinder A1

ZKP-Number: 1.8004.500

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

302 – AL Timing Cylinder A2

ZKP-Number: 1.8004.501

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

303 – AL Timing Cylinder A3

ZKP-Number: 1.8004.502

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

TIM-ID: 0000008506 - 002

304 – AL Timing Cylinder A4

ZKP-Number: 1.8004.503

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

305 – AL Timing Cylinder A5

ZKP-Number: 1.8004.504

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

M015710/04E 2012-09 | Troubleshooting | 101

306 – AL Timing Cylinder A6

ZKP-Number: 1.8004.505

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

307 – AL Timing Cylinder A7

ZKP-Number: 1.8004.506

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

308 – AL Timing Cylinder A8

ZKP-Number: 1.8004.507

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

309 – AL Timing Cylinder A9

ZKP-Number: 1.8004.508

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

310 – AL Timing Cylinder A10

ZKP-Number: 1.8004.509

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

TIM-ID: 0000008506 - 002

102 | Troubleshooting | M015710/04E 2012-09

311 – AL Timing Cylinder B1

ZKP-Number: 1.8004.510

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

312 – AL Timing Cylinder B2

ZKP-Number: 1.8004.511

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

313 – AL Timing Cylinder B3

ZKP-Number: 1.8004.512

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

TIM-ID: 0000008506 - 002

314 – AL Timing Cylinder B4

ZKP-Number: 1.8004.513

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

315 – AL Timing Cylinder B5

ZKP-Number: 1.8004.514

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

M015710/04E 2012-09 | Troubleshooting | 103

316 – AL Timing Cylinder B6

ZKP-Number: 1.8004.515

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

317 – AL Timing Cylinder B7

ZKP-Number: 1.8004.516

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

318 – AL Timing Cylinder B8

ZKP-Number: 1.8004.517

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

319 – AL Timing Cylinder B9

ZKP-Number: 1.8004.518

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

320 – AL Timing Cylinder B10

ZKP-Number: 1.8004.519

Cause Corrective action

Time-of-flight measuring fault of
injector: Time-of flight measured
value extremely low or extremely
high.

u Replace injector concerned if the fault message appears

frequently (→ Page 146).

TIM-ID: 0000008506 - 002

104 | Troubleshooting | M015710/04E 2012-09

321 – AL Wiring Cylinder A1

ZKP-Number: 1.8004.520

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

322 – AL Wiring Cylinder A2

ZKP-Number: 1.8004.521

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

323 – AL Wiring Cylinder A3

ZKP-Number: 1.8004.522

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

324 – AL Wiring Cylinder A4

ZKP-Number: 1.8004.523

Cause Corrective action

TIM-ID: 0000008506 - 002

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

325 – AL Wiring Cylinder A5

ZKP-Number: 1.8004.524

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

326 – AL Wiring Cylinder A6

ZKP-Number: 1.8004.525

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

327 – AL Wiring Cylinder A7

ZKP-Number: 1.8004.526

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

M015710/04E 2012-09 | Troubleshooting | 105

328 – AL Wiring Cylinder A8

ZKP-Number: 1.8004.527

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

329 – AL Wiring Cylinder A9

ZKP-Number: 1.8004.528

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

330 – AL Wiring Cylinder A10

ZKP-Number: 1.8004.529

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

331 – AL Wiring Cylinder B1

ZKP-Number: 1.8004.530

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

332 – AL Wiring Cylinder B2

ZKP-Number: 1.8004.531

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

333 – AL Wiring Cylinder B3

ZKP-Number: 1.8004.532

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

334 – AL Wiring Cylinder B4

ZKP-Number: 1.8004.533

Cause Corrective action

TIM-ID: 0000008506 - 002

Short circuit in injector cabling to
cylinder. Result: Misfiring.

106 | Troubleshooting | M015710/04E 2012-09

1. Check solenoid valve.

2. Contact Service.

335 – AL Wiring Cylinder B5

ZKP-Number: 1.8004.534

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

336 – AL Wiring Cylinder B6

ZKP-Number: 1.8004.535

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

337 – AL Wiring Cylinder B7

ZKP-Number: 1.8004.536

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

338 – AL Wiring Cylinder B8

ZKP-Number: 1.8004.537

Cause Corrective action

TIM-ID: 0000008506 - 002

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

339 – AL Wiring Cylinder B9

ZKP-Number: 1.8004.538

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

340 – AL Wiring Cylinder B10

ZKP-Number: 1.8004.539

Cause Corrective action

Short circuit in injector cabling to
cylinder. Result: Misfiring.

1. Check solenoid valve.

2. Contact Service.

341 – AL Open Load Cylinder A1

ZKP-Number: 1.8004.540

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

M015710/04E 2012-09 | Troubleshooting | 107

342 – AL Open Load Cylinder A2

ZKP-Number: 1.8004.541

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

343 – AL Open Load Cylinder A3

ZKP-Number: 1.8004.542

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

344 – AL Open Load Cylinder A4

ZKP-Number: 1.8004.543

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

345 – AL Open Load Cylinder A5

ZKP-Number: 1.8004.544

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

346 – AL Open Load Cylinder A6

ZKP-Number: 1.8004.545

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

347 – AL Open Load Cylinder A7

ZKP-Number: 1.8004.546

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

348 – AL Open Load Cylinder A8

ZKP-Number: 1.8004.547

Cause Corrective action

TIM-ID: 0000008506 - 002

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

108 | Troubleshooting | M015710/04E 2012-09

1. Check solenoid valve.

2. Contact Service.

349 – AL Open Load Cylinder A9

ZKP-Number: 1.8004.548

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

350 – AL Open Load Cylinder A10

ZKP-Number: 1.8004.549

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

351 – AL Open Load Cylinder B1

ZKP-Number: 1.8004.550

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

352 – AL Open Load Cylinder B2

ZKP-Number: 1.8004.551

Cause Corrective action

TIM-ID: 0000008506 - 002

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

1. Check solenoid valve.

2. Contact Service.

353 – AL Open Load Cylinder B3

ZKP-Number: 1.8004.552

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

354 – AL Open Load Cylinder B4

ZKP-Number: 1.8004.553

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

355 – AL Open Load Cylinder B5

ZKP-Number: 1.8004.554

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

M015710/04E 2012-09 | Troubleshooting | 109

356 – AL Open Load Cylinder B6

ZKP-Number: 1.8004.555

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

357 – AL Open Load Cylinder B7

ZKP-Number: 1.8004.556

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

358 – AL Open Load Cylinder B8

ZKP-Number: 1.8004.557

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

359 – AL Open Load Cylinder B9

ZKP-Number: 1.8004.558

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

360 – AL Open Load Cylinder B10

ZKP-Number: 1.8004.559

Cause Corrective action

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

1. Check solenoid valve.

2. Contact Service.

361 – AL Power Stage Low

ZKP-Number: 1.8004.496

Cause Corrective action

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 Engine Control Unit.

TIM-ID: 0000008506 - 002

110 | Troubleshooting | M015710/04E 2012-09

362 – AL Power Stage high

ZKP-Number: 1.8004.497

Cause Corrective action

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 Engine Control Unit.

363 – AL Stop Power Stage

ZKP-Number: 1.8004.560

Cause Corrective action

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

1. Check cabling.

2. Attempt to restart engine.

365 – AL Stop MV-Wiring Ground

ZKP-Number: 1.8004.561

Cause Corrective action

Injector cabling fault. If bit
"1.1020.021" (power stage
failure: Stop engine) is set,
engine is additionally stopped in
this case. 1. Short circuit of
injector + connection of one or
more injectors to ground 2. Short
circuit of injector – connection of
one or more injectors to ground.

1. Check cabling.

2. Attempt to restart engine.

TIM-ID: 0000008506 - 002

371 – AL Wiring TO 1

ZKP-Number: 1.8004.634

Cause Corrective action

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

1. Check charger valve/cabling, repair as necessary.

2. Replace Engine Control Unit.

372 – AL Wiring TO 2

ZKP-Number: 1.8004.635

Cause Corrective action

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

1. Check recirculation valve/cabling, repair as necessary.

2. Replace ECU.

M015710/04E 2012-09 | Troubleshooting | 111

373 – AL Wiring TO 3

ZKP-Number: 1.8004.636

Cause Corrective action

Short circuit or wire break on
transistor output 3 (TO 3).

u -

374 – AL Wiring TO 4

ZKP-Number: 1.8004.637

Cause Corrective action

Short circuit or wire break on
transistor output 4 (TO 4).

u -

381 – AL Wiring TOP 1

ZKP-Number: 2.8006.638

Cause Corrective action

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

u Check cabling to plant.

382 – AL Wiring TOP 2

ZKP-Number: 2.8006.639

Cause Corrective action

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

u Check cabling to plant.

383 – AL Wiring TOP 3

ZKP-Number: 2.8006.640

Cause Corrective action

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

u Check cabling to plant.

384 – AL Wiring TOP 4

ZKP-Number: 2.8006.641

Cause Corrective action

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

u Check cabling to plant.

TIM-ID: 0000008506 - 002

112 | Troubleshooting | M015710/04E 2012-09

390 – AL MCR exceeded

ZKP-Number: 1.1085.009

Cause Corrective action

DBR/MCR function: MCR
exceeded.

1. No action required if alarm only applied temporarily.

2. Contact Service if alarm applied constantly.

392 – HI T-Coolant Red

ZKP-Number: 2.0129.931

Limit value 1

Cause Corrective action

Redundant coolant temperature
reading too high.

1. Check cabling.

2. Contact Service.

393 – SS T-Coolant Red

ZKP-Number: 2.0129.932

Limit value 2

Cause Corrective action

Redundant coolant temperature
reading too high; Engine stop.

1. Check cabling and sensor.

2. Contact Service.

394 – LO P-Lube Oil Red

TIM-ID: 0000008506 - 002

ZKP-Number: 2.0112.921

Limit value 1

Cause Corrective action

Redundant lube oil pressure
reading too low.

1. Check cabling and sensor.

2. Contact Service.

395 – SS P-Lube Oil Red

ZKP-Number: 2.0112.922

Limit value 2

Cause Corrective action

Redundant lube oil pressure
reading too low.

1. Check cabling and sensor.

2. Contact Service.

396 – TD T-Coolant Sensor Deviation

ZKP-Number: 1.0480.193

Cause Corrective action

Maximum coolant temperature
deviation.

1. Check cabling and sensor.

2. Contact Service.

M015710/04E 2012-09 | Troubleshooting | 113

397 – TD P-Oil Sensor Deviation

ZKP-Number: 1.0480.293

Cause Corrective action

Maximum lube oil pressure
deviation.

1. Check cabling and sensor.

2. Contact Service.

400 – AL Open Load Digital Input 1

ZKP-Number: 2.8006.625

Cause Corrective action

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

1. Check cabling.

2. Check target device input.

3. Contact Service.

401 – AL Open Load Digital Input 2

ZKP-Number: 2.8006.626

Cause Corrective action

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

1. Check cabling.

2. Check target device input.

3. Contact Service.

402 – AL Open Load Digital Input 3

ZKP-Number: 2.8006.627

Cause Corrective action

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

1. Check cabling.

2. Check target device input.

3. Contact Service.

403 – AL Open Load Digital Input 4

ZKP-Number: 2.8006.628

Cause Corrective action

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

1. Check cabling.

2. Check target device input.

3. Contact Service.

404 – AL Open Load Digital Input 5

ZKP-Number: 2.8006.629

Cause Corrective action

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

1. Check cabling.

2. Check target device input.

3. Contact Service.

TIM-ID: 0000008506 - 002

114 | Troubleshooting | M015710/04E 2012-09

405 – AL Open Load Digital Input 6

ZKP-Number: 2.8006.630

Cause Corrective action

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

1. Check cabling.

2. Check target device input.

3. Contact Service.

406 – AL Open Load Digital Input 7

ZKP-Number: 2.8006.631

Cause Corrective action

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

1. Check cabling.

2. Check target device input.

3. Contact Service.

407 – AL Open Load Digital Input 8

ZKP-Number: 2.8006.632

Cause Corrective action

Line disruption on digital input 8;
Cabling faulty or no resistance
over switch.

1. Check cabling.

2. Check target device input.

3. Contact Service.

408 – AL Open Load Emerg. Stop Input ESI

TIM-ID: 0000008506 - 002

ZKP-Number: 2.8006.633

Cause Corrective action

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

1. Check cabling.

2. Check target device input.

3. Contact Service.

410 – LO U-PDU

ZKP-Number: 2.0141.921

Limit value 1

Cause Corrective action

Injector voltage too low. 1. Check cabling.

2. Check supply.

3. Contact Service.

411 – LOLO U-PDU

ZKP-Number: 2.0141.922

Limit value 2

Cause Corrective action

Injector voltage too low. 1. Check cabling.

2. Check supply.

3. Contact Service.

M015710/04E 2012-09 | Troubleshooting | 115