Operating Instructions: Diesel Engine 20 V 4000 G23 20 V 4000 G43 20 V 4000 G63, G63L 20 V 4000 G83, G83L

Operating Instructions
Diesel engine
20 V 4000 G23
20 V 4000 G43
20 V 4000 G63, G63L
20 V 4000 G83, G83L
M015715/03E
Printed in Germany
© 2013 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-
crofilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Table of Contents
1 Safety 4.4 Safety system – Override 58
4.5 Starting the engine in emergency situations
1.1 Important provisions for all products 5 (override mode) 59
1.2 Personnel and organizational requirements 6 4.6 Operational checks 60
1.3 Transport 7 4.7 Stopping the engine in manual mode (test
1.4 Crankshaft transport locking device 8 run) 61
1.5 Safety regulations for startup and operation 11 4.8 Emergency stop 62
1.6 Safety regulations for maintenance and 4.9 After stopping the engine – Engine remains
repair work 12 ready for operation 63
1.7 Fire prevention and environmental 4.10 After stopping the engine – Putting the
protection, fluids and lubricants, auxiliary engine out of operation 64
materials 15 4.11 Plant cleaning 65
1.8 Conventions for safety instructions in the
text 17
5 Maintenance
2 General Information 5.1 Maintenance task reference table [QL1] 66
2.1 Engine side and cylinder designations 18
6 Troubleshooting
2.2 Engine layout 19
2.3 Sensors, actuators and injectors – Overview 21 6.1 Troubleshooting 67
6.2 Fault messages on PAU display 70
3 Technical Data 6.3 Engine governor ADEC (ECU 7) for Series
4000 genset engines – Fault messages 71
3.1 20 V 4000 Gx3 engine data: Continuous
operation, unrestricted 3A, optimized fuel
7 Task Description
consumption 24
3.2 20 V 4000 Gx3 engine data: Continuous 7.1 Engine 120
operation, variable 3B, optimized fuel 7.1.1 Engine – Barring manually 120
consumption 29 7.1.2 Engine – Barring with starting system 121
3.3 20 V 4000 Gx3 engine data: Continuous 7.1.3 Engine – Test run 122
operation, variable 3B, optimized exhaust 7.2 Cylinder Liner 123
emissions (EPA2) 35 7.2.1 Cylinder liner – Endoscopic examination 123
3.4 20 V 4000 Gx3 engine data: Continuous 7.2.2 Instructions and comments on endoscopic and
operation, variable 3B, optimized exhaust visual examination of cylinder liners 125
emissions (TA-Luft) 39 7.3 Crankcase Breather 127
3.5 20 V 4000 Gx3 engine data: Standby 7.3.1 Crankcase breather – Oil separator element
operation 3D, optimized fuel consumption 43 replacement, diaphragm check and
3.6 20 V 4000 Gx3 engine data: Standby replacement 127
operation 3D, optimized exhaust emissions
7.4 Valve Drive 129
(EPA stage 2) 49
7.4.1 Valve gear – Lubrication 129
3.7 Firing order 53 7.4.2 Valve clearance – Check and adjustment 130
3.8 Engine – Main dimensions 54
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7.4.3 Cylinder head cover – Removal and

installation 132
4 Operation
7.5 Injection Pump / HP Pump 133
4.1 Putting the engine into operation after 7.5.1 HP pump – Filling with engine oil 133
extended out-of-service periods (>3 months) 55 7.6 Injection Valve / Injector 134
4.2 Putting the engine into operation after 7.6.1 Injector – Replacement 134
scheduled out-of-service-period 56 7.6.2 Injector – Removal and installation 135
4.3 Starting the engine in manual mode (test
7.7 Fuel System 140
run) 57
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7.7.1 Fuel system – Venting 140 7.15.5 Engine coolant pump – Relief bore check 170
7.15.6 Engine coolant – Sample extraction and
7.8 Fuel Filter 141 analysis 171
7.8.1 Fuel filter – Replacement 141
7.8.2 Fuel prefilter cleaning 142 7.16 Low-Temperature Circuit 172
7.8.3 Fuel prefilter – Differential pressure gauge 7.16.1 Charge-air coolant – Level check 172
check and adjustment 143 7.16.2 Charge-air coolant – Change 173
7.8.4 Fuel prefilter – Draining 144 7.16.3 Draining charge-air coolant 174
7.8.5 Fuel prefilter – Flushing 145 7.16.4 Charge-air coolant – Filling 175
7.8.6 Fuel prefilter – Filter element replacement 147 7.16.5 Charge-air coolant pump – Relief bore check 178
7.9 Charge-Air Cooling 149 7.17 Engine Mounting / Support 179

7.9.1 Intercooler – Checking condensate drain for 7.17.1 Engine mounting – Check 179
coolant discharge and obstructions 149
7.18 Belt Drive 180
7.10 Air Filter 150 7.18.1 Drive belt – Condition check 180
7.10.1 Air filter – Replacement 150
7.10.2 Air filter – Check 151
7.19 Battery-Charging Generator 181
7.19.1 Battery-charging generator drive – Drive belt
7.10.3 Air filter – Removal and installation 152
replacement 181
7.11 Air Intake 153 7.19.2 Battery-charging generator drive – Drive belt
7.11.1 Service indicator – Signal ring position check tension adjustment 183
(optional) 153
7.20 Wiring (General) for Engine/Gearbox/Unit 184
7.12 Starting Equipment 154 7.20.1 Engine wiring – Check 184
7.12.1 Air starter – Manual operation 154
7.21 Accessories for (Electronic) Engine
7.13 Lube Oil System, Lube Oil Circuit 155 Governor / Control System 185
7.13.1 Engine oil – Level check 155 7.21.1 CDC parameters – Reset with DiaSys® 185
7.13.2 Engine oil – Change 156 7.21.2 Engine governor and connectors – Cleaning 186
7.13.3 Engine oil – Sample extraction and analysis 158 7.21.3 Engine governor plug connections – Check 187
7.21.4 ECU 7 engine governor – Removal and
7.14 Oil Filtration / Cooling 159
installation 188
7.14.1 Engine oil filter – Replacement 159
7.14.2 Oil indicator filter – Check 160
7.14.3 Centrifugal oil filter – Cleaning and filter- 8 Appendix A
sleeve replacement 162
8.1 Abbreviations 189
7.15 Coolant Circuit, General, High-Temperature
8.2 MTU contact persons/service partners 191
Circuit 164
7.15.1 Engine coolant – Level check 164
7.15.2 Engine coolant – Change 165 9 Appendix B
7.15.3 Engine coolant – Draining 166
7.15.4 Engine coolant – Filling 167
9.1 Special Tools 192
9.2 Index 198
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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ product data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ applicable Spare Parts
Catalog)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety instructions and in adherence to all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation.The manufacturer will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the product compromise safety.
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The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
M015715/03E 2013-01 | Safety | 5

1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and protective equipment

Wear proper protective clothing for all work.
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6 | Safety | M015715/03E 2013-01

1.3 Transport
Transport
Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.
Always use the lifting eyes on the engine when transporting an engine separately.
Only use transport and lifting devices approved by MTU.
The engine/genset must only be transported in installation position: maximum permissible diagonal pull
10°.
Remove any loose parts on the genset.
Raise the engine/genset slowly. The lifting ropes or chains must not make contact with the engine or
its components. Readjust lifting device as necessary.
Pay attention to the center of gravity of the engine/genset.
For special packaging with aluminium foil: Suspend the engine/genset by the lifting eyes on the bearing
pedestal or transport by means of handling equipment (forklift truck) capable of bearing the load.
Fit the crankshaft transportation lock on the engine and fit the engine mount locking devices prior to
transport.
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Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip-
ping and tipping when driving up or down inclines and ramps.
Placement after transport

Place the engine/genset on a firm, flat surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis.
M015715/03E 2013-01 | Safety | 7

1.4 Crankshaft transport locking device
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30510423 1
Engine oil
Transport locking device

Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine
transport.
For installation and removal of the transport locking device, follow the in-
structions below:
1. The transport locking device must remain installed as long as possible during engine installation in or-
der to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both sides accord-
ing to the instructions.
3. If the engine is to be moved together with the generator, the transport locking device for the generator
must also be installed.
4. Always use the screws supplied with or installed in the transport locking device to secure it on the en-
gine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the genera-
tor is already mounted on the engine, ensure that the transport locking device of the generator is also
removed.
6. Attach these instructions, clearly visible, to the engine.
Removing guard plates and en-

gine mounting brackets (if appli-
cable) on driving end (KS)
1. Remove screws (4) on both sides and take
off with washers (3), guard plates (1) and
engine mounting brackets (2).
2. Store the removed parts of the transport
locking device carefully for possible reuse.
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8 | Safety | M015715/03E 2013-01

Fitting the transport locking de-
vice on driving end (KS)
Note: Attach plate (6) only to the upper part of the openings.
1. Secure plates (6) with screws (4) and washers (5) at the bores on both sides of the flywheel housing
and tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
2. Screw nut (2) onto screw (1) up to the end of the thread.
3. The long end of holder (3) must face downwards. Push holder (3) through the plate opening (6).
Note: The holder (3) must lock the flywheel only, not the ring gear.
4. Install screw (1) into the bore of holder (3) until holder (3) is locked in position.
Note: Screw (1) must be tightened alternately on both sides of the flywheel housing.
5. Tighten screw (1) with torque wrench to the specified tightening torque.
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
6. Screw on nut (2) of both screw (1) at plates (6) and secure.
Removing the transport locking

device from driving end (KS)
1. Release locknut (2) on both sides of the fly-
wheel housing, remove screw (1) and take
off the lock (3).
2. Unscrew screw (4) and remove together
with washer (5) and plate (6).
3. Store the removed parts of the transport
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locking device together with this documen-

tation carefully for possible reuse.
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Installing guard plates and en-
gine mounting brackets (if appli-
cable) on driving end (KS)
Note: Always use the screws supplied with the or
removed from the guard plates and engine
mounting brackets to secure them on the
engine.
1. Install engine mounting brackets (2) on
both sides with guard plates (1) wash-
ers (3), and screws (4).
2. Tighten screws (4).
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10 | Safety | M015715/03E 2013-01

1.5 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance the manufacturer's specifications
before putting the product into service.
Before the product is put into operation for the first time, all official authorizations must be available
and commissioning preconditions met.
When putting the product into operation, always ensure
• that all maintenance and repair work has been completed;
• that all loose parts have been removed from rotating machine components;
• that no-one is present in the danger zone of rotating machine components.
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the signaling and alarm systems work properly.
Safety regulations for equipment operation

The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with re-
gard to present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop

The procedures for cases of emergency, in particular, emergency stop, must be practiced regularly.
The following steps must be taken if a malfunction of the system is recognized or reported by the sys-
tem:
• Inform supervisor(s) in charge,
• Analyze the message,
• If required, carry out emergency operations e.g. emergency stop.
Operation
The following conditions must be fulfilled before starting the product:
• Wear ear protection.
• Ensure that the engine room is well ventilated.
• Do not inhale the exhaust gases of the product.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
• Protect battery terminals, generator terminals or cables against accidental contact.
Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.
Observe the safety instructions for these devices.
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M015715/03E 2013-01 | Safety | 11

1.6 Safety regulations for maintenance and repair work
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion
of oil vapors, fluids and lubricants, risk of burning).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use
suitable containers of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the engine room is adequately venti-
lated.
Never carry out maintenance and repair work with the product in operation.
Carry out function checks on a product in operation only if expressly permitted to do so.
Secure the product against unintentional starting, e.g. with start interlock.
Attach "Do not operate" sign in the operating area or to control equipment.
Disconnect the battery. Lock circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the product.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz-
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing
or the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction
device as an additional measure.
Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assemblies or plants which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
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Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are prop-
erly protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com-
ponents or assemblies are placed on stable surfaces.
12 | Safety | M015715/03E 2013-01

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

Before barring, make sure that nobody is standing in the danger zone of the product.
Check that all guards have been reinstalled and that all tools and loose parts have been removed after
working on the product (in particular, the barring tool).
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when weld-
ing in its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is
going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product.
The welding current may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand.
Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into
shaft end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries

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Observe the safety instructions of the battery manufacturer when working with batteries.
Gases emanating from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come in contact with skin or clothing.
Wear protective clothing and protective gloves.
Never place tools on the battery.
Before connecting the cable to the battery, check the battery polarity.Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.
M015715/03E 2013-01 | Safety | 13

Working on electrical and electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged dur-
ing operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a function check on completion of all repair work. In partic-
ular, check the function of the engine emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack
defective electronic components and assemblies in a suitable manner when dispatched for repair, i.e.
protected, in particular, against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi-
ly focused radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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14 | Safety | M015715/03E 2013-01

1.7 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore al-
ways keep the product in a clean condition. Do not leave cloths soaking with fluids and lubricants on
the product. Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power
source to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with
their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85dB (A).
Environmental protection and disposal

Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents as well as the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer. Noncompliance with these guidelines will lead to forfeiture of the operating permit issued by
the emission monitoring authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they are subjected to
proper recycling procedures.
Auxiliary materials, fluids and lubricants

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The applicable version may be downloaded at: http://
www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.
Auxiliary materials, fluids and lubricants might be hazardous goods or toxic substances.When using flu-
ids, lubricants, auxiliary materials and other chemical substances, follow the safety instructions that ap-
ply to the product. Take special care when using hot, chilled or caustic materials. When using flamma-
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ble materials, avoid contact with ignition sources and do not smoke.
Used oil
Used oil contains harmful combustion residue.
Rub barrier cream into hands.
Wash hands after contact with used oil.
M015715/03E 2013-01 | Safety | 15

Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Wear goggles when blowing off components or blowing away chips.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Pay special attention to the pressure level in the compressed air network or pressure vessel.
• Assemblies or products to be connected must either be designed for this pressure, or, if the permit-
ted pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before the equipment or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Paints and lacquers

• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems,
ensure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• Avoid open flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in specified containers (without fixed cov-
ers).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids/alkaline solutions/urea solution (AdBlue, DEF)

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• When working with acids and alkaline solutions, wear face mask, gloves and protective clothing.
• Do not inhale vapors.
• If urea solution was swallowed, rinse mouth and drink plenty of water.
• If the solutions was spilled onto clothing, remove the affected clothing immediately.
• In case of skin contact, rinse parts of the body thoroughly with clean water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possi-
ble.
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1.8 Conventions for safety instructions in the text
DANGER
In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
WARNING
In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
CAUTION
In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
1. Read and familiarize yourself with all safety notices before starting up or repairing the product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
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M015715/03E 2013-01 | Safety | 17

2 General Information
2.1 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
1 Left engine side 3 Right engine side

2 KGS = Free end 4 KS = Driving end
TIM-ID: 0000002185 - 010
18 | General Information | M015715/03E 2013-01

2.2 Engine layout
1 Oil heat exchanger 6 Oil filter 11 Belt drive

2 Exhaust turbocharger 7 Fuel filter 12 Charge-air coolant inlet
3 Lifting eye 8 LP fuel pump 13 Engine coolant outlet
4 Air supply 9 HP fuel pump
5 Oil filler neck 10 Vibration damper
TIM-ID: 0000002065 - 004
M015715/03E 2013-01 | General Information | 19

1 Intercooler 6 Engine coolant inlet 11 Oil pan
2 Exhaust pipework to inter- 7 Charge-air coolant outlet 12 Valve gear
cooler 8 Coolant pump 13 Cylinder head
3 Air filter 9 Generator 14 Starting equipment
4 Centrifugal oil filter 10 Engine mounting 15 PTO system, driving end
5 Crankcase breather
Engine model designation

Key to the engine model designation 20 V 4000 Gx3
20 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
G Application
x Application segment (2, 4, 6, 8)
3 Design index
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2.3 Sensors, actuators and injectors – Overview
1 Injectors Y39.11 to 3 F33 (connection for exter- 5 B09 (charge-air tempera-

Y39.20 (B side cylinders) nal sensor F33) ture)
2 Engine governor ECU-7 4 F57 (connection for exter- 6 B10 (charge-air pressure)
nal sensor F57)
The injectors are located below the cylinder head covers. Injector replacement and required tasks
(→ Page 134).
TIM-ID: 0000001088 - 004

1 B13 (crankshaft speed)
TIM-ID: 0000001088 - 004
1 Injectors Y39.1 to Y39.10 2 B34 (fuel pressure after fil- 3 M8 (HP fuel pump actua-
(A side cylinders) ter) tor)
The injectors are located below the cylinder head covers. Injector replacement and required tasks
(→ Page 134).

1 B05.3 (oil pressure before 4 B48 (fuel pressure after 7 B26 (charge-air coolant
filter) HP pump) temperature)
2 B05 (oil pressure after fil- 5 B01 (camshaft speed) 8 B06 (coolant temperature)
ter) 6 B33 (fuel temperature)
3 B07 (oil temperature)
TIM-ID: 0000001088 - 004

3 Technical Data
3.1 20 V 4000 Gx3 engine data: Continuous operation,
unrestricted 3A, optimized fuel consumption
Explanation
Abbr. Meaning
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
Reference conditions
Engine model 20 20 20 20 20
4000G43 4000G63 4000G63L 4000G83 4000G83L
Application group 3A 3A 3A 3A 3A
1800
Intake air tempera- °C 25 25 25 25 25
ture
Charge-air coolant °C 55 55 55 55 55
temperature
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above m 100 100 100 100 100
sea level
Power-related data (power ratings are net brake power to ISO 3046)
Number of cylin- 20 20 20 20 20
ders
Rated engine speed A rpm 1800 1500 1500 1800 1800
Continuous power A kW 1890 2000 2170 2230 2500
ISO 3046 (10% over-
TIM-ID: 0000026839 - 002
load capability, de-

sign power DIN
6280, ISO 8528)
Fuel stop power ISO 2079 2200 2390 2453 2750
3046
24 | Technical Data | M015715/03E 2013-01

General conditions (for max. power)
ders
Intake depression A mbar 15 15 15 15 15
(new filter)
Intake depression, L mbar 30 30 30 30 30
max.
Exhaust overpres- A mbar 30 30 30 30 30
sure
Exhaust overpres- L mbar 50 50 50 50 50
sure, max.
Model related data (basic design)

ders
Cylinder arrange- Degrees 90 90 90 90 90
ment: V angle
Bore mm 170 170 170 170 170
Stroke mm 210 210 210 210 210
Cylinder displace- Liters 4.77 4.77 4.77 4.77 4.77
ment
Total displacement Liters 95.4 95.4 95.4 95.4 95.4
Compression ratio 16.4 16.4 16.4 16.4 16.4
Number of inlet 2 2 2 2 2
valves per cylinder
Number of exhaust 2 2 2 2 2
valves per cylinder
Combustion air / exhaust gas

ders
Charge-air pressure R bar abs 2.2 2.3 2.5 2.4 2.8
before cylinder - DL
Coolant system (high-temperature circuit)

ders
Coolant tempera- A °C 100 100 100 100 100
TIM-ID: 0000026839 - 002
ture (at engine con-

nection: outlet to
cooling equipment)
Coolant tempera- R °C 102 102 102 102 102
ture after engine,
warning
Coolant tempera- L °C 104 104 104 104 104
ture after engine,
shutdown
M015715/03E 2013-01 | Technical Data | 25

ders
Coolant antifreeze L % 50 50 50 50 50
content, max.
Pressure loss in off- L bar 0.7 0.7 0.7 0.7 0.7
engine cooling sys-
tem, max.
Coolant system (low-temperature circuit)

Number of cylin- 20 20 20 20 20 20
ders
Coolant tempera- A °C 55 55 55 55 55 55
ture before inter-
cooler (at engine
connection: inlet
from cooling equip-
ment)
Coolant antifreeze L % 50 50 50 50 50 50
content, max.
Pressure loss in off- L bar 0.7 0.7 0.7 0.7 0.7 0.7
engine cooling sys-
tem, max.
Lube oil system

ders
Lube oil operating R °C 88 88 88 88 88
temperature before
engine, from
Lube oil operating R °C 98 98 98 98 98
temperature before
engine, to
Lube oil tempera- R °C 99 99 99 99 99
ture before engine,
warning
Lube oil tempera- L °C 101 101 101 101 101
ture before engine,
shutdown
Lube oil operating R bar 5.2 5.0 5.0 5.0 5.0
pressure before en-
gine, from
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Lube oil operating R bar 8.0 7.0 7.0 7.0 7.0

pressure before en-
gine, to

Fuel system
ders
Fuel pressure at en- L bar -0.1 -0.1 -0.1 -0.1 -0.1
gine inlet connec-
tion, min. (when en-
gine is starting)
Fuel pressure at en- L bar 1.5 1.5 1.5 1.5 1.5
gine inlet connec-
tion, max. (when en-
gine is starting)
General operating data

ders
Cold start capability: R °C 10 10 10 10 10
air temperature
(w/o start aid, w/o
preheating) - (case
A)
Coolant preheating: R °C 32 32 32 32 32
preheating tempera-
ture (min.)
Firing speed, from R rpm 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120
Capacities
ders
Engine coolant, en- R Liters 205 205 205 205 205
gine side (without
cooling equipment)
Charge-air coolant, R Liters 55 55 55 55 55
engine side
Engine oil capacity, R Liters 390 390 390 390 390
initial filling (stand-
ard oil system) (op-
tion: max. operating
inclinations)
Oil pan capacity at L Liters 245 245 245 245 245
dipstick mark “min.”
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(standard oil sys-

tem) (option: max.
operating inclina-
tions)
Oil pan capacity at L Liters 340 340 340 340 340
dipstick mark
“max.” (standard oil
system) (option:
max. operating incli-
nations)

Weights / main dimensions
ders
Engine weight, dry R kg 9640 9640 9640 9640 9640
(basic engine config-
uration acc. to
scope of supply
specification)
Sound
ders
Exhaust noise, unsi- R dB(A) 131 129 130 132 134
lenced - DL (sound
power level LW, ISO
6798)
TIM-ID: 0000026839 - 002

3.2 20 V 4000 Gx3 engine data: Continuous operation, variable
3B, optimized fuel consumption
Explanation
Abbr. Meaning
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 20V 20V 20V 20V 20V 20V
4000G23 4000G43 4000G63 4000G63 4000G83 4000G83
L L
Application group 3B 3B 3B 3B 3B 3B
Intake air temper- °C 25 25 25 25 25 25
ature
Charge-air cool- °C 55 55 55 55 55 55
ant temperature
Raw-water inlet °C - - - - - -
temperature
Barometric pres- mbar 1000 1000 1000 1000 1000 1000
sure
Site altitude m 100 100 100 100 100 100
above sea level
Number of cylin- 20 20 20 20 20 20
ders
Rated engine A rpm 1500 1800 1500 1500 1800 1800
speed
Continuous power A kW 2200 2490 2420 2590 2740 3010
TIM-ID: 0000002954 - 002
ISO 3046 (10%

overload capabili-
ty, design power
DIN 6280, ISO
8528)

Number of cylin- 20 20 20 20 20 20
ders
Intake depression A mbar 15 15 15 15 15 15
(new filter)
Intake depres- L mbar 50 50 50 50 50 50
sion, max.
Exhaust overpres- A mbar 30 30 30 30 30 30
sure
Exhaust overpres- L mbar 85 85 85 85 85 85
sure, max.

Number of cylin- 20 20 20 20 20 20
ders
Engine with ex- X X X X X X
haust turbocharg-
ing (ETC) and
charge-air cooling
(CAC)
Uncooled exhaust X X X X X X
lines
Operating meth- X X X X X X
od: Four-stroke
cycle, diesel, sin-
gle-action
Combustion X X X X X X
method: direct
fuel injection
Cooling method: X X X X X X
treated water
Direction of rota- X X X X X X
tion: c.c.w. (fac-
ing driving end)
Cylinder arrange- Degrees 90 90 90 90 90 90
ment: V angle
Bore mm 170 170 170 170 170 170
Stroke mm 210 210 210 210 210 210
Cylinder displace- Liters 4.77 4.77 4.77 4.77 4.77 4.77
ment
TIM-ID: 0000002954 - 002
Total displace- Liters 95.4 95.4 95.4 95.4 95.4 95.4

ment
Compression ra- 16.5 16.5 16.5 16.5 16.5 16.5
tio
Cylinder heads: X X X X X X
individual cylinder
heads
Cylinder liners: X X X X X X
wet, replaceable

Number of cylin- 20 20 20 20 20 20
ders
Number of inlet 2 2 2 2 2 2
valves per cylin-
der
Number of ex- 2 2 2 2 2 2
haust valves per
cylinder
Standard housing SAE 00 00 00 00 00 00
connecting flange
(engine main PTO)
Flywheel interface DISC 21 21 21 21 21 21

Number of cylin- 20 20 20 20 20 20
ders
Charge-air pres- R bar abs 2.3 2.8 2.5 2.6 3.1 3.3
sure before cylin-
der - DL

Number of cylin- 20 20 20 20 20 20
ders
ture (at engine
connection: outlet
to cooling equip-
ment)
Coolant tempera- R °C 102 102 102 102 102 102
ture after engine,
warning
Coolant tempera- L °C 104 104 104 104 104 104
ture after engine,
shutdown
content, max.
Pressure loss in L bar 0.7 0.7 0.7 0.7 0.7 0.7
off-engine cooling
system, max.
TIM-ID: 0000002954 - 002

Number of cylin- 20 20 20 20 20 20
ders
ture before inter-
cooler (at engine
connection: inlet
from cooling
equipment)
content, max.
off-engine cooling
system, max.
Lube oil system

Number of cylin- 20 20 20 20 20 20
ders
Lube oil operating R °C 88 88 88 88 88 88
temperature be-
fore engine, from
temperature be-
fore engine, to
Lube oil tempera- R °C 99 99 99 99 99 99
ture before en-
gine, warning
Lube oil tempera- L °C 101 101 101 101 101 101
ture before en-
gine, shutdown
Lube oil operating R bar 4.6 5.2 4.5 4.4 5.0 4.9
pressure before
engine, from
pressure before
engine, to
Lube oil operating R bar -- -- -- -- -- --
pressure before
engine, warning
Lube oil operating L bar -- -- -- -- -- --
pressure before
TIM-ID: 0000002954 - 002
engine, shutdown

Fuel system
Number of cylin- 20 20 20 20 20 20
ders
Fuel pressure at L bar -0.1 -0.1 -0.1 -0.1 -0.1 -0.1
engine inlet con-
nection, min.
(when engine is
starting)
Fuel pressure at L bar 1.5 1.5 1.5 1.5 1.5 1.5
engine inlet con-
nection, max.
(when engine is
starting)

Number of cylin- 20 20 20 20 20 20
ders
Cold start capabil- R °C 10 10 10 10 10 10
ity: air tempera-
ture (w/o start
aid, w/o preheat-
ing) - (case A)
Coolant preheat- R °C 32 32 32 32 32 32
ing: preheating
temperature
(min.)
Firing speed, from R rpm 80 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120 120
Capacities
Number of cylin- 20 20 20 20 20 20
ders
Engine coolant, R Liters 205* 205* 205* 205* 205* 205*
engine side (with-
out cooling equip-
ment)
Charge-air cool- R Liters 55* 55* 55* 55* 55* 55*
ant, engine side
Engine oil capaci- R Liters 390* 390* 390* 390* 390* 390*
ty, initial filling
(standard oil sys-
TIM-ID: 0000002954 - 002
tem) (option:
max. operating in-
clinations)
Oil change quanti- R Liters
ty, max. (standard
oil system) (op-
tion: max. operat-
ing inclinations)

Number of cylin- 20 20 20 20 20 20
ders
Oil pan capacity L Liters 245* 245* 245* 245* 245* 245*
at dipstick mark
“min.” (standard
oil system) (op-
tion: max. operat-
ing inclinations)
at dipstick mark
“max.” (standard
oil system) (op-
tion: max. operat-
ing inclinations)

Number of cylin- 20 20 20 20 20 20
ders
Engine weight, R kg 9640 9640 9640 9640 9640 9640
dry (basic engine
configuration acc.
to scope of sup-
ply specification)
Sound
Number of cylin- 20 20 20 20 20 20
ders
Exhaust noise, un- R dB(A) 130 133 131 132 134 136
silenced - DL
(sound power lev-
el LW, ISO 6798)
Engine surface R dB(A) 125 128 126 126 129 130
noise with attenu-
ated intake noise
(filter) - DL (sound
power level LW,
ISO 6798)
TIM-ID: 0000002954 - 002

3B, optimized exhaust emissions (EPA2)
Explanation
Abbr. Meaning
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 20V 20V 20V
4000G43 4000G83 4000G83
L
Application group 3B 3B 3B
Intake air temperature °C 25 25 25
Charge-air coolant temperature °C 45 45 45
Raw-water inlet temperature °C - - -
Barometric pressure mbar 1000 1000 1000
Site altitude above sea level m 100 100 100
Number of cylinders 20 20 20
Rated engine speed A rpm 1800 1800 1800
Continuous power ISO 3046 (10% overload capability, A kW 2490 2740 3010
design power DIN 6280, ISO 8528)

Intake depression (new filter) A mbar 15 15 15
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Intake depression, max. L mbar 50 50 50

Exhaust overpressure A mbar 30 30 30
Exhaust overpressure, max. L mbar 85 85 85

Engine with exhaust turbocharging (ETC) and charge- X X X
air cooling (CAC)
Uncooled exhaust lines X X X
Operating method: Four-stroke cycle, diesel, single-ac- X X X
tion
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
Cylinder arrangement: V angle Degrees 90 90 90
Bore mm 170 170 170
Stroke mm 210 210 210
Cylinder displacement Liters 4.77 4.77 4.77
Total displacement Liters 95.4 95.4 95.4
Compression ratio 16.5 16.5 16.5
Cylinder heads: individual cylinder heads X X X
Cylinder liners: wet, replaceable X X X
Number of inlet valves per cylinder 2 2 2
Number of exhaust valves per cylinder 2 2 2
Standard housing connecting flange (engine main SAE 00 00 00
PTO)
Flywheel interface DISC 21 21 21

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

Coolant temperature (at engine connection: outlet to A °C 100 100 100
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
TIM-ID: 0000002980 - 002
Pressure loss in off-engine cooling system, max. L bar 0.7 0.7 0.7

Coolant temperature before intercooler (at engine A °C 45 45 45
connection: inlet from cooling equipment)

Lube oil system
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 4.9
Lube oil operating pressure before engine, to R bar 7.8 7.8 7.7
Lube oil operating pressure before engine, warning R bar -- -- --
Lube oil operating pressure before engine, shutdown L bar -- -- --
Fuel system
Fuel pressure at engine inlet connection, min. (when L bar -0.1 -0.1 -0.1
engine is starting)
Fuel pressure at engine inlet connection, max. (when L bar 1.5 1.5 1.5
engine is starting)

Cold start capability: air temperature (w/o start aid, R °C 10 10 10
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
Capacities
Engine coolant, engine side (without cooling equip- R Liters 205* 205* 205*
ment)
Charge-air coolant, engine side R Liters 55* 55* 55*
Engine oil capacity, initial filling (standard oil system) R Liters 390* 390* 390*
(option: max. operating inclinations)
Oil change quantity, max. (standard oil system) (op- R Liters
tion: max. operating inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil L Liters 245* 245* 245*
TIM-ID: 0000002980 - 002
system) (option: max. operating inclinations)

Oil pan capacity at dipstick mark “max.” (standard oil L Liters 340* 340* 340*

Engine weight, dry (basic engine configuration acc. to R kg 9640 9640 9640
scope of supply specification)

Sound
Exhaust noise, unsilenced - DL (sound power level LW, R dB(A) 134 136 136
ISO 6798)
Engine surface noise with attenuated intake noise (fil- R dB(A) 129 130 132
ter) - DL (sound power level LW, ISO 6798)
TIM-ID: 0000002980 - 002

3B, optimized exhaust emissions (TA-Luft)
Explanation
Abbr. Meaning
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
4000G23 4000G63 4000G63
L
Application group 3B 3B 3B
Continuous power ISO 3046 (10% overload capability, A kW 2200 2420 2590
design power DIN 6280, ISO 8528)

TIM-ID: 0000003002 - 002


air cooling (CAC)
tion
Bore mm 170 170 170
Stroke mm 210 210 210
PTO)

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

cooling equipment)
TIM-ID: 0000003002 - 002


Lube oil system
Fuel system
engine is starting)
engine is starting)

Capacities
ment)
TIM-ID: 0000003002 - 002



Sound
Exhaust noise, unsilenced - DL (sound power level LW, R dB(A) 130 131 132
ISO 6798)
ter) - DL (sound power level LW, ISO 6798)
TIM-ID: 0000003002 - 002

3.5 20 V 4000 Gx3 engine data: Standby operation 3D, optimized
fuel consumption
Explanation
Abbr. Meaning
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 20V 20V 20V 20V 20V 20V
4000G23 4000G43 4000G63 4000G63 4000G83 4000G83
L L
Application group 3D 3D 3D 3D 3D 3D
Intake air temper- °C 25 25 25 25 25 25
ature
Charge-air cool- °C 55 55 55 55 55 55
ant temperature
Raw-water inlet °C - - - - - -
temperature
Barometric pres- mbar 1000 1000 1000 1000 1000 1000
sure
Site altitude m 100 100 100 100 100 100
above sea level
Number of cylin- 20 20 20 20 20 20
ders
Rated engine A rpm 1500 1800 1500 1500 1800 1800
speed
Fuel stop power A kW 2420 2740 2670 2850 3010 3490
TIM-ID: 0000002872 - 002
ISO 3046

Number of cylin- 20 20 20 20 20 20
ders
Intake depression A mbar 15 15 15 15 15 15
(new filter)
Intake depres- L mbar 50 50 50 50 50 50
sion, max.

Number of cylin- 20 20 20 20 20 20
ders
Exhaust overpres- A mbar 30 30 30 30 30 30
sure
Exhaust overpres- L mbar 85 85 85 85 85 85
sure, max.

Number of cylin- 20 20 20 20 20 20
ders
Engine with ex- X X X X X X
haust turbocharg-
ing (ETC) and
charge-air cooling
(CAC)
Uncooled exhaust X X X X X X
lines
Operating meth- X X X X X X
od: Four-stroke
cycle, diesel, sin-
gle-action
Combustion X X X X X X
method: direct
fuel injection
Cooling method: X X X X X X
treated water
Direction of rota- X X X X X X
tion: c.c.w. (fac-
ing driving end)
Cylinder arrange- Degrees 90 90 90 90 90 90
ment: V angle
Bore mm 170 170 170 170 170 170
Stroke mm 210 210 210 210 210 210
Cylinder displace- Liters 4.77 4.77 4.77 4.77 4.77 4.77
ment
Total displace- Liters 95.4 95.4 95.4 95.4 95.4 95.4
ment
Compression ra- 16.5 16.5 16.5 16.5 16.5 16.5
tio
Cylinder heads: X X X X X X
TIM-ID: 0000002872 - 002
individual cylinder
heads
Cylinder liners: X X X X X X
wet, replaceable
Number of inlet 2 2 2 2 2 2
valves per cylin-
der
Number of ex- 2 2 2 2 2 2
haust valves per
cylinder

Number of cylin- 20 20 20 20 20 20
ders
Standard housing SAE 00 00 00 00 00 00
connecting flange
(engine main PTO)
Flywheel interface DISC 21 21 21 21 21 21

Number of cylin- 20 20 20 20 20 20
ders
Charge-air pres- R bar abs 2.5 3.1 2.7 2.9 3.3 3.6
sure before cylin-
der - BL

Number of cylin- 20 20 20 20 20 20
ders
ture (at engine
connection: outlet
to cooling equip-
ment)
Coolant tempera- R °C 102 102 102 102 102 102
ture after engine,
warning
Coolant tempera- L °C 104 104 104 104 104 104
ture after engine,
shutdown
content, max.
off-engine cooling
system, max.

Number of cylin- 20 20 20 20 20 20
ders
ture before inter-
cooler (at engine
connection:inlet
TIM-ID: 0000002872 - 002
from cooling
equipment)
content, max.
off-engine cooling
system, max.

Lube oil system
Number of cylin- 20 20 20 20 20 20
ders
temperature be-
fore engine, from
temperature be-
fore engine, to
Lube oil tempera- R °C 99 99 99 99 99 99
ture before en-
gine, warning
Lube oil tempera- L °C 101 101 101 101 101 101
ture before en-
gine, shutdown
pressure before
engine, from
pressure before
engine, to
Lube oil operating R bar -- -- -- -- -- --
pressure before
engine, warning
Lube oil operating L bar -- -- -- -- -- --
pressure before
engine, shutdown
Fuel system
Number of cylin- 20 20 20 20 20 20
ders
Fuel pressure at L bar -0.1 -0.1 -0.1 -0.1 -0.1 -0.1
engine inlet con-
nection, min.
(when engine is
starting)
Fuel pressure at L bar 1.5 1.5 1.5 1.5 1.5 1.5
engine inlet con-
nection, max.
(when engine is
starting)
TIM-ID: 0000002872 - 002

Number of cylin- 20 20 20 20 20 20
ders
Cold start capabil- R °C 10 10 10 10 10 10
ity: air tempera-
ture (w/o start
aid, w/o preheat-
ing) - (case A)
Coolant preheat- R °C 32 32 32 32 32 32
ing: preheating
temperature
(min.)
Firing speed, from R rpm 80 80 80 80 80 80
Firing speed, to R rpm 120 120 120 120 120 120
Capacities
Number of cylin- 20 20 20 20 20 20
ders
Engine coolant, R Liters 205* 205* 205* 205* 205* 205*
engine side (with-
out cooling equip-
ment)
Charge-air cool- R Liters 55* 55* 55* 55* 55* 55*
ant, engine side
Engine oil capaci- R Liters 390* 390* 390* 390* 390* 390*
ty, initial filling
(standard oil sys-
tem) (option:
max. operating in-
clinations)
Oil change quanti- R Liters
ty, max. (standard
oil system) (op-
tion: max. operat-
ing inclinations)
at dipstick mark
“min.” (standard
oil system) (op-
tion: max. operat-
ing inclinations)
TIM-ID: 0000002872 - 002
at dipstick mark
“max.” (standard
oil system) (op-
tion: max. operat-
ing inclinations)

Number of cylin- 20 20 20 20 20 20
ders
Engine weight, R kg 9640 9640 9640 9640 9640 9640
dry (basic engine
configuration acc.
to scope of sup-
ply specification)
Sound
Number of cylin- 20 20 20 20 20 20
ders
Exhaust noise, un- R dB(A) 131 134 130 131 136 136
silenced - BL
(sound power lev-
el LW, ISO 6798)
Engine surface R dB(A) 126 129 127 128 130 133
noise with attenu-
ated intake noise
(filter) - BL (sound
power level LW,
ISO 6798)
TIM-ID: 0000002872 - 002

3.6 20 V 4000 Gx3 engine data: Standby operation 3D, optimized
exhaust emissions (EPA stage 2)
Explanation
Abbr. Meaning
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
4000G43 4000G83 4000G83
L
Application group 3D 3D 3D
Fuel stop power ISO 3046 A kW 2740 3010 3490

TIM-ID: 0000002921 - 002


air cooling (CAC)

tion
Bore mm 170 170 170
Stroke mm 210 210 210
PTO)

Charge-air pressure before cylinder - BL R bar abs 3.1 3.3 3.6

cooling equipment)

TIM-ID: 0000002921 - 002


Lube oil system
Fuel system
engine is starting)
engine is starting)

Capacities
ment)
TIM-ID: 0000002921 - 002



Sound
Exhaust noise, unsilenced - BL (sound power level LW, R dB(A) 136 136 127
ISO 6798)
ter) - BL (sound power level LW, ISO 6798)
TIM-ID: 0000002921 - 002

3.7 Firing order
Firing order
Num- Firing order
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
TIM-ID: 0000002796 - 003

3.8 Engine – Main dimensions
Engine – Main dimensions
Length (A) approx. 3520 mm

Width (B) approx. 1620 mm
Height (C) approx. 2490 mm
TIM-ID: 0000002132 - 002

4 Operation
4.1 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Preservation and Represervation Specifications (A001070/..) are available.
Putting the PowerPack into operation after extended out-of-service-periods (>3

months)
Item Action
Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001070/..).
Valve gear Lubricate valve gear every ≥ 6 months (→ Page 129).
Lube oil system Check engine oil level (→ Page 155).
Fuel prefilter Fill with fuel (→ Page 147).
Fuel prefilter, pressure Align adjustable pointer with position of pressure indicator (→ Page 143).
gauge
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 165).
Change charge-air coolant (→ Page 173).
Coolant circuit Check engine coolant level (→ Page 164);
Check charge-air coolant level (→ Page 172).
Coolant circuit Heat engine coolant with coolant preheating unit.
Engine governor Check plug-in connections (→ Page 187).
Monitoring system Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch ON;
system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.
HP fuel pump Only for engines without oil priming pump
Fill HP fuel pump with new engine oil (→ Page 133).
TIM-ID: 0000002195 - 002
M015715/03E 2013-01 | Operation | 55

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

Item Task
Lube oil system Check oil level (→ Page 155);
Cooling system Check engine coolant level (→ Page 164);
Check charge-air coolant level (→ Page 172).
Cooling system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 144).
Monitoring equipment Carry out lamp test (see manufacturer's documentation).
Engine/generator control Switch ON;
system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.
TIM-ID: 0000002677 - 001
56 | Operation | M015715/03E 2013-01

4.3 Starting the engine in manual mode (test run)
Preconditions
☑ Generator (if fitted) is not connected to network.
☑ External start interlock is not active.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Action
Operating mode switch (if Change to manual mode.
fitted)
Preheating pump (if fitted) Switch on.
Starting the engine

Item Action
Switchgear cabinet, control If coolant temperature is
panel etc. (depending on • > 40 °C (with preheating system), or
manufacturer) • > 5 °C (without preheating system):
Press start button.
• Automatic starting sequence is performed;
• Engine speed display instrument indicates increasing speed;
• After the starting sequence is completed, engine is running at rated
speed.
Connecting the generator (if fitted) to network, engine warm-up procedure to

reach operating temperature
Item Action
Switchgear cabinet, control Close the generator circuit breaker.
panel etc. (depending on
manufacturer)
TIM-ID: 0000002226 - 003
Engine Apply full load only after engine has reached operating temperature (coolant
temperature approx. 75 °C).
M015715/03E 2013-01 | Operation | 57

4.4 Safety system – Override
CAUTION
Safety functions and engine shutdown alarms will be disregarded.
Serious damage to plant!
• Initiate emergency start only in emergency situations.
CAUTION
Inadmissible operational condition.
Major material damage!
• Use override function only in hazardous situations to ensure full capability in case of engine mal-
functions.
Preparation
Note: This function is only available when a pushbutton is provided.
Bypassing the safety system (Override)

Item Action
Switchgear cabinet, control Activate pushbutton for Override input of the ECU.
panel etc. (depending on • Certain shutdown criteria and/or starting prerequisites are ignored.
manufacturer)
Switchgear cabinet, control Actuate start button, for further starting sequence, refer to engine start
panel etc. (depending on (→ Page 57).
manufacturer)
Control and display panels During operation, check the displayed operational data (speed, temperature,
pressures).
Constantly monitor plant limit values.
TIM-ID: 0000000984 - 002
58 | Operation | M015715/03E 2013-01

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 complet-
ed.
Connecting the generator (if fitted) to mains

Item Task
Control cabinet If generator is not connected to mains: Close generator circuit breaker.
Engine Operate engine at rated power.
TIM-ID: 0000010665 - 001
M015715/03E 2013-01 | Operation | 59

4.6 Operational checks
DANGER
• Take special care when working on a running engine.
WARNING
Operational checks
Item Measure
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine oil Check engine oil level (→ Page 155)
Engine under load Check engine/plant and piping for leaks, repair leaky pipes with the engine
Engine at nominal speed stopped (exhaust lines and turbocharger turbine housings may be red-hot. If
the maximum exhaust temperatures are not exceeded, no restrictions in en-
gine operation are required)
Check for abnormal running noises and vibration.
Fuel prefilter Check reading on differential pressure gauge to ensure that maximum per-
missible value is not exceeded (→ Page 143).
Exhaust system Check exhaust color (→ Page 67).
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 149).
Air filter Check signal ring position of contamination indicator (→ Page 153).
Replace air filter (→ Page 150) if the signal ring is completely visible in the
contamination indicator control window.
Engine coolant pump Check relief bore (→ Page 170).
Charge-air coolant pump Check relief bore (→ Page 178).
Compressed-air system (if Check operating pressure on pressure gauge;
installed) Always fill compressed-air tank to max. pressure;
Drain condensate from compressed-air tank, pressure drop must not exceed
1 bar.
TIM-ID: 0000002258 - 003
60 | Operation | M015715/03E 2013-01

4.7 Stopping the engine in manual mode (test run)
Preconditions
☑ Generator (if fitted) is 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 a generator drive (only if generator circuit breaker is provided)

Item Action
Engine After the generator breaker (if provided) has been opened, allow the engine
to cool down by running it idle for approx. 5 minutes.
Preparing a pump drive (diesel-mechanical/diesel-electric)

Item Action
Engine Allow the engine to cool down by running it at reduced speed for approx. 5
minutes.Observe nthe natural frequencies (plant-specific values) of the en-
gine!
Stopping the engine

Item Action
Switchgear cabinet, control Press stop button.
panel etc. (depending on • Automatic stopping sequence is performed;
manufacturer) • Engine at a standstill.
After stopping the engine

Item Action
Coolant circulation pump Operate pump for a sufficient period of time after the engine was stopped.
TIM-ID: 0000002285 - 002
M015715/03E 2013-01 | Operation | 61

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 button 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 Press button for alarm acknowledgement.
panel etc. (depending on • Audible and visual signalization stops.
manufacturer)
TIM-ID: 0000002305 - 002
62 | Operation | M015715/03E 2013-01

4.9 After stopping the engine – Engine remains ready for
operation

Item Action
Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
control
TIM-ID: 0000000983 - 003
M015715/03E 2013-01 | Operation | 63

4.10 After stopping the engine – Putting the engine out of
operation
Preconditions
☑ MTU Preservation and Represervation Specifications (A001070/..) are available.

Item Action
Coolant circuit Drain engine coolant (→ Page 166);
Drain charge-air coolant (→ Page 174) if:
• freezing temperatures are to be expected and the engine is to remain out
of service for an extended period and if no antifreeze has been added to
the coolant;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera-
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Engine/generator/pump Switch off.
control
Air intake and exhaust sys- If the engine is to remain out of service for more than 1 week, seal the en-
tem gine's air and exhaust sides. If the engine is to remain out of service for more
than 1 month, carry out preservation (→ Preservation and Represervation
Specifications A001070/..).
TIM-ID: 0000002706 - 003
64 | Operation | M015715/03E 2013-01

4.11 Plant cleaning
Preconditions
☑ Operating voltage is not present.

Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
WARNING
Water jet.
Risk of injury and scalding!
• Do not direct water jet at persons.
• Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• Observe manufacturer's instructions.
NOTICE
Dry with compressed air.
• Never aim compressed air directly at electronic components.
Plant cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet
unit carefully and observe the safety precautions.
3. During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must
be observed. The temperature of the cleaning medium must not exceed 80 °C.
TIM-ID: 0000010171 - 024
4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable fashion.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
Note: Never aim compressed air directly at electronic components.
e) Dry engine.
M015715/03E 2013-01 | Operation | 65

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 155)
W0501 Visually inspect engine for leaks and general condition. (→ Page 60)
W0502 X Check intercooler drain(s). (→ Page 149)
W0503 Check signal ring position of service indicator on air filter. (→ Page 153)
W0505 Check relief bores of water pump(s). (→ Page 170)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 60)
and vibrations.
W0507 X Drain water and contaminants from fuel prefilter. (→ Page 60)
W0508 X Check reading on differential pressure gage of fuel prefil- (→ Page 60)
ter.
W0534 Carry out test run, minimum duration: until steady-state (→ Page 122)
temperature is reached, no less than 1/3 load (monthly).
W1001 Replace fuel filter or fuel filter element. (→ Page 141)
W1005 Replace air filter. (→ Page 150)
W1006 Replace fuel injectors. (→ Page 134)
W1008 Replace engine oil filter when changing engine oil, or when (→ Page 159)
the interval (years) is reached, at the latest.
W1009 X Check layer thickness of the oil residue, clean out and re- (→ Page 162)
place filter sleeve, at every engine oil change, at the lat-
est.
W1011 Perform endoscopic examination. (→ Page 123)
W1046 Crankcase breather: Replace filter or filter element. (→ Page 127)
W1207 Check valve clearance, adjust if necessary. ATTENTION! (→ Page 130)
First adjustment after 1,000 operating hours.
W1241 Check condition of belt drive and replace if necessary; ad- (→ Page 180)
just belt tension.
W1463 Check general condition of engine mounting (visual in- (→ Page 179)
TIM-ID: 0000026933 - 002
spection).
W1713 Injector: Reset drift correction (CDC) parameters. (→ Page 185)
W1714 X Check and clean oil indicator filter. (→ Page 160)
Table 1: Maintenance task reference table [QL1]
66 | Maintenance | M015715/03E 2013-01

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
documentation).
Cable connections defective Check if cable connections are properly
secured (see manufacturer's documen-
tation).
Starter (electric) Engine wiring or starter defective Check cable connections for secure
seating,
Contact Service.
Starter (compressed Cabling on starting valve or starter de- Check cable connections for secure
air) fective seating,
Contact Service.
Engine wiring Defective Check (→ Page 184).
Engine/generator Secure seating of assemblies or connec- Perform visual inspection (see manufac-
control system tors not provided turer's documentation).
Engine Governor Plug-in connections are loose Check plug connections (→ Page 187).
Engine Running gear blocked (engine cannot be Contact Service.
barred manually)
Engine turns but does not fire

Starter (electric) Poor rotation by starter: Battery low or Charge or replace battery (see manufac-
defective turer's documentation).
Starter (compressed Poor rotation by starter: Air pressure too Check compressed air system.
air) low
Fuel system Not vented Vent fuel system (→ Page 140).
Engine Governor Defective Contact Service.
Engine fires unevenly

TIM-ID: 0000002537 - 001
Fuel injection equip- Injector defective Replace (→ Page 134).

ment
M015715/03E 2013-01 | Troubleshooting | 67

Engine does not reach nominal speed
Fuel supply Fuel prefilter clogged Replace (→ Page 147).
Easy-change fuel filter clogged Replace (→ Page 141).
Air supply Air filter clogged Check signal ring position of service in-
dicator (→ Page 153).
ment
Engine Overloaded Contact Service.
Engine speed not steady

ment
Speed sensor Defective Contact Service.
Charge-air temperature too high

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

Intercooler Contaminated Contact Service.
Exhaust turbocharger Defective Contact Service.
Coolant leaks on intercooler

Intercooler Leaking, major coolant discharge Contact Service.
TIM-ID: 0000002537 - 001
Exhaust gas black

ment
Engine Overloaded Contact Service.
68 | Troubleshooting | M015715/03E 2013-01

Exhaust gas blue
Engine oil Too much engine oil in the engine Drain engine oil (→ Page 156).
Oil separator of crankcase breather con- Replace (→ Page 127).
taminated
Exhaust turbocharger, Defective Contact Service.
cylinder head, piston
rings, cylinder liner
Exhaust gas white

Engine Not at operating temperature Run engine to reach operating tempera-
ture.
Fuel system Water in fuel Check fuel system on fuel prefilter.
Drain fuel prefilter (→ Page 144).
Intercooler Leaking Contact Service.
TIM-ID: 0000002537 - 001

6.2 Fault messages on PAU display
The fault code numbers are generated by the engine governor and, depending on the relevant control
system, transmitted to the display.
The display is a two-line B/W-LCD for 16 ASCII characters per line and equipped with background illu-
mination.
The PAU provides four mini keys to control the display.
1 Display 3 Control key (move up in 5 Control key "ESC"

2 Control key "ENTER" the menu)
4 Control key (move down in
the menu)
Fault messages can also be caused by faulty sensors/actuators. Contact Service should troubleshoot-
ing as prescribed in the table below prove unsuccessful. Our Service will check sensors/actuators and
replace them if necessary.
If a yellow alarm occurs, locomotive operation can be continued. However, performance might be limit-
ed.
Remedial action must be taken within 24 hours.
TIM-ID: 0000016551 - 004
Not all fault codes are applicable depending on engine configuration and number of cylinders.
The following fault codes may appear on the display: (→ Page 71).

6.3 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
Limit value 2
Fuel temperature too high; u Contact Service.
Engine stop.
005 – HI T-Charge Air

Limit value 1
Charge-air temperature too high. 1. Reduce power.
2. Check intercooler.
006 – SS T-Charge Air

Limit value 2
Charge-air temperature too high 1. Reduce power.
Engine stop. 2. Check intercooler.
009 – HI T-Coolant Intercooler

Limit value 1
TIM-ID: 0000008506 - 003

Coolant temperature in u Reduce power.
intercooler too high.

010 – SS T-Coolant Intercooler
Limit value 2
Coolant temperature in u Reduce power.
intercooler too high; Engine
stop.
015 – LO P-Lube Oil

Limit value 1
Lube oil pressure too low. u Check oil level, top up as necessary (→ Page 155).
016 – SS P-Lube Oil

Limit value 2
Lube oil pressure too low; u Engine must not be started (risk of engine failure), contact
Automatic engine shutdown. Service.
019 – HI T-Exhaust A
Limit value 1
Exhaust gas temperature (A- 1. Check wiring (→ Page 184).
side) too high. 2. Contact Service.
020 – SS T-Exhaust A
Limit value 2
Exhaust gas temperature (A- 1. Check wiring (→ Page 184).
TIM-ID: 0000008506 - 003
side) too high; Engine stop. 2. Contact Service.
021 – HI T-Exhaust B
Limit value 1
Exhaust gas temperature (B- 1. Check wiring (→ Page 184).

022 – SS T-Exhaust B
Limit value 2
Exhaust gas temperature (B- 1. Check wiring (→ Page 184).
side) too high; Engine stop. 2. Contact Service.
023 – LO Coolant Level

Limit value 1
Coolant level too low. u Check coolant level in expansion tank(→ Page 164) .
025 – HI P-Diff. Lube Oil

Limit value 1
Oil filter differential pressure too u Replace oil filter (→ Page 159).
high.
026 – SS P-Diff. Lube Oil

Limit value 2
Oil filter differential pressure too u Replace oil filter (→ Page 159).
high.
027 – HI Level Leakage Fuel

Limit value 1
Leak-fuel level too high. 1. Check fuel system.
2. Contact Service.
TIM-ID: 0000008506 - 003
029 – HI ETC2 Idle Speed too High


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

030 – SS Engine Overspeed
Limit value 2
Reduced fuel injection. 1. Acknowledge alarm.
2. Attempt to restart engine.
031 – HI ETC1 Overspeed

Limit value 1
Speed of primary turbocharger u Contact Service.
too high.
032 – SS ETC1 Overspeed

Limit value 2
Speed of primary turbocharger 1. Automatic power reduction by engine control system.
too high. 2. Check air filters (→ Page 151).
33 – HI P-Diff Fuel
Limit value 1
Fuel filter differential pressure u Replace fuel filter (→ Page 141).
too high.
34 – SS P-Diff-Fuel
Limit value 2
Fuel filter differential pressure u Replace fuel filter (→ Page 141).
TIM-ID: 0000008506 - 003
too high.

Limit value 1
Speed of first secondary 1. Reduce power.
turbocharger too high. 2. Contact Service.

Limit value 2
Speed of first secondary 1. Reduce power.
turbocharger too high. 2. Contact Service.
038 – AL ETC Speed Deviation


Synchro fault between primary 1. Reduce power.
turbocharger and one of the 2. Contact Service.
secondary turbochargers.
039 – AL ETC2 Cutin Failure


Cut-in of turbocharger ETC 2 1. Reduce power.
failed. 2. Contact Service.
044 – LO Coolant Level Intercooler

Limit value 1
Intercooler coolant level too low. u Check coolant level (→ Page 172).
051 – HI T-Lube Oil

Limit value 1
Lube oil temperature too high. u Reduce power.
052 – SS T-Lube Oil

TIM-ID: 0000008506 - 003
Limit value 2
Lube oil temperature too high. 1. Reduce power.
Engine stop. 2. Check engine oil level (→ Page 155).

057 – LO P-Coolant
Limit value 1
Coolant pressure too low. u Check coolant circuit.
058 – SS P-Coolant
Limit value 2
Coolant pressure too low; 1. Automatic engine shutdown.
Engine stop or reduced fuel 2. Check coolant level (→ Page 164).
injection.
59 – SS T-Coolant L3
Limit value 3
Coolant temperature too 1. Allow engine to cool down.
high/low 2. Check engine coolant cooler, clean if dirty.
3. Contact Service.
60 – SS T-Coolant L4
Limit value 4
Coolant temperature too 1. Allow engine to cool down.
high/low 2. Check engine coolant cooler, clean if dirty.
3. Contact Service.
063 – HI P-Crank Case

Limit value 1
TIM-ID: 0000008506 - 003

Crankcase pressure too high. 1. Reduce power.
2. Replace oil separator element (→ Page 127).

064 – SS P-Crank Case
Limit value 2
Crankcase pressure too high; u Engine must not be started (risk of engine failure), contact
Automatic engine shutdown. Service.
065 – LO P-Fuel
Limit value 1
Fuel supply pressure too low. 1. Check fuel lines for leakage.
2. Clean fuel prefilter (→ Page 142).
3. Flush fuel prefilter (→ Page 145).
4. Replace filter element of fuel prefilter (→ Page 147).
5. Replace fuel filter (→ Page 141).
066 – SS P-Fuel
Limit value 2
Fuel supply pressure too low; 1. Check fuel lines for leakage.
Engine stop. 2. Clean fuel prefilter (→ Page 142).
3. Flush fuel prefilter (→ Page 145).
4. Replace filter element of fuel prefilter (→ Page 147).
5. Replace fuel filter (→ Page 141).
067 – HI T-Coolant
Limit value 1
Coolant temperature too high. u Reduce power.
068 – SS T-Coolant
TIM-ID: 0000008506 - 003
Limit value 2
Coolant temperature too high; 1. Allow engine to cool down.
Engine stop. 2. Check engine coolant cooler, clean if dirty.
3. Restart engine (→ Page 57).
4. Contact Service.

081 – AL Rail Leakage

Pressure gradient in rail is too u Contact Service.
low during starting or too high
during stopping; HP system
leaky, air in system.
082 – HI P-Fuel (Common Rail)


Rail pressure > set value; Speed- u Contact Service.
sensitive fuel limiter reduction,
start of injection moved towards
late; Suction restrictor of HP fuel
block jamming or HP fuel control
block wiring faulty.
083 – LO P-Fuel (Common Rail)


Rail pressure < set value; Speed- u Contact Service.
sensitive fuel limiter reduction;
Suction restrictor of HP fuel
control block faulty or leakage in
HP fuel system.
085 – HI T-Umblasen
Limit value 1
Recirculation temperature too u Reduce power.
high.
086 – HIHI T-Umblasen

TIM-ID: 0000008506 - 003
Limit value 2
Recirculation temperature too u Reduce power.
high.

089 – SS Engine Speed too Low

Engine speed too low. u Observe additional messages.
090 – SS Idle Speed Not Reached


Idling speed was not attained. u Contact Service.
091 – SS Release Speed Not Reached


Runup speed was not attained. u Contact Service.
092 – SS Starter Speed Not Reached


Starter speed was not attained; u Contact Service.
Termination of starting
sequence; Starter rotates too
slowly or does not rotate at all.
093 – SS T-Preheat
Limit value 2
Preheating temperature too low; u Check preheater.
Coolant temperature too low for
engine start; Engine start
interlock active.
094 – LO T-Preheat
TIM-ID: 0000008506 - 003
Limit value 1
Preheating temperature too low; u Check preheater.
Coolant temperature too low for
engine start.

095 – AL Prelubrication Fault

Oil priming fault. u Check oil priming system.
102 – AL Fuel Cons. Counter Defect


Consumption meter faulty. u Contact Service.
104 – AL Eng Hours Counter Defect


Hour meter faulty. u Contact Service.
118 – LO ECU Power Supply Voltage

Limit value 1
Supply voltage too low. 1. Check supply voltage of engine governor.
2. Contact Service.
119 – LOLO ECU Power Supply Voltage

Limit value 2
Supply voltage too low. 1. Check supply voltage of engine governor.
2. Contact Service.
120 – HI ECU Power Supply Voltage

Limit value 1
TIM-ID: 0000008506 - 003

Supply voltage too high. 1. Check supply voltage of engine governor.
2. Contact Service.

121 – HIHI ECU Power Supply Voltage
Limit value 2
Supply voltage too high. 1. Check supply voltage of engine governor.
2. Contact Service.
122 – HI T-ECU
Limit value 1
Electronic unit temperature too 1. Reduce power.
high. 2. Improve engine room ventilation.
141 – AL Power too high


Alarm is tripped when average u Reduce power.
power value has exceeded the
max. value defined in
PR1.1088.001 over the last 24
hours.
142 – AL MCR exceeded 1 hour


The MCR has been exceeded for u Reduce power.
more than 1 hour within the last
12 hours.
176 – AL LifeData not available


No (appropriate) LifeData u Contact Service.
TIM-ID: 0000008506 - 003
backup system available, ECU

reset after expiration of time-out
period.

177 – AL LifeData restore incomplete

This fault message is generated u Contact Service.
if a CRC is faulty during a data
upload to ADEC (indicated for
each individual module).
180 – AL CAN1 Node Lost


Connection to a node on CAN u Contact Service.
bus 1 failed.
181 – AL CAN2 Node Lost


Connection to a node on CAN u Contact Service.
bus 2 failed.
182 – AL CAN Wrong Parameters


Incorrect parameter values u Contact Service.
entered in data record.
183 – AL CAN No PU-Data


The selected CAN mode u Contact Service.
initializes communication by
means of the PU data module.
However, the required PU data
module is not available or not
valid.
TIM-ID: 0000008506 - 003
184 – AL CAN PU-Data Flash Error


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

186 – AL CAN1 Bus Off

CAN controller 1 is in "Bus-Off" 1. Check CAN bus for short circuit, rectify short circuit as
status. necessary.
2. Check shielding, improve shielding as necessary.
3. Contact Service.
187 – AL CAN1 Error Passive


CAN controller 1 has indicated a 1. Check CAN bus for short circuit, rectify short circuit as
warning. necessary.
3. Contact Service.
188 – AL CAN2 Bus Off


CAN controller 2 is in "Bus-Off" 1. Check CAN bus for short circuit, rectify short circuit as
status. => automatic changeover necessary.
to CAN 1. Short circuit, massive 2. Check shielding, improve shielding as necessary.
interference or Baud rate 3. Contact Service.
incompatibility.
189 – AL CAN2 Error Passive


CAN controller 2 has indicated a 1. Check CAN bus for short circuit, rectify short circuit as
warning. necessary.
3. Contact Service.
190 – AL EMU Parameter Not Supported


TIM-ID: 0000008506 - 003
EMU parameters are not u Contact Service.

supported.

201 – SD T-Coolant

Coolant temperature sensor u Check sensor and cabling (B6), replace as necessary. Error
faulty; Short circuit or wire cleared after restarting the engine.
break.
202 – SD T-Fuel

Fuel temperature sensor faulty; u Check sensor and wiring (B33), replace as necessary. Error
Short circuit or wire break. cleared after restarting the engine.
203 – SD T-Charge Air


Charge-air temperature sensor u Check sensor and cabling (B9), replace as necessary. Error
break.
204 – SD Level Lube Oil


Lube oil level sensor defective; u Check sensor and cabling, replace as necessary.
Short circuit or wire break.
205 – SD T-Coolant Intercooler


Intercooler coolant temperature u Check sensor and wiring (B26), replace as necessary. Error
sensor faulty; Short circuit or cleared after restarting the engine.
wire break.
206 – SD T-Exhaust A
TIM-ID: 0000008506 - 003

Exhaust temperature sensor on u Check sensor and cabling (B4.21), replace if necessary. Error
A-side faulty; Short circuit or cleared after restarting the engine.
wire break.

207 – SD T-Exhaust B

Exhaust temperature sensor on u Check sensor and cabling (B4.22), replace if necessary.
B-side faulty. Short circuit or
wire break
208 – SD P-Charge Air


Charge-air pressure sensor u Check sensor and cabling (B10), replace as necessary. Error
break.
211 – SD P-Lube Oil


Lube oil pressure sensor faulty; u Check sensor and cabling (B5), replace as necessary. Error
212 – SD P-Coolant

Coolant pressure sensor faulty; u Check sensor and cabling (B16), replace as necessary. Error
213 – SD P-Coolant Intercooler


Intercooler coolant pressure u Check sensor and cabling (B43), replace as necessary. Error
wire break.
214 – SD P-CrankCase
TIM-ID: 0000008506 - 003

Crankcase pressure sensor u Check sensor and cabling (B50), replace as necessary. Error
break.

215 – SD P-HD

Rail pressure sensor faulty; u Check sensor and cabling (B48), replace as necessary. Error
High-pressure regulator in cleared after restarting the engine.
emergency mode ==> Short
circuit or wire break.
216 – SD T-Lube Oil


Lube oil temperature sensor u Check sensor and cabling (B7), replace as necessary. Error
break.
219 – SD T-Intake Air


Intake air temperature sensor u Check sensor and cabling (B3), replace as necessary. Error
break.
220 – SD Level Coolant Water


Coolant level sensor faulty; u Check sensor and cabling (F33), replace as necessary. Error
221 – SD P-Diff Lube Oil


Lube oil pressure differential u Check sensor and cabling (F25), replace as necessary. Error
wire break.
TIM-ID: 0000008506 - 003
222 – SD Level Leakage Fuel


Leak-off fuel level sensor faulty; u Check sensor and cabling (F46), replace as necessary. Error

223 – SD Level Coolant Intercooler

Sensor for intercooler coolant u Check sensor and cabling (F57), replace as necessary. Error
level faulty; Short circuit or wire cleared after restarting the engine.
break.
227 – SD P-Lube Oil before Filter


Sensor for lube oil pressure u Check sensor and cabling (B5.3), replace as necessary. Error
before filter faulty; Short circuit cleared after restarting the engine.
or wire break.
228 – SD P-Fuel before Filter


Fuel pressure sensor faulty. u Check sensor and cabling (B5.3), replace as necessary.
Short circuit or wire break
229 – AL Stop Camshaft Sensor Defect


Engine stop due to camshaft u Check sensor and cabling to connector B1, replace as
sensor fault (and a previous necessary. Error cleared after restarting the engine.
crankshaft sensor fault in the
same operating cycle).
230 – SD Crankshaft Speed


Crankshaft sensor faulty; Short u Check sensor and cabling (B13), replace as necessary. Error
circuit or wire break. cleared after restarting the engine.
231 – SD Camshaft Speed

TIM-ID: 0000008506 - 003

Camshaft sensor faulty; Short u Check sensor and cabling (B13), replace as necessary. Error
circuit or wire break. cleared after restarting the engine.

232 – SD Charger 1 Speed

Speed sensor of primary u Check sensor and cabling (B44.1), replace as necessary. Error
turbocharger faulty; Short circuit cleared after restarting the engine.
or wire break.
233 – SD Charger 2 Speed


Speed sensor of secondary u Check sensor and cabling (B44.2), replace as necessary. Error
turbocharger faulty; Short circuit cleared after restarting the engine.
or wire break.
239 – SD P-Diff Fuel


Fuel differential pressure sensor u Observe additional message.
faulty.
This alarm occurs only in
combination with the alarm SD
P-Fuel before Filter or SD P-Fuel
after Filter.
240 – SD P-Fuel

Fuel pressure sensor faulty; u Check sensor and cabling (B34), replace as necessary. Error
241 – SD T-Umblasen

Recirculation sensor faulty; u Check sensor and cabling (B49), replace as necessary. Error
TIM-ID: 0000008506 - 003
242 – SD T-Coolant (R)


Redundant coolant pressure u Check sensor and cabling, replace as necessary. Error cleared
sensor faulty; Short circuit or after restarting the engine.
wire break.

244 – SD P-Lube Oil (R)

Redundant lube oil pressure u Check sensor and cabling, replace as necessary. Error cleared
sensor faulty; Short circuit or after restarting the engine.
wire break.
245 – SD ECU Power Supply Voltage


Internal ECU fault; Electronics u Replace engine governor.
faulty.
266 – SD Speed Demand


Analog speed setting faulty; 1. Check cabling.
Short circuit or wire break. 2. Check speed demand.
268 – SD Spinning Value


Analog wheel slip signal faulty; u Check sensor and cabling, replace as necessary.
Short circuit or wire break.
269 – SD Loadp.Analog filt.


Filtered analog signal of load u Check cabling, replace as necessary. Error cleared after
pulse missing; Short circuit or restarting the engine.
wire break.
270 – SD Frequency Input

TIM-ID: 0000008506 - 003

Frequency input faulty; Short 1. Check cabling.
circuit or wire break. 2. Check speed demand transmitter.
3. Contact Service.

301 – AL Timing Cylinder A1

Time-of-flight measuring fault of u Replace injector concerned if the fault message appears
injector: Time-of flight measured frequently (→ Page 134).
value extremely low or
extremely high.


extremely high.


extremely high.


extremely high.


TIM-ID: 0000008506 - 003
extremely high.


extremely high.


extremely high.


extremely high.


extremely high.


TIM-ID: 0000008506 - 003
extremely high.

311 – AL Timing Cylinder B1

extremely high.


extremely high.


extremely high.


extremely high.


TIM-ID: 0000008506 - 003
extremely high.


extremely high.


extremely high.


extremely high.


extremely high.


TIM-ID: 0000008506 - 003
extremely high.

321 – AL Wiring Cylinder A1

Short circuit in injector cabling 1. Check solenoid valve.
to cylinder. Result: Misfiring. 2. Contact Service.










TIM-ID: 0000008506 - 003









331 – AL Wiring Cylinder B1






TIM-ID: 0000008506 - 003















TIM-ID: 0000008506 - 003

341 – AL Open Load Cylinder A1


Open circuit in injector wiring to 1. Check solenoid valve.
cylinder. Result: Misfiring. 2. Contact Service.












TIM-ID: 0000008506 - 003







351 – AL Open Load Cylinder B1








TIM-ID: 0000008506 - 003













361 – AL Power Stage Low


TIM-ID: 0000008506 - 003
Internal electronic fault 1. Check solenoid valve cabling.

(electronics possibly faulty: start 2. Replace engine governor.
ITS).Check additional messages
if ITS indicates diagnosis
"Electronics OK" (e.g. cabling
faulty).

362 – AL Power Stage High

Internal electronic fault 1. Check solenoid valve cabling.
(electronics possibly faulty: start 2. Replace engine governor.
ITS).Check additional messages
if ITS indicates diagnosis
"Electronics OK" (e.g. cabling
faulty).
363 – AL Stop Power Stage


Internal electronic fault 1. Check cabling.
(electronics possibly faulty: start 2. Attempt to restart engine.
ITS).
365 – AL Stop MV-Wiring Ground


Injector cabling fault. If bit 1. Check cabling.
"1.1020.021" (Power Stage 2. Attempt to restart engine.
Failure: Stop engine) is set,
engine is additionally stopped in
this case.
• Short circuit of injector
positive connection to ground
of one or more injectors.
• Short circuit of the negative
injector connection or of one
or more injectors to ground.
371 – AL Wiring TO 1

Short circuit or wire break on 1. Check charger valve/cabling, repair as necessary.
transistor output 1 (TO 1). 2. Replace engine governor.
TIM-ID: 0000008506 - 003

Short circuit or wire break on 1. Check recirculation valve/cabling, repair as necessary.
transistor output 2 (TO 2). 2. Replace engine governor.


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

Short circuit or wire break on u-
transistor output 4 (TO 4).
381 – AL Wiring TOP 1


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


(TOP 2).


(TOP 3).

TIM-ID: 0000008506 - 003

(TOP 4).

390 – AL MCR exceeded

DBR/MCR function: MCR 1. No action required if alarm only applied temporarily.
exceeded. 2. Contact Service if alarm applied constantly.
392 – HI T-Coolant Red

Limit value 1
Redundant coolant temperature 1. Check cabling.
reading too high. 2. Contact Service.
393 – SS T-Coolant Red

Limit value 2
Redundant coolant temperature 1. Check cabling and sensor.
reading too high; Engine stop. 2. Contact Service.
394 – LO P-Lube Oil Red

Limit value 1
Redundant lube oil pressure 1. Check cabling and sensor.
reading too low. 2. Contact Service.
395 – SS P-Lube Oil Red

Limit value 2
Redundant lube oil pressure 1. Check cabling and sensor.
reading too low. 2. Contact Service.
TIM-ID: 0000008506 - 003
396 – TD T-Coolant Sensor Deviation


Maximum coolant temperature 1. Check cabling and sensor.
deviation. 2. Contact Service.

397 – TD P-Oil Sensor Deviation

Maximum lube oil pressure 1. Check cabling and sensor.
deviation. 2. Contact Service.
400 – AL Open Load Digital Input 1


Line disruption on digital input 1. Check cabling.
1; Cabling faulty or no 2. Check target device input.
resistance over switch. 3. Contact Service.







TIM-ID: 0000008506 - 003







408 – AL Open Load Emerg. Stop Input ESI


Line disruption on the input for 1. Check cabling.
emergency stop; Cabling faulty 2. Check target device input.
or no resistance over switch. 3. Contact Service.
410 – LO U-PDU
Limit value 1
Injector voltage too low. 1. Check cabling.
2. Check supply.
3. Contact Service.
TIM-ID: 0000008506 - 003
411 – LOLO U-PDU

Limit value 2
Injector voltage too low. 1. Check cabling.
2. Check supply.
3. Contact Service.

412 – HI U-PDU
Limit value 1
Injector voltage too high. 1. Check cabling.
2. Check supply.
3. Contact Service.
413 – HIHI U-PDU

Limit value 2
Injector voltage too high. 1. Check cabling.
2. Check supply.
3. Contact Service.
414 – HI Level Water Fuel Prefilter

Limit value 1
Water level in fuel prefilter too u Drain water (→ Page 144).
high.
415 – LO P-Coolant InterCooler

Limit value 1
Coolant pressure in intercooler u Top up coolant (→ Page 175).
too low.
416 – SS P-Coolant InterCooler

Limit value 2
TIM-ID: 0000008506 - 003

Coolant pressure in intercooler u Top up coolant (→ Page 175).
too low; Engine stop.

417 – SD Level Water Fuel Prefilter

Sensor for water level in fuel u Check sensor and cabling, replace as necessary. Error cleared
prefilter faulty; Short circuit or after restarting the engine.
wire break.
419 – SD T-Coolant b.Engine


Coolant inlet temperature u Check sensor and cabling (B3), replace as necessary.
sensor faulty; Short circuit or
wire break.
420 – AL L1 Aux 1
Limit value 1
Input signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded/not attained limit
value 1, depending on
configuration.
421 – AL L2 Aux 1
Limit value 2
Input signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded/not attained limit
configuration.
428 – AL L1 T-Aux 1
Limit value 1
TIM-ID: 0000008506 - 003

Temperature signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
exceeded / not attained limit
configuration.

430 – LO P-Coolant before Engine
Limit value 1
431 – SS P-Coolant before Engine

Limit value 2
434 – HI T-Coolant before Engine

Limit value 1
Coolant temperature too high. u Check coolant circuit.
435 – SS T-Coolant before Engine

Limit value 2
Coolant temperature too high. u Check coolant circuit.
440 – AL L1 P-Aux 1
Limit value 1
Pressure signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
configuration.
TIM-ID: 0000008506 - 003
442 – AL L2 P-Aux 1
Limit value 2
Pressure signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
configuration.

444 – SD U-PDU

Injector power stage sensor u Replace engine governor.
defect; Internal fault in ECU.
445 – SD P-Ambient Air


Ambient air pressure sensor u Replace engine governor.
faulty.
448 – HI P-Charge Air

Limit value 1
Charge-air pressure too high. u Contact Service.
449 – SS P-Charge Air

Limit value 2
Charge-air pressure too high. u Contact Service.
450 – SD Idle/End-Torque Input [%]


Input signal for initial/final u Check signal transmitter and cabling, replace as necessary.
torque faulty; Short circuit or Error cleared after restarting the engine.
wire break.
454 – SS Power Reduction Active

TIM-ID: 0000008506 - 003

Power reduction is active. 1. Note further fault messages.
2. Determine cause of power reduction and rectify fault.

455 – AL L1 Aux1 Plant
Limit value 1
Input signal of Aux 1 (plant side) u Determine cause of limit value violation and rectify fault.
has exceeded/not attained limit
configuration.
456 – AL L2 Aux1 Plant

Limit value 2
Input signal of Aux 1 (plant side) u Determine cause of limit value violation and rectify fault.
has exceeded/not attained limit
configuration.
460 – HI T-Exhaust EMU

Limit value 1
EMU exhaust gas temperature 1. Check cabling.
value too high. 2. Contact Service.
461 – LO T-Exhaust EMU

Limit value 1
EMU exhaust gas temperature 1. Check cabling.
value too low. 2. Contact Service.
462 – HI T-Coolant EMU

TIM-ID: 0000008506 - 003
Limit value 1
EMU coolant temperature value u Check configuration with DiaSys.
too high / low.

464 – SD P-AUX 1

Analog input signal for Aux 1 u Check pressure transmitter and cabling, replace as necessary.
pressure faulty; Short circuit or Error cleared after restarting the engine.
wire break.
467 – AL L2 T-Aux 1
Limit value 2
Temperature signal of Aux 1 has u Determine cause of limit value violation and rectify fault.
configuration.
468 – SD T-AUX 1

Analog input for Aux 1 u Replace engine governor.
temperature faulty.
469 – SD AUX 1

Analog input signal for Aux 1 u Check signal transmitter and cabling, replace as necessary.
faulty; Short circuit or wire Error cleared after restarting the engine.
break.
470 – SD T-ECU

Temperature sensor for ECU u Check sensor and cabling, replace as necessary. Error cleared
faulty; Short circuit or wire after restarting the engine.
break.
TIM-ID: 0000008506 - 003
471 – SD Coil Current


Control of HP fuel control block u Check sensor and cabling, replace as necessary. Error cleared
faulty; Short circuit or wire after restarting the engine.
break.

472 – AL Stop SD

Engine stop, since all shutdown 1. Check cabling.
channels have "sensor faulty". 2. Contact Service.
473 – AL Wiring PWM_CM2


Cable break or short circuit on 1. Check cabling.
channel PWM_CM2. 2. Contact Service.
474 – AL Wiring FO

Cable break or short circuit on 1. Check cabling.
channel FO. 2. Contact Service.
475 – AL CR Trigger Engine Stop


Tripped by crash recorder u Determine and rectify cause of triggering / engine shutdown.
triggering due to engine
shutdown.
476 – AL Crash Rec. Init. Error


Initialization error of crash u Check settings with DiaSys.
recorder.
478 – AL Comb. Alarm Yel (Plant)

TIM-ID: 0000008506 - 003

Combined alarm YELLOW from u Check additional messages.
plant.
479 – AL Comb. Alarm Red (Plant)


Combined alarm RED from plant. u Check additional messages.

480 – AL Ext. Engine Protection

External engine protection u Monitoring of plant signal by ECU active (plant side). Check
function active. plant signal.
482 – SD T-Exhaust C

A side faulty. Short circuit or
wire break
483 – SD T-Exhaust D

A side faulty. Short circuit or
wire break
484 – HI T-Exhaust C
Limit value 1

Exhaust gas temperature (C- 1. Reduce power.
485 – SS T-Exhaust C
Limit value 2
Exhaust gas temperature (C- 1. Reduce power.
TIM-ID: 0000008506 - 003
486 – HI T-Exhaust D
Limit value 1
Exhaust gas temperature (D- 1. Reduce power.

487 – SS T-Exhaust D
Limit value 2
Exhaust gas temperature (D- 1. Reduce power.

Limit value 1
Speed of second secondary u Reduce power.
turbocharger too high.

Limit value 2
Speed of second secondary u Reduce power.

Limit value 1
Speed of the 3rd secondary u Reduce power.

Limit value 2
Speed of the 3rd secondary u Reduce power.
TIM-ID: 0000008506 - 003


ETC4 failed to cut in. u Check control valve at turbocharger 4.


ETC3 failed to cut in. u Check control valve at turbocharger 3.
500 – AL Wiring POM Starter 1


A cabling fault in connection of u Check connection between POM and starter.
starter 1 of CPM has been
detected. This may be due to a
missing consumer, wire break or
a short circuit.
501 – AL Wiring POM Starter 2


A cabling fault in connection of u Check connection between POM and starter.
starter 2 of CPM has been
detected. This may be due to a
missing consumer, wire break or
a short circuit.
502 – AL Open Load POM Alternator


A line interruption was detected u Check connection between POM and battery-charging
at the battery-charging generator.
connection for the POM.
503 – AL Battery Not Charging


Battery is not charged by u Check battery-charging generator and cabling.
battery-charging generator.
TIM-ID: 0000008506 - 003
504 – AL CAN POM Node Lost


POM missing on CAN bus. u Check connection and POM.

506 – AL Low Starter Voltage

The battery voltage is too low for u Check starter battery and cabling.
the starting process.
507 – AL POM Error


A general POM fault occurred. u Replace POM.
508 – AL Wrong POM-ID


POM sends a different ID u Check POM wiring harness.
number than expected.
510 – AL Override applied


Override was activated. u Deactivate Override pushbutton again.
515 – AL Starter Not Engaged


Starter on CPM / POM could 1. Repeat starting attempt
not be engaged. If the number of 2. Check CPM, starter and cabling.
automatic start attempts from
PR 2.1090.134 Number of Start
Attempts is used up then start is
canceled. Check CPM, starter
and cabling.
519 – Oillevel Calibration Error

TIM-ID: 0000008506 - 003

Error writing calibration value 1. Check sensor and cabling, replace as necessary.
into flash or SD of level sensor. 2. Contact Service.

521 – SS P-Lube Oil Mid Val
Limit value 1
Average oil pressure value from u Check oil level, top up as necessary.
three sources is too low.
523 – SS T-Coolant Red Mid Val

Limit value 2
Average coolant temperature u Reduce power.
value from three sources is too
high.
524 – SS Engine Overspeed Mid Val

Limit value 2
Average engine overspeed value 1. Acknowledge alarm.
from three sources is too high. 2. Attempt to restart engine.
525 – SD P-Lube Oil (R2)


Redundant lube-oil pressure u Check sensor and cabling, replace as necessary.
sensor faulty. Short circuit or
wire break
526 – SD T-Coolant (R2)


Redundant coolant pressure u Check sensor and cabling, replace as necessary.
sensor faulty. Short circuit or
TIM-ID: 0000008506 - 003
wire break
527 – TD EngineSpd. Sensor Deviation


Maximum deviation of speed 1. Check speed sensor cabling.
sensors 2. Observe additional messages.
3. Contact Service.

528 – SD Engine Speed 3rd Sensor

Redundant crankshaft speed u Check sensor and cabling, replace as necessary.
sensor faulty; Short circuit or
wire break.
529 – SS T-Coolant Red2

Limit value 2
Second redundant coolant u Check coolant circuit.
temperature too high.
530 – SS P-Lube Oil Red2

Limit value 2
Second redundant lube-oil u Check oil level, top up as necessary.
pressure too high.
543 – AL Multiple FDH Slaves


There is more than one device u Contact Service.
activated as backup medium for
FDH.
544 – AL Configuration Changed


This alarm is activated when the u Fault remains active until changes are revoked or data have
system configuration was been transferred by active maintenance. Fault is then
changed, e.g. because the ECU automatically cleared.
TIM-ID: 0000008506 - 003
or SAM was exchanged.

549 – AL Power Cut-Off detected
This is an alarm from the emergency stop counter function.
ECU operating voltage was u Instruct operators to switch off the power supply only after the
switched off while the engine engine has come to a standstill.
was running. This can result in
overpressure in the high-
pressure system, whereby the
engine may be damaged.
550 – SS Engine Overspeed Red2

Limit value 2
Redundant engine overspeed. 1. Acknowledge alarm.
551 – SS Engine Overspeed Camshaft

Limit value 2
Camshaft overspeed. 1. Acknowledge alarm.
555 – AL Call MTU Field Service


This fault becomes active if a u Request enabling code via internet.
maintenance case has been
processed by the ECU Field Data
Handling (FDH) feature that
results in a change of engine
parameters.
This fault remains active even
after switching off and back on
TIM-ID: 0000008506 - 003
until a valid enabling code is

entered via the SAM display and
key controls.This enabling code
can be requested via the
internet using a special
procedure.

576 – AL ESCM Override

Violation of corrected MCR or u Reduce power.
DBR/MCR curve. Engine
overload!
577 – SD T-Lube Oil Pan


Oil pan temperature sensor u Check sensor and cabling, replace as necessary.
faulty. Short circuit or wire
break
578 – AL L1 T-Lube Oil Pan

Limit value 1
L1 T-Lube oil in oil pan violated u-
limit 1.
579 – AL MD CAN Request Idle Speed


MD forced idle demand => node u-
failure (node 3, 4 or 5)
580 – AL MD CAN Speed Limitation


MD speed limitation demand => u-
node failure (node 3, 4 or 5)
581 – AL MD CAN Stop

TIM-ID: 0000008506 - 003

MD CAN stop demand => node u-
failure (node 3 4 or 5)

7 Task Description
7.1 Engine
7.1.1 Engine – Barring manually
Preconditions

Barring device F6555766 1
Ratchet with extension F30006212 1
DANGER
Risk of serious injury – Danger to life!
• Before barring the engine, ensure that nobody is in the danger zone.
Engine – Barring manually

1. Remove guard plate.
2. Engage barring device (2) with ring gear (3)
and install on flywheel housing.
3. Place ratchet (1) onto barring device (2).
4. Rotate crankshaft in engine direction of ro-
tation. Apart from the normal compression
resistance, there should be no further re-
sistance.
5. For barring device removal, follow reverse
sequence of working steps.
TIM-ID: 0000000917 - 008
120 | Task Description | M015715/03E 2013-01

7.1.2 Engine – Barring with starting system
DANGER
• Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
Engine – Barring with starting system

1. Release latch of connector X4.
2. Remove connector from engine governor.
3. Bar engine in unloaded condition: Press START button.
4. Let the crankshaft rotate until oil pressure is indicated.
5. Engine start is automatically interrupted when specified starting period has passed. If necessary, re-
start the engine after approx. 20 seconds.
6. Connect connector X4 to engine governor and latch in position.
TIM-ID: 0000000918 - 004
M015715/03E 2013-01 | Task Description | 121

7.1.3 Engine – Test run
DANGER
WARNING
Engine – Test run

1. Start engine (→ Page 57).
2. Perform test run not below 1/3 load and at least until steady-state temperature is reached.
3. Carry out operational checks (→ Page 60).
4. Stop engine (→ Page 61).
TIM-ID: 0000000870 - 007

7.2 Cylinder Liner
7.2.1 Cylinder liner – Endoscopic examination
Preconditions
☑ Engine is stopped and starting disabled

Barring device F6555766 1
Ratchet with extension F30006212 1
Endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 132).
2. Remove injector (→ Page 135).
Positioning crankshaft at BDC

1. Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached
BDC.
2. Insert endoscope into cylinder liner through injector seat.
Cylinder liner endoscopic examination

Findings Measure
• Thin carbon coating on carbon scraper ring No action required.
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits on entire circumference between top piston ring and
bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark on entire circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Dark areas with even or varying degrees of discoloration Further endoscopic examina-
• Beginning and end of the discoloration are not sharply defined and do tion required as part of mainte-
not cover the entire stroke area nance work.
• Dark areas in the upper section of the cooling bore, remaining circum-
ference cannot be faulted
• Piston rings cannot be faulted
TIM-ID: 0000003304 - 004
• On the entire circumference, apart from light areas of discoloration (do Cylinder liner must be replaced;
not impair operation) clearly darker stripes that start at the top piston Service must be contacted.
ring
• Heat discoloration in the direction of stroke and honing pattern dam-
age
• Heat discoloration of piston rings

1. Compile endoscopy report using the table.
2. Use technical terms for description of the liner surface (→ Page 125).
3. Depending on findings:
• Do not take any action or
• carry out a further endoscopic examination as part of maintenance work or
• contact Service; cylinder liner must be replaced.
Final steps
1. Install injector (→ Page 135).
2. Install cylinder head cover (→ Page 132).
TIM-ID: 0000003304 - 004

7.2.2 Instructions and comments on endoscopic and visual examination of cylinder
liners
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex-
amination report.
Findings Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
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usually discolored. The circumferential length varies.

Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.

Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough
investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To
avoid unnecessary disassembly work, it is recommended that another inspection be carried out after
further operation of the engine.
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7.3 Crankcase Breather
7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and
replacement
Preconditions

Ratchet F30027340 1
Engine oil
Filter element (→ Spare Parts Catalog)
Diaphragm (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Avoid contact with skin.
• Do not inhale oil vapor.
Replacing oil separator element

1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from housing (4).
3. Insert new filter element in housing (4).
4. Install cover (2) with new O-ring.
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5. Use torque wrench to tighten the screws of cover (2) to the specified torque.
Screw Tightening torque (Engine oil) 10 Nm −2 Nm
6. Replace further oil separator elements in the same way.

Checking diaphragm
1. Remove cover (4).
2. Remove spring (5), gasket (2) and dia-
phragm (3).
3. Check diaphragm (3) for damage, fit new
diaphragm if used one is damaged.
4. Install diaphragm (3) on housing (1).
5. Install new seal (2) and spring (5) together
with cover (4).
6. Use torque wrench to tighten the screws of cover (4) to the specified torque.
Screw Tightening torque (Engine oil) 10 Nm −2 Nm
7. Check diaphragms in further oil separators in the same way.
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7.4 Valve Drive
7.4.1 Valve gear – Lubrication
Preconditions

Engine oil
Valve gear – Lubrication

1. Remove cylinder head covers
(→ Page 132).
2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjust-
ing screws with oil.
4. Install cylinder head covers (→ Page 132).
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7.4.2 Valve clearance – Check and adjustment
Preconditions
☑ Engine shut down and starting disabled.
☑ Engine coolant temperature is max. 40°C.
☑ Valves are closed.

Feeler gauge Y20098771 1
Torque wrench, 60-320Nm F30452768 1
Box wrench socket, 24mm F30039526 1
Ratchet adapter F30027341 1
Engine oil
Preparatory steps
2. Install barring device (→ Page 120).
Note: The TDC marking (if fitted) on the flywheel
must not be used.
3. Rotate crankshaft with barring device in di-
rection of engine rotation until TDC-A1
marking and pointer are aligned.
Checking valve clearance at two crankshaft positions

1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
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• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance adjustment with cold engine:
• Inlet (long rocker arm) = 0.2 ±0.05mm
• Exhaust (short rocker arm) = 0.5 ±0.05mm
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as
per diagram:

1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the set value exceeds 0.1mm, adjust valve clearance.
Adjusting valve clearance

1. Release locknut (1).
2. Insert feeler gauge (3) between valve
bridge and rocker arm.
3. Use Allen key to set adjusting screw (2) so
that the specified valve clearance is estab-
lished.
4. Feeler gauge (3) must just pass through
the gap.
5. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting
screw (2) to prevent it from turning.
Locknut M16 x 1.5 Tightening torque (Engine oil) 90Nm +9Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
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7. Check valve clearance.
Final steps
1. Remove barring device (→ Page 120).

7.4.3 Cylinder head cover – Removal and installation
Preconditions

Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
O-ring (→ Spare Parts Catalog)
Removing cylinder head cover

1. Clean very dirty cylinder head covers (1)
prior to removal.
2. Remove screws (3, 4,) with washers (2, 5).
3. Take off cylinder head cover (1) with O-
ring (6) from cylinder head (7).
Installing cylinder head cover

1. Clean mounting surface.
2. Check O-ring (6) for damage, replace if necessary.
3. Coat O-ring (6) with grease.
4. Position O-ring (6) in groove of cylinder head cover (1).
5. Fit cylinder head cover (1) on cylinder head (7).
6. Install cylinder head cover (1) with screws (3, 4) and washers (2, 5).
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7.5 Injection Pump / HP Pump
7.5.1 HP pump – Filling with engine oil
Preconditions

Engine oil
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Oils/oil vapors are combustible/explosive.
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.
CAUTION
Fuel system high-pressure pump not filled with engine oil.
Damage to components, major material damage!
• Make sure that the high-pressure fuel pump is filled with engine oil before installation or initial
operation.
Filling HP pump
1. Remove plug screw (1).
2. Use pump oiler to fill HP pump with engine
oil until engine oil emerges.
3. Insert plug screw (1).
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7.6 Injection Valve / Injector
7.6.1 Injector – Replacement
Injector (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new injector (→ Page 135).
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7.6.2 Injector – Removal and installation
Preconditions

Installation/removal tool F6789889 1
Milling cutter F30452739 1
Torque wrench, 0.5-5 Nm 0015384230 1
Assembly paste (Optimoly Paste White T) 40477 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil
WARNING
• Do not smoke.
Preparatory steps
1. Shut off fuel supply to engine.
Removing injector
1. Disconnect cable connector on injector.
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2. Remove HP fuel line (4).
3. Remove return line (5).
Note: The injector accumulator will be emptied
when removing the adapter.
4. Remove adapter (3).
5. Remove screw (2) and take off hold-down
clamp (1).
6. Install installation/removal tool on cylinder

head.
7. Remove injector with installation/removal
tool.
8. Remove installation/removal tool.
9. Remove sealing ring (4) from injector or

use a self-made hook to take it out of the
cylinder head.
10. Remove O-rings (3), O-ring (2) and damper
ring (1) from injector.
11. Clean all mating and sealing surfaces.
12. Cover all connections and bores, or seal
with suitable plugs.
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Installing injector
1. Remove plug before installing the injector.
(Do not remove the plug from the HP line
before installing the adapter.)
2. Coat injector with assembly paste at the
seat of the nozzle clamping nut.
3. Fit new sealing ring (4) (included in the
scope of supply of the injector) with grease
on injector, observe installation position of
sealing ring (4).
4. Fit new O-rings (3) (included in the scope

of supply of the injector), O-ring (2) and
damping ring (1) onto the injector and coat
with grease.
5. Clean sealing face on cylinder head and
protective sleeve with milling cutter.
6. Insert injector into cylinder head, ensuring
that the HP line adapter is correctly
aligned.
7. Use installation/removal tool to press in in-

jector.
8. Remove installation/removal tool.
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9. Coat screw head mating face (2) and
thread with engine oil.
10. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the speci-
fied initial tightening torque.
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
Note: Ensure special cleanness.
11. Coat thread and sealing cone of adapter (3) with engine oil.
12. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
Adapter Preload torque (Engine oil) 5 Nm to 10 Nm
Screw M12 Tightening torque 100 Nm + 10 Nm
14. Tighten adapter (3) with torque wrench to the specified tightening torque.
Adapter Tightening torque 100 Nm + 10 Nm
15. Install return line (7).
Note: Ensure special cleanness.
16. Coat thread and sealing cone of HP line (5) with engine oil.
Note: Two HP line versions (single- and double-walled) with different torques as described below.
17. Mount single-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening
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sequence:
1 Rail (6)
2 Adapter (4)
Union nut / thrust Tightening torque 30 Nm + 5 Nm
screw

18. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening
sequence:
1 Adapter (4)
2 Rail (6)
Union nut / thrust Tightening torque 40 Nm + 5 Nm
screw
19. Fit cable connector onto injector.
Note: If the CDC parameters are not reset, the
exhaust emissions certification of the en-
gine will become null and void.
20. Reset CDC parameters (→ Page 185).
Final steps
2. Open fuel supply to engine.
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7.7 Fuel System
7.7.1 Fuel system – Venting
Preconditions

Diesel fuel
WARNING
• Do not smoke.
Venting LP fuel system

1. Open vent plug (1).
2. Unlock fuel priming pump (2), screw out
handle by turning it counterclockwise.
3. Operate the pump with the handle (2) until
bubble-free fuel emerges from the vent
plug (1).
4. Close vent plug (1).
5. Screw in handle by turning it clockwise.
6. Verify that fuel priming pump (2) is locked:
handle must be tightened.
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7.8 Fuel Filter
7.8.1 Fuel filter – Replacement
Preconditions

Filter wrench F30379104 1
Engine oil
Easy-change filter (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Fuel filter – Replacement

1. Remove easy-change filter using the filter
wrench.
2. Clean sealing surface on filter head.
3. Slightly lubricate seal on the easy-change
filter (arrow).
4. Screw on the easy-change filter by hand
until the seal makes contact and tighten
finger-tight.
5. Replace further easy-change filters in the
same way.
6. Vent fuel system (→ Page 140).
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7.8.2 Fuel prefilter cleaning
Preconditions

Diesel fuel
Sealing ring (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Fuel prefilter cleaning

1. Shut off fuel supply.
2. Remove nuts from filter head.
3. Take off filter housing and drain fuel into
appropriate container.
4. Remove filter-element securing nut and re-
move filter element by pulling it down-
wards.
5. Wash filter element in clean fuel using a
smooth brush.
6. Wash filter housing with clean fuel.
7. Insert filter element into filter housing and
secure with nut.
8. Place new sealing ring into groove in filter
head.
9. Fit cover with seal and secure it with nuts
crosswise.
10. Open fuel supply.
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7.8.3 Fuel prefilter – Differential pressure gauge check and adjustment
DANGER
WARNING
Adjusting differential pressure

gauge
1. When installing the new filter element:
align adjustable pointer (2) with pressure-
indicating pointer (3) of pressure gauge (1).
2. Check differential pressure.
Checking differential pressure of fuel prefilter

1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating
pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 145).
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7.8.4 Fuel prefilter – Draining
Preconditions

Diesel fuel
WARNING
• Do not smoke.
Fuel prefilter – Draining

1. Cut out filter to be drained.
1 Left filter cut in
2 Right filter cut in
2. Open threaded vent plug (5) of filter to be

drained.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and contaminants from filter
until pure fuel emerges.
5. Close drain valve (6).
6. Remove screws for cover and take off cov-
er (2).
7. Fill filter housing with clean fuel.
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8. Place new gasket in cover (2).

9. Fit cover with gasket and secure it with
screws.
10. Cut in the cut-out filter again.
11. Close threaded vent plug (5) when fuel
emerges.

7.8.5 Fuel prefilter – Flushing
Fuel
DANGER
WARNING
• Do not smoke.
WARNING
Fuel prefilter ‒ Flushing

1. Cut out clogged filter.
I Left filter cut in
II Right filter cut in
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2. Open threaded vent plug (5) of filter to be
flushed.
3. Unlock drain valve (6) by pressing valve
toggle, open it and drain fuel.
Result: Fuel flows from filtered side back to the un-
filtered side, flushing the filter deposits
downwards out of the filter.
4. Close threaded vent plug (5) and drain
valve (6).
Fuel prefilter – Topping up with fuel

1. Stop engine (→ Page 61) and disable engine start.
2. Remove screws for cover and take off cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 143).
Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel pre-
filter (→ Page 147).
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7.8.6 Fuel prefilter – Filter element replacement
Preconditions

Diesel fuel
Filter element (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Replacing filter element

1. Cut out filter to be drained.
I Left filter cut in
II Right filter cut in
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2. Open threaded vent plug (5) of contaminat-
ed filter.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and dirt from filter.
6. Remove screws securing the cover and
take off cover (2).
7. Remove spring housing (4) and filter ele-
ment (3).
8. Insert new filter element (3) and spring
housing (4).
11. Fit cover with gasket and secure it with
screws.
12. Cut in the cut-out filter again.
13. Close threaded vent plug (5) when fuel
emerges.
14. Adjust the differential pressure gauge
(→ Page 143).
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7.9 Charge-Air Cooling
7.9.1 Intercooler – Checking condensate drain for coolant discharge and obstructions
DANGER
WARNING
WARNING
Compressed air
Risk of injury!
Intercooler – Checking conden-

sate drain for coolant discharge
and obstructions
1. With the engine running, check that air
blows out of the condensate drain hole(s)
on the left and right sides of the engine at
the main PTO end. If no air blows out:
• Clean condensate drain hole(s)
• Blow through with compressed air
2. If a large amount of coolant is continuously
discharged, the intercooler is leaking; con-
tact Service.
Emergency measures prior to starting engine with a leaking intercooler

1. Remove injectors (→ Page 135).
2. Crank engine manually (→ Page 120).
3. Crank engine using starting system to blow combustion chambers clear(→ Page 121).
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4. Refit injectors (→ Page 135).

7.10 Air Filter
7.10.1 Air filter – Replacement
Air filter (→ Spare Parts Catalog)
Air filter – Replacement

1. Remove air filter and install new one (→ Page 152).
2. Reset signal ring of service indicator (→ Page 153).
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7.10.2 Air filter – Check
Air filter (→ Spare Parts Catalog)
Checking air filter

1. Check entire circumference of air filter for damage.
2. Fit new air filter if damaged (→ Page 152).
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7.10.3 Air filter – Removal and installation
Preconditions

Torque wrench, 4-20Nm F30044239 1
Removing and installing air fil-

ter
1. Release clamp (2).
2. Remove air filter (1) and clamp (2) from
connecting flange of intake housing (3).
3. Verify that there are no objects in the con-
necting flange of the intake housing (3) and
clean it.
4. Place new air filter (1) with clamp (2) onto
intake housing (3).
5. Tighten screw on clamp (2) with torque wrench to the specified tightening torque.
Screw - Tightening torque 5Nm
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7.11 Air Intake
7.11.1 Service indicator – Signal ring position check (optional)
Preconditions
Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 150).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves
back to initial position.
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7.12 Starting Equipment
7.12.1 Air starter – Manual operation
DANGER
WARNING
Air starter – Manual operation

1. Press pushbutton for manual start and hold
it.
2. Allow compressed air to enter the air start-
er, until the engine fires evenly.
3. Release pushbutton.
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7.13 Lube Oil System, Lube Oil Circuit
7.13.1 Engine oil – Level check
Preconditions
Checking oil level prior to en-

gine start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to
stop, withdraw after approx. 10 seconds
and check oil level.
Note: After extended standstill, the oil level may
exceed the mark (1) by up to 2 cm. This
can be caused by oil flowing from e.g. oil
filter or heat exchanger back to the oil pan.
3. The oil level must reach mark (1) or exceed
mark (1) by up to 2 cm.
4. Top up with oil to mark (1) as necessary
(→ Page 156).
5. Insert oil dipstick into guide tube up to the
stop.
Checking oil level after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert oil dipstick into guide tube up to stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between marks (1) and (2).
4. Top up with oil to mark (1) as necessary (→ Page 156).
5. Insert oil dipstick into guide tube up to the stop.
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7.13.2 Engine oil – Change
Preconditions
☑ Engine is at operating temperature.
☑ MTU fluids and lubricants specifications (A001061/..) are available.

Ratchet F30027341 1
Engine oil
WARNING
Hot oil.
Version without semirotary hand pump: Drain the engine oil through the
drain plug(s) on the oil pan.
1. Provide a suitable container in which to collect the engine oil.
2. Remove drain plug(s) and drain engine oil.
3. Install drain plug(s) with new sealing ring.
Version with semirotary hand pump: Extracting the engine oil

1. Provide a suitable container in which to collect the engine oil.
2. Extract all engine oil from oil pan using the semirotary hand pump.
Draining residual oil from equip-

ment carrier (only with unsched-
uled engine oil change)
1. Provide a suitable container in which to
collect the engine oil.
2. Remove drain plug (1) and drain engine oil
from engine oil heat exchanger and from
engine oil filter.
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3. Remove drain plugs (2) and (3) and drain

engine oil.
4. Replace engine oil filter (→ Page 159).
5. Install drain plug(s) with new sealing ring.

6. Tighten drain (2) and (3) with torque wrench to specified tightening torque.
Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm
Filling with new engine oil

1. Open cover on filler neck.
2. Pour engine oil through the filler neck up to
the "max." mark on the oil dipstick.
3. Close cover on filler neck.
4. Check engine oil level (→ Page 155).
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7.13.3 Engine oil – Sample extraction and analysis
Preconditions
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

MTU test kit 5605892099/00 1
DANGER
WARNING
Hot oil.
WARNING
Engine oil – Sample extraction

and analysis
1. With the engine running at operating tem-
perature, open screw on centrifugal oil fil-
ter carrier by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw.
5. Using the equipment and chemicals of the
MTU test kit, examine oil for:
• Dispersion capability (spot test);
• Water content;
• Dilution by fuel.
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7.14 Oil Filtration / Cooling
7.14.1 Engine oil filter – Replacement
Preconditions

Filter wrench F30379104
Engine oil
Oil filter (→ Spare Parts Catalog)
WARNING
Hot oil.
Engine oil filter – Replacement

1. Unscrew engine oil filter with filter wrench.
2. Clean sealing face on connecting piece.
3. Check sealing ring of new engine oil filter
and apply a thin layer of engine oil.
4. Screw on and tighten engine oil filter by
hand.
5. Replace other engine oil filters in the same
way.
6. Check engine oil level (→ Page 155).
7. After changing engine oil and replacing oil
filter(s), bar engine with starting equipment
(→ Page 121).
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7.14.2 Oil indicator filter – Check
Preconditions

Cleaner (Snow-White 11-0) 40460 1
Cleaner (Hakupur 312) 30390 1
Engine oil
Strainer (→ Spare Parts Catalog)
Square-section ring (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
Compressed air
Risk of injury!
CAUTION
Unsuitable cleaning tool.
• Observe manufacturer's instructions.
• Use appropriate cleaning tool.
Removing strainer
1. Clean oil indicator filter before disassem-
bling it.
2. Remove screws (1).
3. Take off cover (2) with O-ring (3).
4. Remove strainer (5) from housing and allow
oil to drip into container.
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Cleaning strainer
1. Shake coarse contamination out of strainer (5).
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
3. Use a soft brush to remove stubborn deposits from strainer if required. Ensure that the mesh is not
damaged.
4. Blow out strainer (5) with compressed air from inside.
Checking strainer
Item Findings Action
Strainer Metallic residues • Clean
• Monitor engine operation
• Check strainer daily
• Contact Service.
Strainer Damaged Fit new part
Square-section ring Damaged Fit new part
O-ring Damaged Fit new part
Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Insert strainer into housing.
3. Fill housing with new engine oil.
4. Coat O-ring (3) with engine oil and fit in filter housing.
5. Fit cover (2) and secure with screws (1) and washers.
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7.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement
Preconditions

Cold cleaner (Hakutex 60) X00056750 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
Compressed air
Risk of injury!
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Centrifugal oil filter – Cleaning
and filter-sleeve replacement
1. Remove clamp (14).
2. Release cover screw (2) and take off cov-
er (1).
3. Carefully lift rotor (11), allow oil to drain
and remove from housing.
4. Holding the rotor (11) firmly, release rotor
cover nut (3).
5. Take off rotor cover (4).
6. Remove filter sleeve (6).
7. Measure thickness of oil residues on filter
sleeve (6).
8. If maximum layer thickness of oil residues
exceeds 45 mm, shorten maintenance in-
terval.
9. Disassemble rotor tube (7), conical disk (8)
and rotor base (10).
10. Wash rotor cover (4), rotor tube (7), conical
disk (8) and rotor base (10) with cold
cleaner.
11. Blow out with compressed air.
12. Check sealing ring (9), fit new one if neces-
sary.
13. Assemble rotor tube (7), conical disk (8)
and rotor base (10) with sealing ring (9).
14. Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the
wall.
15. Check sealing ring (5), fit new one if neces-
sary.
16. Mount rotor cover (4) with sealing ring (5).
17. Tighten rotor cover nut (3) with torque wrench to the specified torque.
Nut Tightening torque 35 Nm to 45 Nm
18. Place rotor (11) in housing (12) and check for ease of movement.
19. Check sealing ring (13), fit new one if necessary.
20. Fit sealing ring (13) on housing (12).
21. Fit cover (1).
22. Tighten cover screw (2) by hand.
23. Install clamp (14) and tighten with torque wrench to the specified torque.
Clamp Tightening torque 8 Nm to 10 Nm
TIM-ID: 0000000934 - 010
24. Tighten cover screw (2) with torque wrench to the specified torque.
Screw Tightening torque 5 Nm to 7 Nm

7.15 Coolant Circuit, General, High-Temperature Circuit
7.15.1 Engine coolant – Level check
Preconditions
WARNING
Coolant is hot and under pressure.
• Let the engine cool down.
Checking engine coolant level at filler neck:

1. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to
escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Check engine coolant level (coolant must be visible at the bottom edge of the filler neck's cast eye).
Checking engine coolant level at

remote cooler:
1. Check engine coolant level (coolant must
be visible at marker plate).
2. Top up engine coolant if necessary
(→ Page 167).
3. Check and clean breather valve.
4. Place breather valve on filler neck and
close.
Checking engine coolant level via level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up engine coolant if necessary (→ Page 167).
TIM-ID: 0000000937 - 012

7.15.2 Engine coolant – Change
Coolant
Engine coolant – Change

1. Drain engine coolant (→ Page 166).
2. Fill with engine coolant (→ Page 167).
TIM-ID: 0000000036 - 030

7.15.3 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheating unit.
Engine coolant – Draining

1. Turn breather valve of coolant expansion
tank counterclockwise until the first stop
and allow pressure to escape.
2. Continue to turn breather valve counter-
clockwise and remove.
3. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• Preheating unit
• Thermostat housing
• Twin elbow
• HT coolant pump elbow;
• Crankcase, left and right sides.
5. Close all open drain points.
close.
TIM-ID: 0000000960 - 003

7.15.4 Engine coolant – Filling
Preconditions

Engine coolant
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
TIM-ID: 0000000935 - 003

Filling coolant with pump
1. Connect a suitable pump with a hose to the
drain valve of the engine coolant pump (ar-
rowed).
2. Open vent points at distributor and exhaust

turbochargers (arrowed).
3. Open drain valve and pump coolant into en-
gine at 0.5 bar minimum.
4. When coolant emerges from the vent
points, close vent points one by one, pro-
ceeding from the lowest point upwards.
5. Fill expansion tank until overflow edge is
reached.
6. Close drain valve.
7. Check proper condition of breather valve
on coolant expansion tank, clean sealing
faces if required.
8. Fit breather valve and close it.
10. After 10 seconds of running the engine
without load, shut down the engine
(→ Page 61).
13. Check coolant level (→ Page 164) and top
up engine coolant as required:
a) Top up coolant in expansion tank via
filler neck until coolant level at top
edge of filler neck remains constant.
b) Fit breather valve and close it.
TIM-ID: 0000000935 - 003
14. Repeat the steps from "Start engine"

(→ Step 9) until coolant is no longer needed
to be topped up.
15. Disconnect pump and hose.

Alternatively: Filling coolant
through filler neck
1. Open vent points at distributor and exhaust
turbochargers (arrowed).
2. Fill in coolant via filler neck on expansion
tank until coolant level remains constant at
top edge of filler neck.
3. When coolant emerges from the vent
points, close vent points one by one, pro-
ceeding from the lowest point upwards.
faces if required.
(→ Page 61).
9. Turn breather valve counterclockwise and
remove.
up with coolant through the filler neck if re-
quired:
to be topped up.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 164) and top up engine coolant as required.
TIM-ID: 0000000935 - 003

7.15.5 Engine coolant pump – Relief bore check
DANGER
WARNING
Engine coolant pump – Relief

bore check
1. Check relief bore for oil and coolant dis-
charge.
2. Shut down engine (→ Page 61) and disable
engine start, observe general safety in-
structions “Maintenance and Repair”.
3. Clean the relief bore with a wire if it is
dirty.
• Permissible coolant discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits:
Contact Service.
TIM-ID: 0000000939 - 003

7.15.6 Engine coolant – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
WARNING
Engine coolant – Sample extrac-

tion and analysis
1. With the engine running, open drain
valve (1).
2. Flush sample-extraction point by draining
approx. 1 liter coolant.
3. Drain approx. 1 liter coolant into a clean
container.
5. Using the equipment and chemicals of the
MTU test kit, check the coolant for:
• Antifreeze concentration
• Corrosion inhibitor concentration
• pH value.
6. For engine coolant change intervals,
(→ MTU Fluids and Lubricants Specifica-
tions (A001061/..)).
TIM-ID: 0000000938 - 007

7.16 Low-Temperature Circuit
7.16.1 Charge-air coolant – Level check
Preconditions
WARNING
Checking charge-air coolant lev-

el at filler neck:
3. Check coolant level (coolant must be visi-
ble at marking plate).
4. Top up coolant if necessary (→ Page 175).
5. Check proper condition of breather valve,
clean sealing faces if required.
Checking charge-air coolant level by means of level sensor:

1. Switch on engine control system and check display (coolant level is automatically monitored by engine
control system).
2. Top up coolant if necessary (→ Page 175).
TIM-ID: 0000000042 - 007

7.16.2 Charge-air coolant – Change
Coolant
Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 174).
2. Fill with charge-air coolant (→ Page 175).
TIM-ID: 0000000041 - 011

7.16.3 Draining charge-air coolant
Preconditions
☑ Engine shut down and secured against being restarted.

WARNING
Draining charge-air coolant

1. Have a suitable container ready to catch
the coolant.
2. Turn pressure cap on coolant expansion
3. Continue to turn pressure cap counter-
4. Draw off separated corrosion inhibitor fluid
in expansion tank through the filler neck.
5. Open drain valves and/or drain plugs and
drain coolant at the following points:
• on the low-temperature coolant pump
• on the low-temperature thermostat
housing.
6. Drain off residual coolant:

• on the intercooler
7. Close all drain valves and screw in drain
plugs using new sealing rings.
8. Place pressure cap on filler neck and close.
TIM-ID: 0000007022 - 004

7.16.4 Charge-air coolant – Filling
Preconditions

Coolant
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
TIM-ID: 0000000940 - 004

Filling with coolant using a
pump
1. Connect a suitable pump with a hose to the
drain valve (arrowed).
2. Undo the vent line union at the distributor

piece (arrowed).
3. Open drain valve and pump coolant into en-
gine at 0.5 bar minimum.
4. Tighten the union (arrowed) if coolant leaks
out at the loose union.
5. Fill expansion tank until overflow edge is
reached.
6. Close drain valve.
and clean sealing faces if required.
close.
(→ Page 61).
up coolant as required:
a) Fill in coolant in expansion tank until
the coolant level at top edge of filler
neck remains constant.
b) Place breather valve on filler neck and
close.
TIM-ID: 0000000940 - 004

to be topped up.
15. Disconnect pump and hose.

Alternatively: Filling with cool-
ant through filler neck
1. Undo the vent line union at the distributor
piece (arrowed).
2. Top up coolant in expansion tank via filler
neck until coolant level at top edge of filler
neck remains constant.
3. Tighten the union (arrowed) if coolant leaks
out at the loose union.
faces if required.
(→ Page 61).
9. Turn breather valve counterclockwise and
remove.
up with coolant through the filler neck if re-
quired:
to be topped up.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 172) and top up coolant as required.
TIM-ID: 0000000940 - 004

7.16.5 Charge-air coolant pump – Relief bore check
DANGER
WARNING
Charge-air coolant pump – Relief

bore check
1. Check relief bore for oil and coolant dis-
charge.
2. Shut down engine (→ Page 61) and disable
engine start, observe general safety in-
structions “Maintenance and Repair”.
3. Clean the relief bore with a wire if it is
dirty.
• Permissible coolant discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits:
Contact Service.
TIM-ID: 0000000943 - 003

7.17 Engine Mounting / Support
7.17.1 Engine mounting – Check
Engine mounting – Check

Visually inspect mounts. • Damage Replace (contact Service).
• Brittleness
• Deformation
• Crack formation
• Swelling visible
TIM-ID: 0000015370 - 004

7.18 Belt Drive
7.18.1 Drive belt – Condition check
Preconditions
☑ Guard is removed.
Drive belt – Condition check

Drive belt A Singular cracks None
Drive belt Belt is oily, shows signs of over- Replace (→ Page 181)
heating
Drive belt B Cracks on entire circumference
Drive belt C Chunking
TIM-ID: 0000000920 - 010

7.19 Battery-Charging Generator
7.19.1 Battery-charging generator drive – Drive belt replacement
Preconditions

Ratchet F30027341 1
Ratchet F30027340 1
Drive belt (→ Spare Parts Catalog)
WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
Battery-charging generator drive – Drive belt replacement

1. Remove protective cover.
2. Slacken screws (2) and (3) by half a turn.
3. Place socket adapter or box wrench on
screw (1) and press belt tensioner in the di-
rection indicated by the arrow as far as it
will go.
4. Tighten screw (3).
5. Remove the used drive belt.
6. Fit new drive belt.
7. Slacken screw (3) by half a turn.
Result: Belt tensioner moves against the drive belt
and tensions it.
TIM-ID: 0000022970 - 005
Screw M10 Tightening torque 60 Nm +5 Nm
Screw M10 Tightening torque 42 Nm

10. Install protective cover.
11. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 183).
TIM-ID: 0000022970 - 005

7.19.2 Battery-charging generator drive – Drive belt tension adjustment
Preconditions

Ratchet F30027341 1
Ratchet F30027340 1
WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
Adjusting belt tension

1. Remove protective cover.
2. Slacken screws (1) and (2) by half a turn.
Result: Belt tensioner moves against the drive belt
and tensions it.
Screw M10 Tightening torque 60 Nm +5 Nm
TIM-ID: 0000000945 - 007
Screw M10 Tightening torque 42 Nm
5. Install protective cover.

7.20 Wiring (General) for Engine/Gearbox/Unit
7.20.1 Engine wiring – Check
Preconditions

Isopropyl alcohol X00058037 1
Engine wiring – Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check that cable ties are firm, tighten loose cable ties.
4. Replace faulty cable ties.
5. Visually inspect the following electrical line components for damage:
• connector housings;
• contacts;
• sockets;
• cables and terminals;
• plug-in contacts.
6. (→ Contact Service) if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
8. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 018

7.21 Accessories for (Electronic) Engine Governor / Control System
7.21.1 CDC parameters – Reset with DiaSys®
Preconditions
Resetting CDC parameters (DiaSys® is available)

Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer ap-
plicable.
u Reset the CDC parameters with DiaSys® (→ Manufacturer's documentation).
Resetting CDC parameters (DiaSys® is not available)

Note: The CDC parameters must be reset, otherwise the emission certification of the engine is no longer ap-
plicable.
u Contact Service.
TIM-ID: 0000037821 - 001

7.21.2 Engine governor and connectors – Cleaning
Preconditions

Isopropyl alcohol X00058037 1
Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise
the contacts could be bent.
Engine governor and connectors – Cleaning

1. Remove coarse dirt from housing surface with isopropyl alcohol.
2. Remove dirt from connector and cable surfaces with isopropyl alcohol.
3. Check legibility of cable labels. Clean or replace illegible labels.
Cleaning severely contaminated connectors on the engine governor

Note: Seal unused connectors with the supplied protective cap.
1. Release the latch and pull off connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and lock them.
TIM-ID: 0000000047 - 009

7.21.3 Engine governor plug connections – Check
Preconditions
Note: Always use test plugs to check the connections. Never use test leads. Otherwise, the contacts might be
bent.
Engine governor plug connections – Check

1. Check all plug connections for secure seating.
2. Latch plugs if loose.
TIM-ID: 0000000048 - 007

7.21.4 ECU 7 engine governor – Removal and installation
Preconditions
CAUTION
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given
engine is installed.
Removing Engine Control Unit

from engine
1. Note or mark assignment of cables and
connectors.
2. Remove all screws (2).
3. Undo latches (3) of the connectors.
4. Remove all connectors.
5. Remove screws (1).
6. Take off Engine Control Unit.
Installing Engine Control Unit on engine

1. Install in reverse order. In doing so, ensure correct assignment of connectors and sockets.
2. Check rubber mounts before installation.
Result: Replace rubber mounts if they are found porous or defective.
TIM-ID: 0000000049 - 006

8 Appendix A
8.1 Abbreviations
Abbre- Meaning Explanation
viation
AC Alternating Current
AdBlue - Brand name given by the German automotive indus-
try association (VDA)
Urea solution with 32.5% urea content
ADEC Advanced Diesel Engine Controller Engine management system
EGR Exhaust Gas Recirculation
AL Alarm
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger
BDM Backup Data Module Data backup module
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica-
tion No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CaPoS Capacitor Power System Starting system based on capacitors
CDC Calibration Drift Compensation Resets the drift correction with DiaSys® in engine
governor to ensure optimum emission and consump-
tion behavior
CRC Cyclic Redundancy Control Check sum procedure to detect data transmission
faults
DC Direct Current
DEF Diesel Exhaust Fluid Urea solution with 32.5% urea content
Term used in North America
DIFF Difference
DIN Deutsches Institut für Normung e. V. German National Standards Institute, at the same
time identifier of German standards (DIN = “Deut-
sche Industrie-Norm”)
DL Default Lost Alarm: CAN bus failure
DPF Diesel particulate filter
ECU Engine Control Unit Engine governor
ETK Ersatzteilkatalog Spare Parts Catalog
TIM-ID: 0000009959 - 008
FO Frequency output
GND Ground
HP High Pressure
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
ID Identification number
M015715/03E 2013-01 | Appendix A | 189

Abbre- Meaning Explanation
viation
IIE Initial Injector Equalization Input of the injector code with DiaSys® in engine
governor to ensure optimum emission and consump-
tion behavior
ISO International Organization for Standardiza- International umbrella organization for all national
tion standardization institutes
ITS Integrated Test System
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LED Light Emitting Diode
LO Low Alarm: Measured value lower than 1st minimum limit
LOLO Low Low Alarm: Measured value lower than 2nd minimum lim-
it
MTU Motoren- und Turbinenunion
MV Magnetventil Solenoid valve
OEM Original Equipment Manufacturer
OT Oberer Totpunkt Top Dead Center
PAU Power Automation Unit Module for monitoring, control and plant-related sys-
tem integration of peripheral components
PDU Process Data Unit
POM Power Output Module Module to control starter and battery-charging gen-
erator
PU Projektierungsumgebung Project planning environment
P-xyz Pressure-xyz Pressure measuring point, xyz specifies the measur-
ing point designation
SAE Society of Automotive Engineers U.S. standardization organization
SAM Service and Automation Module
SD Sensor Defect Alarm: Sensor failure
SS Safety System Safety system alarm
TBO Time Between Overhaul Time until major overhaul
T-xyz Temperature-xyz Temperature measuring point, xyz specifies the
measuring point designation
U Symbol for electric voltage
UIC Union Internationale des Chemins de Fer International railway association
Ultra- UltraCaps modules Capacitors for starting system
Caps
UT Unterer Totpunkt Bottom Dead Center
TIM-ID: 0000009959 - 008
WZK Werkzeugkatalog Tool Catalog
190 | Appendix A | M015715/03E 2013-01

8.2 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact at Headquarters: [email protected]
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: [email protected]
Phone: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 014
M015715/03E 2013-01 | Appendix A | 191

9 Appendix B
9.1 Special Tools
Barring device
Part No.: F6555766
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 120)
Qty.: 1
Used in: 7.2.1 Cylinder liner – Endoscopic examination
(→ Page 123)
Box wrench socket, 24mm

Part No.: F30039526
Qty.: 1
Used in: 7.4.2 Valve clearance – Check and adjustment
(→ Page 130)
Endoscope
Part No.: Y20097353
Qty.: 1
(→ Page 123) DCL-ID: 0000010309 - 003
192 | Appendix B | M015715/03E 2013-01

Feeler gauge
Part No.: Y20098771
Qty.: 1
(→ Page 130)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.8.1 Fuel filter – Replacement (→ Page 141)
Qty.:
Used in: 7.14.1 Engine oil filter – Replacement (→ Page 159)
Installation/removal tool
Part No.: F6789889
Qty.: 1
Used in: 7.6.2 Injector – Removal and installation (→ Page 135)
Milling cutter
Part No.: F30452739
Qty.: 1
DCL-ID: 0000010309 - 003
M015715/03E 2013-01 | Appendix B | 193

MTU test kit
Part No.: 5605892099/00
Qty.: 1
Used in: 7.13.3 Engine oil – Sample extraction and analysis
(→ Page 158)
Qty.: 1
Used in: 7.15.6 Engine coolant – Sample extraction and analysis
(→ Page 171)
Ratchet
Part No.: F30027340
Qty.: 1
Used in: 7.3.1 Crankcase breather – Oil separator element re-
placement, diaphragm check and replacement
(→ Page 127)
Qty.: 1
Used in: 7.19.1 Battery-charging generator drive – Drive belt re-
placement (→ Page 181)
Qty.: 1
Used in: 7.19.2 Battery-charging generator drive – Drive belt
tension adjustment (→ Page 183)
Ratchet adapter
Part No.: F30027341
Qty.: 1
(→ Page 130)
Ratchet with extension

Part No.: F30006212
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 120)
DCL-ID: 0000010309 - 003
Qty.: 1
(→ Page 123)
194 | Appendix B | M015715/03E 2013-01

Steam jet cleaner
Part No.: -
Qty.: 1
Used in: 4.11 Plant cleaning (→ Page 65)
Torque wrench, 0.5-5 Nm

Part No.: 0015384230
Qty.: 1
Torque wrench, 10-60 Nm

Part No.: F30510423
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)

Part No.: F30452769
Qty.: 1
Qty.: 1
Used in: 7.19.1 Battery-charging generator drive – Drive belt re-
placement (→ Page 181)
Qty.: 1
Used in: 7.19.2 Battery-charging generator drive – Drive belt
tension adjustment (→ Page 183)
DCL-ID: 0000010309 - 003
M015715/03E 2013-01 | Appendix B | 195

Torque wrench, 4-20Nm
Part No.: F30044239
Qty.: 1
Used in: 7.10.3 Air filter – Removal and installation
(→ Page 152)

Part No.: F30027337
Qty.: 1
Used in: 7.13.2 Engine oil – Change (→ Page 156)

Part No.: F30027336
Qty.: 1
Used in: 7.3.1 Crankcase breather – Oil separator element re-
placement, diaphragm check and replacement
(→ Page 127)
Qty.: 1
Used in: 7.14.3 Centrifugal oil filter – Cleaning and filter-sleeve
replacement (→ Page 162)
Torque wrench, 60-320Nm

Part No.: F30452768
Qty.: 1
(→ Page 130)
DCL-ID: 0000010309 - 003
196 | Appendix B | M015715/03E 2013-01

Part No.: F30047446
Qty.: 1
Used in: 1.4 Crankshaft transport locking device (→ Page 8)
DCL-ID: 0000010309 - 003
M015715/03E 2013-01 | Appendix B | 197

9.2 Index
Numerics Crankshaft transport locking device
20 V 4000 Gx3 engine data – Removal/installation 8
– Continuous operation, unrestricted 3A Cylinder
– Optimized fuel consumption 24 – Designation 18
– Continuous operation, variable 3B Cylinder head cover
– Optimized exhaust emissions (EPA2) 35 – Removal and installation 132
– optimized exhaust emissions (TA-Luft) 39 Cylinder liner
– Optimized fuel consumption 29 – Endoscopic examination 123
– Standby operation 3D – Instructions and comments on endoscopic and visual
– Optimized exhaust emissions (EPA stage 2) 49 examination 125
– Optimized fuel consumption 43
D
A Drive belt
Abbreviations 189 – Condition check 180
ADEC (ECU 7)
E
– Fault messages 71
After stopping the engine ECU 7 engine governor
– Engine remains ready for operation 63 – Removal and installation 188
– Putting the engine out of operation 64 Emergency stop 62
Air filter Engine
– Check 151 – Barring manually 120
– Installation 152 – Barring with starting system 121
– Removal 152 – Main dimensions 54
– Replacement 150 – Starting in manual mode (test run) 57
Air starter – Stopping in manual mode (test run) 61
– Manual operation 154 – Test run 122
– Wiring check 184
B Engine coolant
Battery-charging generator – Change 165
– Drive belt replacement 181 – Draining 166
– Drive belt tension adjustment 183 – Filling 167
– Level check 164
C – Sample extraction and analysis 171
CDC parameters Engine coolant pump
– Reset 185 – Relief bore check 170
Centrifugal oil filter Engine governor
– Cleaning 162 – Cleaning 186
Charge-air coolant – Plug connections
– Change 173 – Check 187
– Draining 174 Engine layout 19
– Filling 175 Engine mounting
– Level check 172 – Check 179
Charge-air coolant level Engine oil
– Check 172 – Centrifugal oil filter
Charge-air coolant pump – Cleaning 162
DCL-ID: 0000010309 - 003
– Relief bore check 178 – Change 156

Connectors – Filter sleeve
– Cleaning 186 – Replacement 162
Contact persons 191 – Sample extraction and analysis 158
Coolant Engine oil filter
– Change 173 – Replacement 159
Coolant - charge air Engine oil level
– Level check 172 – Check 155
Crankcase breather Engine side
– Diaphragm check 127 – Designation 18
– Oil separator element replacement 127
198 | Appendix B | M015715/03E 2013-01

Engine wiring Putting the engine into operation after scheduled out-of-
– Check 184 service-period 56
F S
Fault messages Safety instructions
– Engine governor ADEC (ECU 7) 71 – Conventions 17
– Indication on PAU display 70 Safety regulations
Filter sleeve – Auxiliary materials 15
– Replacement 162 – Environmental protection 15
Firing order 53 – Fire prevention 15
Fuel – Fluids and lubricants 15
– prefilter – Important provisions 5
– Flushing 145 – Maintenance work 12
Fuel filter – Operation 11
– Replacement 141 – Organizational requirements 6
Fuel prefilter – Personnel requirements 6
– Differential pressure gauge – Repair work 12
– Check and adjustment 143 – Startup 11
– Draining 144 Safety system
– Filter element – Override 58
– Replacement 147 Service indicator
– Flushing 145 – Signal ring position check 153
Fuel prefilter cleaning 142 Service partners 191
Fuel system Spare parts service 191
– Venting 140 Starting the engine in emergency situations (override
mode) 59
H
Hotline 191 T
HP pump Transport 7
– Filling with engine oil 133 Troubleshooting 67
I V
Injector Valve clearance
– Removal and installation 135 – Adjustment 130
– Replacement 134 – Check 130
Intercooler Valve gear
– Checking condensate drain for coolant discharge – Lubrication 129
149
– Checking condensate drain for obstructions 149 W
Wiring - engine
M – Check 184
Maintenance task reference table [QL1] 66
MTU contact persons 191
O
Oil indicator filter
– Check 160
Operational checks 60
DCL-ID: 0000010309 - 003
Overview
– Sensors, actuators and injectors 21
P
PAU
– Fault message indication 70
Plant
– Cleaning 65
Putting the engine into operation after extended out-of-
service periods (>3 months) 55
M015715/03E 2013-01 | Appendix B | 199

Operating Instructions: Diesel Engine 20 V 4000 G23 20 V 4000 G43 20 V 4000 G63, G63L 20 V 4000 G83, G83L

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Operating Instructions: Diesel Engine 20 V 4000 G23 20 V 4000 G43 20 V 4000 G63, G63L 20 V 4000 G83, G83L

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Operating Instructions

7.4.3 Cylinder head cover – Removal and

M015715/03E 2013-01 | Table of Contents | 3

7.9 Charge-Air Cooling 149 7.17 Engine Mounting / Support 179

4 | Table of Contents | M015715/03E 2013-01

M015715/03E 2013-01 | Safety | 5

Working clothes and protective equipment

TIM-ID: 0000040531 - 001

6 | Safety | M015715/03E 2013-01

Placement after transport

M015715/03E 2013-01 | Safety | 7

Transport locking device

Removing guard plates and en-

8 | Safety | M015715/03E 2013-01

Removing the transport locking

locking device together with this documen-

M015715/03E 2013-01 | Safety | 9

TIM-ID: 0000004010 - 010

10 | Safety | M015715/03E 2013-01

Safety regulations for equipment operation

Malfunctions and emergency stop

Operation of electrical equipment

M015715/03E 2013-01 | Safety | 11

Safety regulations during maintenance and repair work

12 | Safety | M015715/03E 2013-01

Safety regulations after completion of maintenance and repair work

Hydraulic installation and removal

Working with batteries

M015715/03E 2013-01 | Safety | 13

Working with laser equipment

TIM-ID: 0000040535 - 001

14 | Safety | M015715/03E 2013-01

Environmental protection and disposal

Auxiliary materials, fluids and lubricants

M015715/03E 2013-01 | Safety | 15

Paints and lacquers

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

16 | Safety | M015715/03E 2013-01

M015715/03E 2013-01 | Safety | 17

1 Left engine side 3 Right engine side

18 | General Information | M015715/03E 2013-01

1 Oil heat exchanger 6 Oil filter 11 Belt drive

M015715/03E 2013-01 | General Information | 19

Engine model designation

20 | General Information | M015715/03E 2013-01

1 Injectors Y39.11 to 3 F33 (connection for exter- 5 B09 (charge-air tempera-

M015715/03E 2013-01 | General Information | 21

TIM-ID: 0000001088 - 004

22 | General Information | M015715/03E 2013-01

M015715/03E 2013-01 | General Information | 23

load capability, de-

24 | Technical Data | M015715/03E 2013-01

Model related data (basic design)

Combustion air / exhaust gas

Coolant system (high-temperature circuit)

ture (at engine con-

M015715/03E 2013-01 | Technical Data | 25

Coolant system (low-temperature circuit)

Lube oil system