Operating Instructions

Diesel Engine
12V2000Sx6/Cx6/Cx6x
16V2000Sx6/Cx6

MS150094/07E
Engine model kW/cyl. Application group
12V2000S56 65 kW/cyl. 4B, Continuous operation, variable
16V2000S56 60 kW/cyl. 4B, Continuous operation, variable
12V2000S96 71 kW/cyl. 4D, Frac operation (continuous operation at low load)
16V2000S96 72 kW/cyl. 4D, Frac operation (continuous operation at low load)
12V2000C66 65 kW/cyl. 5B, Continuous operation, variable
12V2000C66R 65 kW/cyl. 5B, Continuous operation, variable
16V2000C66 60 kW/cyl. 5B, Continuous operation, variable

Table 1: Applicability

Rolls-Royce Solutions refers to Rolls-Royce Solutions GmbH or an affiliated company pursuant to §15 AktG (German Stock
Corporation Act) or a controlled company (joint venture), and Rolls-Royce Solutions Ruhstorf GmbH.

© Copyright Rolls-Royce Solutions

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of Rolls-Royce Solutions. This particularly applies to its reproduction, distribution, editing, translation, microfilming
and storage and/or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. Rolls-Royce Solutions re-
serves the right to change, delete or supplement the information provided as and when required.
 California Proposition 65
This warning applies only to the State of California, USA, in compliance with Title 27 California Code of Regu-
lations, Article 6, Clear and Reasonable Warnings.

(→ www.P65warnings.ca.gov/diesel )
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MS150094/07E 2022-05 | California Proposition 65 | 3

 TIM-ID: 0000085026 - 002

4 | California Proposition 65 | MS150094/07E 2022-05

 Table of Contents
1 Preface 6.8 Emergency engine stop 59
6.9 After stopping the engine – Putting the
1.1 Preface 7 engine out of operation 60
6.10 Plant – Cleaning 61
2 Safety
2.1 Important provisions for all products 8 7 Maintenance
2.2 Intended use of all products 9 7.1 Maintenance task reference table [QL1] for
2.3 Personnel and organizational requirements 10 Non-EPA regions 63
2.4 Safety regulations for commissioning and 7.2 Maintenance task reference table [QL1] for
operation 11 EPA regions 64
2.5 Safety regulations for assembly,
maintenance, and repair work 13
8 Troubleshooting
2.6 Fire and environmental protection, indirect
materials 17 8.1 Troubleshooting 65
2.7 Standards for warning messages in the text 8.2 Engine Control Unit ECU9 – Fault messages 68
and highlighted information 20
9 Task Description
3 Transport
9.1 Engine 96
3.1 Transport 21 9.1.1 Engine – Barring manually 96
9.1.2 Engine – Turning on starting system 97
4 General Information 9.2 Cylinder Liner 98
9.2.1 Cylinder liner – Instructions and comments on
4.1 Engine side and cylinder designations 22
endoscopic and visual examination 98
4.2 Engine – Overview 23 9.2.2 Cylinder liner – Endoscopic examination 100
4.3 Tightening specifications for screws, nuts
and bolts 24 9.3 Crankcase Breather 102
4.4 Data acquisition and data transmission 37 9.3.1 Crankcase breather – Oil mist separator
replacement 102

5 Technical Data 9.4 Valve Drive 103

9.4.1 Valve clearance – Check and adjustment 103
5.1 Product data 12/16V2000C66 38 9.4.2 Cylinder head cover – Removal and
5.2 Product data 12V2000C66R 41 installation 106
5.3 Product data 12/16V2000S56 44
9.5 Injector 107
5.4 Product data 12/16V2000S96 47 9.5.1 Injector – Replacement 107
5.5 Firing order 50 9.5.2 Injector – Removal and installation 108
5.6 Engine, main dimensions 51
9.6 Fuel System 113
9.6.1 HP fuel line and pressure pipe neck –
6 Operation
Replacement 113
6.1 Preparations for putting into operation after 9.6.2 Fuel system – Venting 115
9.6.3 Fuel – Draining 116
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extended out-of-service periods (>3 months) 52

6.2 Preparations for putting into operation after 9.7 Fuel Filter 117
scheduled out-of-service-period 53 9.7.1 Fuel filter – Replacement 117
6.3 Engine – Starting 54 9.7.2 Fuel prefilter – Differential pressure check
6.4 Re-starting the engine following an and adjustment of gauge 118
automatic safety shutdown 55 9.7.3 Fuel prefilter – Draining 119
9.7.4 Fuel prefilter – Flushing 121
6.5 Operational monitoring 56
9.7.5 Fuel prefilter – Filter element replacement 124
6.6 Emission label – Check 57
6.7 Engine shutdown 58 9.8 Charge-Air Cooling 126

MS150094/07E 2022-05 | Table of Contents | 5

 9.8.1 Intercooler – Checking condensate drain for 9.16.1 Drive belt – Condition check 158
coolant leakage and obstruction 126 9.16.2 Drive belt – Tension check 159
9.16.3 Drive belt – Tension adjustment 161
9.9 Air Filter 127 9.16.4 Drive belt – Replacement 163
9.9.1 Air filter – Replacement 127
9.17 Battery-Charging Generator 164
9.10 Air Intake 128 9.17.1 Battery-charging generator drive – Drive-belt
9.10.1 Service indicator – Check 128
check and adjustment 164
9.11 Exhaust Gas Recirculation 129 9.17.2 Battery-charging generator drive – Drive belt
9.11.1 Exhaust gas recirculation flaps – Overview 129 replacement 166
9.11.2 Exhaust gas recirculation – Flap function
9.18 Engine Governor 167
check 130
9.18.1 Engine governor – Overview 167
9.12 Lube Oil System, Lube Oil Circuit 131 9.18.2 Engine governor – Removal 168
9.12.1 Engine oil level – Check 131 9.18.3 Engine governor – Installation 169
9.12.2 Engine oil – Change 132 9.18.4 Engine governor plug connections – Check 170

9.13 Oil Filtration / Cooling 134 9.19 Wiring (General) for Engine/Gearbox/Unit 171
9.13.1 Engine oil filter – Replacement 134 9.19.1 Engine cabling – Check 171
9.13.2 Centrifugal oil filter – Cleaning and filter 9.19.2 Lambda, NOx and humidity sensors –
sleeve replacement 135 Overview 172
9.19.3 Lambda sensor – Replacement 173
9.14 Coolant Circuit, General, High-Temperature 9.19.4 NOx sensor – Replacement 175
Circuit 138 9.19.5 Humidity sensor – Replacement 177
9.14.1 Drain and vent points 138
9.14.2 Engine coolant – Level check 143 9.20 Accessories for (Electronic) Engine
9.14.3 Engine coolant – Change 144 Governor / Control System 179
9.14.4 Engine coolant – Draining 145 9.20.1 Resetting CDC parameter and entering IIG
9.14.5 Engine coolant – Filling 146 with DiaSys® 179
9.14.6 Engine coolant pump – Relief bore check 148 9.20.2 Еngine governor and connectors – Cleaning 180
9.14.7 Engine coolant – Sample extraction and 9.20.3 Engine governor plug connections – Check 181
analysis 149

9.15 Low-Temperature Circuit 150 10 Appendix A

9.15.1 Intercooler – Vent and drain points 150
9.15.2 Charge-air coolant level – Check 151 10.1 List of abbreviations 182
9.15.3 Charge-air coolant – Change 153 10.2 Contact person/Service partner 185
9.15.4 Charge-air coolant – Filling 154
9.15.5 Charge-air coolant – Draining 156 11 Appendix B
9.15.6 Charge-air coolant pump – Relief bore check 157
11.1 Standard Tools and Special Tools 186
9.16 Belt Drive 158
11.2 Index 196
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6 | Table of Contents | MS150094/07E 2022-05

 1 Preface
1.1 Preface
These Operating Instructions contain general instructions for the proper and safe operation of your product
from the manufacturer Rolls-Royce Solutions.
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MS150094/07E 2022-05 | Preface | 7

 2 Safety
2.1 Important provisions for all products
General
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications which are neither made nor authorized by the manufacturer
• Noncompliance with the safety instructions and warning notices

Nameplates
The product is identified by nameplate, model designation or serial number. This data must match the speci-
fications in these instructions.
Nameplates, model designation or serial number can be found on the product.
All EU-certified engines delivered by Rolls-Royce Solutions come with a second nameplate. This second
nameplate is delivered "loosely" with the engine. If the nameplate secured to the engine after installation in
the vehicle/system is not visible without the removal of components, the system integrator must install the
second nameplate in a clearly visible area on the vehicle/system.

Emissions regulations
Prior to operation, make sure that the latest version is used. The latest version can be found at:http://
www.mtu-solutions.com

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8 | Safety | MS150094/07E 2022-05

 2.2 Intended use of all products
Intended use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/Rolls-
Royce Solutions contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-
so applies to engine control/parameters)
• In compliance with all safety regulations and in adherence with all safety and warning notices in this man-
ual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• Work which requires communication with the control units must only be carried out with a diagnosis soft-
ware or with tools approved by the manufacturer.
• 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 re-
pair
The product must not be operated in explosive atmospheres unless the engine fulfills the conditions for such
use and approval has been granted.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found at:
• http://www.mtu-solutions.com

Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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MS150094/07E 2022-05 | Safety | 9

 2.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and repair based on this manual. In particular, per-
sonnel must have read and understood the safety requirements and warnings before starting work.
This is important in the case of personnel who only occasionally perform work on or around the product.
Such personnel must be instructed repeatedly.

Personnel requirements
All work on the product must be carried out by trained, instructed and qualified personnel only:
• Training at the Training Center of the manufacturer
• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering
and also for work with live parts
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.

Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the respective
descriptions of the individual activities or the manufacturer's documentation included in the delivery.
When working on live components, in particular on electrical switchgear or on high-voltage component, wear
special protective clothing according to IEC 61482.
Safe handling of Substances of Very High Concern pursuant to the REACH regulation (Registration, Evalua-
tion, Authorization and restriction of CHemicals): We recommend wearing protective gloves at all times in
order to reduce risk when working.

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10 | Safety | MS150094/07E 2022-05

 2.4 Safety regulations for commissioning and operation
Safety regulations for commissioning
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before commissioning the product. All necessary approvals must be granted by the relevant authorities and
all requirements for commissioning must be fulfilled.
Whenever the product is subsequently put into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All protective devices are in place.
• All lines bearing media are ready for operation.
• The walkways in the operating room are unobstructed and safe.
• No persons wearing pacemakers or any other technical body aids are present.
• Adequate ventilation of the operating room is ensured for any operating status.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and the gases are vented to atmosphere.
• The product is free of any damage, this applies in particular to lines and cabling.
• All components are properly grounded. Ground separately by means of a grounding stake as necessary.
• The power supply (mains plug) is always freely accessible to facilitate disconnecting the device or system
from the power supply at any time.
• Battery terminals, generator terminals or cables are protected against accidental contact.
• All connections have been correctly allocated e.g. +/- polarity, fuel line/reducing agent line, supply/
return.
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the monitoring, signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.

Safety regulations during 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 observed with regard to present op-
erating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.
Take the following steps if any system malfunctions are detected or signaled by the system:
• Inform supervisor(s) in charge.
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• Analyze the message.

• Respond by taking any necessary emergency action, e.g. emergency stop.
After a safety shutdown, the engine may only be started after the cause of the shutdown has been eliminat-
ed.
Contact Service if the root cause of the malfunction cannot be clearly identified.

Operation
Do not remain in the operating room when the product is running unless absolutely necessary. Keep your
stay as short as possible.

MS150094/07E 2022-05 | Safety | 11

 Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
to do so following a written procedure.
Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear hearing protection.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent.

Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.
Follow the applicable operating and safety instructions when operating the devices and heed warnings at all
times.

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12 | Safety | MS150094/07E 2022-05

 2.5 Safety regulations for assembly, maintenance, and repair
work
Safety regulations for work prior to assembly, maintenance, and repair
Have assembly, maintenance, or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion from oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble containers of adequate capacity to catch fluids and lubricants.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
Work may only be carried out on lines when they are free of fluids and lubricants.
Ensure adequate ventilation of the operating room when conducting an oil change, working on the gaseous/
liquid fuel system or working with process materials (e.g. adhesive, cleaner).
Never carry out assembly, maintenance, or repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• Close supply line for hydraulic starting.
• Close the main valve on the compressed-air system and vent the compressed-air line when air starters are
fitted.
Attach a “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolator switch, if fitted. Lock circuit breakers.
Before starting work on CaPoS, if used:
• Switch off the charging system (DC/DC converter).
• Discharge the UltraCap modules using the appropriate discharger.
• Short-circuit the UltraCap modules with a suitable wire jumper.
Before working on the exhaust gas aftertreatment system, close the shutoff valve on the reducing agent
tank. Note that the reducing agent pumps continue to run for a certain period when the engine is stopped.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.

Safety regulations when performing assembly, maintenance, and repair work

Special tools and lifting equipment
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
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Setting down, lifting and climbing

Carry out work only on assemblies or plants which are properly secured.
Use appropriate lifting equipment for all components. Use all specified attachment points and observe the
center of gravity.
Never stand beneath a suspended load.
Never work on engines or components when they are held in place by lifting equipment.
Make sure components or assemblies are placed on stable surfaces and secured against tilting over or roll-
ing away. Adopt suitable measures to prevent components/tools from falling down.

MS150094/07E 2022-05 | Safety | 13

 Assume a safe standing position when performing assembly work.
Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Special instructions
for outdoor areas: There must be no risk of slipping e.g. due to icing.

Removing, installing and cleanliness

Pay particular attention to cleanliness at all times.
Completely wipe up escaped fluids and lubricants to prevent the risk of slipping.
Take special care when removing ventilation or plug screws from the product.
Ensure that O-rings are not installed in a skewed/twisted condition.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
Note cooling time for components which are heated for installation or removal (risk of burning).
Ensure that all mounts and dampers are installed correctly.
Remove any accumulation of condensate after assembling chilled components. Coat the components with a
suitable corrosion inhibitor as necessary.

Safety regulations for work on exhaust management components

Wear a breathing mask offering protection against soot, dust, and mineral fibers (filter class P3) and a pro-
tective overall when working on exhaust management components. Clean the work area with a class H dust
extraction device.
Use a moistened cloth to avoid raising dust when cleaning accumulated deposits.
Wear appropriate protective gloves and goggles for protection against acidic condensate.

Lines
Ensure that lines for all fluids and lubricants and their connections are clean.
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that the lines for all fluids and lubricants have sufficient play to avoid contact with other components.
Do not route fuel or oil lines near hot components.

Miscellaneous
Follow good hygiene practices, e.g. washing hands after work and before eating.
Sufficient ventilation must be guaranteed during the work.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
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Do not paint elastomer components (e.g. engine mounts, damping elements, couplings and V-belts). Only in-
stall them after painting the engine or mask them prior to painting.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). 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.
• Observe the safety data sheet.

Safety regulations after performing assembly, maintenance, and repair work

Before cranking the engine, make sure no one is in the danger zone of the engine.

14 | Safety | MS150094/07E 2022-05

 Check that all access ports and apertures which have been opened to facilitate working are closed again.
All protective devices must be installed and all tools and loose parts must be removed, especially the barring
tool.
Ensure that no unattached parts have been left in/on the product (e.g. rags and cable straps).
Ensure that the grounding system is properly connected.

Welding work
Welding work on the product or any installed equipment may only be carried out by personnel authorized by
Rolls-Royce Solutions. Cover the product when welding in its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolator switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other assembly, maintenance, or repair work may be carried out in the vicinity of the product while weld-
ing is in progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubri-
cants.
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 can induce interfering voltages in the wiring harnesses which may damage the electrical sys-
tem.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.

Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified jigs
for the 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 which are under pressure.
Before starting work, pay attention to the following:
• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.
• For hydraulic installation, screw on the jig with the piston retracted.
• For hydraulic removal, screw on the jig with the piston extended.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft end
until correct sealing is established.
During hydraulic installation and removal of components, ensure that nobody is standing in the immediate
vicinity of the component being installed/removed.

Working with batteries

Observe the safety instructions of the manufacturer when working on batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
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Do not allow electrolyte to come into contact with skin or clothing.

Wear protective clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. The battery may explode and spray
acid if the battery terminals are connected incorrectly.

MS150094/07E 2022-05 | Safety | 15

 Working on electrical and electronic assemblies
Always obtain the permission of the person in charge before commencing any assembly, maintenance, and
repair work or switching off any part of the electronics required to do so.
De-energize the relevant areas prior to working on assemblies.
ESD (Electrostatic Discharge): Work on components which could be damaged by electrostatic discharge
must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically conductive
work surfaces or antistatic wristbands.
Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable ties to secure lines.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to functional testing on completion of all repair work. The emergen-
cy stop function must be tested in particular. Check operation of the emergency stop functionality, which
entails switching of the power supply to the engine governor may only be carried out when the product is
cold.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil (as necessary)

Working with laser equipment

Work with laser equipment shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser equipment must be equipped with the protective devices necessary for safe operation according to
type and application.

Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.
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16 | Safety | MS150094/07E 2022-05

 2.6 Fire and environmental protection, indirect materials
Fire prevention and fire
Flames, naked light and smoking are prohibited.
In the event of a fire, stop the fuel supply if this is possible without endangering personnel.
Manually-actuated equipment must be easily accessible to authorized personnel to facilitate stopping the
fuel supply in the event of fire.
The product has hot surfaces that can ignite combustible gases and other substances in the surrounding
area. The operating company must ensure that the product is installed and operated a sufficient distance
away from danger sources and any existing safety instructions or recommendations must be observed. Prod-
ucts that comply with the SOLAS convention do not constitute such a danger.
Depending on the operating and ambient conditions, fuel temperatures above the flash point temperature
are possible in the tank. This can lead to the creation of a dangerous potentially explosive atmosphere in the
tank and makes suitable explosion protection measures necessary.
After working with combustible indirect materials (e.g. cleaning agents), ensure that the area is well ventilat-
ed. The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmos-
phere.
Immediately eliminate any fluid or lubricant leakage. Fluids or lubricants splashing on hot components can
cause fires, so keep the product clean at all times. Remove accumulated dirt (e.g. leaves). Do not leave rags
saturated with fluids and lubricants on the product. Do not store combustible materials near the product.
Incorrect refilling of the reducing agent system with fuel can lead to fires.
Before welding, clean the areas to be welded with a nonflammable fluid. Do not carry out welding work on
pipes and components carrying oil or fuel.
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.
A risk of fire due to human error or a technical defect cannot be excluded completely. Always have suitable
extinguishing agents (fire extinguishers) on hand and familiarize yourself fully with their handling.
For safety-critical environments, check whether further fire prevention measures are necessary.
Toxic substances may be created during a fire. Always wear protective gloves and any other personal protec-
tive equipment that may be necessary when touching any components.

Noise
Wear hearing protection in workplaces with a sound pressure level in excess of 85 dB (A).
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are compromised.

Environmental protection and disposal

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Dispose of used fluids, lubricants and components in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
cled.

Indirect materials
Indirect materials may also be hazardous or toxic. When handling indirect materials as well as other chemical
substances, observe the information contained in the associated safety data sheet. The safety data sheet
may be obtained from the manufacturer or from Rolls-Royce Solutions.
Only fluids and lubricants approved by the manufacturer must be used in accordance with the Fluids and
Lubricants Specifications. Request the most recent edition from the manufacturer.

MS150094/07E 2022-05 | Safety | 17

 When operating with biodiesel fuel: Component corrosion during longer engine service life. Follow the special
instructions in the Fluids and Lubricants Specifications.
Contamination of indirect materials with reducing agent (e.g. AdBlue®, DEF): Store indirect materials in sepa-
rate containers and use separate drip trays. Even very slight contamination with reducing agent can lead to
malfunctions in sensors and other components.
Used oil contains combustion residues that are harmful to health.
Wear protective gloves when handling used oil.
Wash affected areas after contact with used oil.

Registration, evaluation, authorization and restriction of chemicals (REACH

ordinance)
Particularly hazardous substances in our products are compiled in a list:
• http://www.mtu-solutions.com → REACH Declaration

Compressed air
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard rating AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Release residual pressure before removing a compressed air device from the supply line. To depressurize
compressed-air lines, shut off the lines first, then release the residual pressure.
• Carry out a leakage test as specified.

Paints
• Observe the relevant safety data sheet for all materials.
• Ensure that the area is well ventilated when carrying out painting work outside the spray stands provided
with fume extraction systems. Make sure that neighboring work areas are not adversely affected.
• No naked flames in the vicinity.
• No smoking.
• Observe fire-prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
TIM-ID: 0000040536 - 029

• Avoid contact with bare skin.

• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that the working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

18 | Safety | MS150094/07E 2022-05

 Acids, alkaline solutions, reducing agents
• Observe the relevant safety data sheet for all materials.
• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
• If reducing agent is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After skin contact, wash body areas with plenty of water.
• Rinse eyes immediately with eye drops or clean tap water. Consult a doctor as soon as possible.
Contamination of reducing agent with other indirect materials: Store reducing agent in separate contain-
ers and use separate drip trays. Even very slight contamination can result in malfunctions in the exhaust
gas aftertreatment system.
Incorrect refilling of the reducing agent system with fuel can cause leakages at the gaskets and in the
hoses.
TIM-ID: 0000040536 - 029

MS150094/07E 2022-05 | Safety | 19

 2.7 Standards for warning messages in the text and highlighted
information
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.

NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial measures.
• Additional information on the product.

Warning messages
1. This manual with all safety instructions and warning messages must be read and understood by all personnel
involved in operation, maintenance, repair, assembly, installation, or transportation.
2. The highest level warning message is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.

Highlighted information
Important
This field contains product information which is important or useful for the user.
This information must not refer to hazards related to personal injury or material damage.
TIM-ID: 0000040578 - 007

20 | Safety | MS150094/07E 2022-05

 3 Transport
3.1 Transport
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Crossbeam T80091731 1

DANGER
Suspended load
Danger to life
• Never stand under suspended loads!
• Wear appropriate personal protective equipment.

Transport
1. Fit the transport locking device on the engine and fit the engine mounting locking devices prior to transport.
2. Always use the lifting eyes provided when transporting the engine. See installation drawings.
3. Only use suitable transport and lifting equipment.
4. Take the engine's center of gravity into account. See installation drawings.
5. The engine must only be transported in installation position: maximum permissible diagonal pull 10°.
6. Remove any loose parts on the system, engine/generator.
7. Always raise/lower the engine slowly. The lifting ropes or chains must not butt against the engine or its com-
ponents during the lifting procedure. Readjust lifting tackle as necessary.
8. Special packaging with aluminum foil: Attach engine at the lifting eyes of the bearing pedestal or transport
the engine with means of transport suitable for the load (forklift truck).
9. Secure the engine against tilting during transport. Secure, in particular, to prevent slipping and tipping when
driving up or down inclines and ramps.

Placement after transport

1. Engine may only be set/transported on a horizontal surface and the engine mounts/transport supports pro-
vided for this purpose.
2. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
3. Never set the engine down on the oil pan unless this has been expressly authorized by Rolls-Royce Solutions.
TIM-ID: 0000071243 - 006

MS150094/07E 2022-05 | Transport | 21

 4 General Information
4.1 Engine side and cylinder designations

1 Left engine side (A-side) 3 Right engine side (B-side)

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-
hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of
each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 014

22 | General Information | MS150094/07E 2022-05

 4.2 Engine – Overview
12/16V2000C66/S56/S96
This overview applies similarly to 12/16V2000C66/S56/S96 engines.

1 Exhaust turbocharger 7 Power supply 13 Valve gear

2 Air intake/air supply 8 Cooling air system 14 Cylinder head
3 EGR cooler 9 Coolant system 15 Exhaust system
4 Intercooler 10 Mounting / support 16 PTO systems, driving end
5 Monitoring, control and reg- 11 Fuel system (low pressure) and free end (coupling)
ulation equipment, general 12 Fuel system (high pressure)
electr. equipment
6 Lube oil system / lube oil
circuit

Engine model designation

Key to engine model designation
12/16 Number of cylinders
V Cylinder configuration: V-engine
TIM-ID: 0000023527 - 004

2000 Series
C/S Application: C, charge-air cooling in internal circuit, with
piston cooling
Application S: Exhaust turbocharging with supercharger
6/9 Application segment (0, 1, 2,...,9)
6 Design index (0, 1, 2,...,9)

MS150094/07E 2022-05 | General Information | 23

 4.3 Tightening specifications for screws, nuts and bolts
Tightening torques for setscrew and stud connections as per MTN 5008
standard
The standard applies to setscrews that are not subject to dynamic load and the associated nuts according to
the following standards:
• MMN 384
• ISO 4762 (DIN 912)
• ISO 4014 (DIN 931-1)
• ISO 4017 (DIN 933)
• DIN EN ISO 8765 (EN 28765; DIN 960)
• DIN EN ISO 8676 (EN 28676; DIN 961)
• DIN 6912
The standard applies to studs and associated nuts according to following standards:
• DIN 833
• DIN 835
• DIN EN ISO 5395 (DIN 836)
• DIN 938
• DIN 939
The standard applies to screws with hexalobular head according to the following standards:
• DIN 34800
• DIN 34801
It does not apply to heat-resistant and highly heat-resisting screws in the hot component section.
Tightening torques MA are specified for screws of strength class 8.8 (surface condition bare, phosphatized or
galvanized) and 10.9 (surface condition bare or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated in engine oil prior to assembly unless a differ-
ent lubricant is expressly specified.
When hand-tightening (defined torque), an assembly tolerance of -5+15% of the figures in the table is permit-
ted.
The admissible assembly tolerance is ±15% for machine tightening.
Important
Specific tightening torques are specified accordingly in the respective task descriptions; these must be ob-
served!

Tightening torque for setscrews

Manual tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 M A (Nm) 8.8 MA (Nm) 10.9 M A (Nm)
M6 9 12 8 11
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M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150

24 | General Information | MS150094/07E 2022-05

 Manual tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 M A (Nm) 8.8 MA (Nm) 10.9 M A (Nm)
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M20 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA = Tightening torques

Tightening torques for studs

Screwed into
Thread steel M A gray cast iron MA AI alloy MA
(Nm) (Nm) (Nm)
M6 9 6 6
M8 11 9 10
M10 17 13 13
M12 27 23 18
M14 37 33 33
M16 55 45 –
MA = Tightening torques

Tightening torques for setscrews and nuts made of stainless steels

The values in the table are based on a friction coefficient µtot = 0.12, lubricated with Molykote on the thread
and under the screw head.
Strength class
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70 80
Basic size Material
MA MA
(Nm) (Nm)
M5 3.7 4.9 A2 / A4
M6 6.4 8.5 A2 / A4
M8 15.3 20.4 A2 / A4
M10 31 41 A2 / A4
M12 52 70 A2 / A4

MS150094/07E 2022-05 | General Information | 25

 Strength class
70 80
Basic size Material
MA MA
(Nm) (Nm)
M16 126 167 A2 / A4
M20 254 326 A2 / A4
MA = Tightening torques

Tightening torques for self-locking hex nuts

Thread MA (Nm) Lubricant
M6 7.5 +1 –
M8 17 +2 –
M10 35 +4 –
M12 59 +6 –
M14 100 +10 –
M16 140 +14 –
M20 290 +29 –
MA = Tightening torques

Tightening torques for stress bolt connections as per MTN 5007 standard
This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of
strength class 10.9 as well as to the associated nuts.
Shaft and transition dimensions as per MMN 209 standard and material and machining as per MMN 389
standard (bright surface or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated in engine oil prior to assembly.
For unavoidable deviations during the tightening procedure, an assembly tolerance of +10% of the table value
is permissible.
The values in the tables are for manual tightening using a torque wrench.

Thread Not torsion-protected MA(Nm) Torsion-protected* MA(Nm)

M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
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M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450

26 | General Information | MS150094/07E 2022-05

 Thread Not torsion-protected MA(Nm) Torsion-protected* MA(Nm)
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
M30 1250 1575
*Protect screw shank from torsion when tightening.
MA=tightening torques.

Tightening torques for plug screws as per MTN 5183-1 standard

This standard applies to plug screws as per DIN 908, DIN 910 and DIN 7604 with screwed plug DIN 3852,
model A (sealed by sealing ring DIN 7603-Cu).
TIM-ID: 0000002333 - 019

MS150094/07E 2022-05 | General Information | 27

 Tightening torques MA are given for plug screws made of steel (St) with surface protected by a phosphate
coating and oiled or galvanized.
Threads and mating faces beneath heads must be coated in engine oil prior to assembly.
For unavoidable deviations during the tightening procedure, an assembly tolerance of +10% of the table value
is permissible.
Tightening torques for plug screws DIN 908, DIN 910 and DIN 7604A (with short screwed plug)
Screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 25 25
M14 x 1.5 35 30
M16 x 1.5 40 35
M18 x 1.5 50 40
M20 x 1.5 60 50
M22 x 1.5 70 70
M24 x 1.5 85 80
M26 x 1.5 100 100
M27 x 2 100 100
M30 x 1.5 110 110
M30 x 2 120 120
M33 x 2 160 160
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M36 x 1.5 190 180

M38 x 1.5 220 200
M42 x 1.5 260 240
M45 x 1.5 290 270
M48 x 1.5 310 300
M52 x 1.5 325 320
M56 x 2 380 360

28 | General Information | MS150094/07E 2022-05

 Screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M64 x 2 400 400
MA = Tightening torques

Tightening torque for plug screws DIN 7604C (with long spigot union)
Screwed into
Thread Steel/gray cast iron M A AI alloy MA
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
MA = Tightening torques

Tightening torque for banjo screws as per MTN 5183-2 standard

This standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603-Cu.
TIM-ID: 0000002333 - 019

MS150094/07E 2022-05 | General Information | 29

 The stated tightening torques MA apply to steel (St) banjo screws with a phosphatized surface and oiled or
galvanized and for copper-aluminum alloy.
Threads and mating faces beneath heads must be coated in engine oil prior to assembly.
For unavoidable deviations during the tightening procedure, an assembly tolerance of +10% of the table value
is permissible.

Tightening torques for steel banjo screws

Screwed in steel/gray cast iron/aluminum alloy
Thread MA
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160
MA = Tightening torques
TIM-ID: 0000002333 - 019

Tightening torques for copper-aluminum alloy banjo screws

Screwed in steel/gray cast iron/aluminum alloy
Thread MA
(Nm)
M10 x 1 15
M16 x 1.5 30
MA = Tightening torques

30 | General Information | MS150094/07E 2022-05

 Tightening torques for male connectors as per MTN 5183-3 standard
This standard applies to male connectors DIN 2353, series L with screwed plug DIN 3852, model A (sealed
by sealing ring DIN 7603-Cu).

Tightening torques MA are given for male connectors made of steel (St) with surface protected by a phos-
phate coating and oiled or galvanized.
Threads and mating faces beneath heads must be coated in engine oil prior to assembly.
For unavoidable deviations during the tightening procedure, an assembly tolerance of +10% of the table value
is permissible.
Screwed in steel/gray cast iron MA
Thread
(Nm)
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 35
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
MA = Tightening torques
TIM-ID: 0000002333 - 019

MS150094/07E 2022-05 | General Information | 31

 Tightening torques for union nuts as per DIN 3859-2
1 Union nut
2 Screw fixture
3 O-ring
4 Ball-type union

Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase
in force), it should be tightened another 1/4 turn (90°) past this point.

Tightening torques for spigot unions with O-ring as per ISO 6149-2

Thread Torque (Nm) +10%

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M8 x 1 10
M10 x 1 20
M12 x 1.5 35
M14 x 1.5 45
M16 x 1.5 55
M18 x 1.5 70
M20 x 1.5 1) 80
M22 x 1.5 100

32 | General Information | MS150094/07E 2022-05

 Thread Torque (Nm) +10%
M27 x 2 170
M33 x 2 310
M42 x 2 330
M48 x 2 420
M60 x 2 500
1)
Only for closing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789).

Tightening torques for spigot unions with O-ring as per ISO 6149-3

Thread Torque (Nm) +10%

M8 x 1 8
M10 x 1 15
M12 x 1.5 25
M14 x 1.5 35
M16 x 1.5 40
M18 x 1.5 45
M22 x 1.5 60
M27 x 2 100
M33 x 2 160
M42 x 2 210
M48 x 2 260
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M60 x 2 315

MS150094/07E 2022-05 | General Information | 33

 Tightening torques for plug screws as per MTN 5183-6

Screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 20 10 +2
M12 x 1.5 35 14 +2
M14 x 1.5 45 15 +3
M16 x 1.5 55 18 +3
M18 x 1.5 70 23 +3
M22 x 1.5 100 33 +4
M27 x 2 170 57 +5
M33 x 2 310 103 +10
M42 x 2 330 110 +11
M48 x 2 420 140 +14
M60 x 2 – 200 +20
MA = Tightening torques

Assembly instructions and tightening torques for hose fittings with union nuts
The instructions do not apply to ORFS hose fittings. When connecting hose fittings with sealing heads and
the associated adapters, assemble in contrast to the instructions for pipe unions in the following manner.
Hose fitting, metallic sealing with union nut: Tighten union nut by hand then tighten max. 1/4 turn with
TIM-ID: 0000002333 - 019

wrench.
Hose fitting with O-ring and union nut: Tighten union nut by hand then tighten max. 1/2 turn with wrench.
Align hoses accordingly prior to tightening the union nut.
Sealing head/sealing cone with metric union nut
Metric thread Pipe outer diameter Torque (Nm)
M12 x 1.5 6 20
M14 x 1.5 8 38

34 | General Information | MS150094/07E 2022-05

 Sealing head/sealing cone with metric union nut
Metric thread Pipe outer diameter Torque (Nm)
M16 x 1.5 8 45
10
M18 x 1.5 10 51
12
M20 x 1.5 12 58
M22 x 1.5 14 74
15
M24 x 1.5 16 74
M26 x 1.5 18 105
M30 x 2 20 135
22
M36 x 2 25 166
28
M42 x 2 30 240
M45 x 2 35 290
M52 x 2 38 330
42

Sealing head with BSP union nut

BSP thread Torque (Nm)
G1/4 20
G3/8 34
G1/2 60
G5/8 69
G3/4 115
G1 140
G1.1/4 210
G1.1/2 290
G2 400

SAE sealing cone with union nut JIC 37°

UNF thread Size Torque (Nm)
7/16–20 –4 15
1/2–20 –5 20
9/16–18 –6 30
3/4–16 –8 50
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7/8–14 –10 69
1.1/16–12 –12 98
1.3/16–12 –14 118
1.5/16–12 –16 140
1.5/8–12 –20 210
1.7/8–12 –24 290
2.1/2–12 –32 450

MS150094/07E 2022-05 | General Information | 35

 ORFS – flat sealing with union nut
UNF thread Size Torque (Nm)
9/16–18 –4 14 +2
11/16–16 –6 24 +3
13/16–16 –8 43 +4
1–14 –10 60 +8
1.3/16–12 –12 90 +5
1.3/16–12 –14 90 +5
1.7/16–12 –16 125 +10
1.11/16–12 –20 170 +20
2–12 –24 200 +25
2–1/2–20 –32 460 +30

TIM-ID: 0000002333 - 019

36 | General Information | MS150094/07E 2022-05

 4.4 Data acquisition and data transmission
Data acquisition and data transmission

Rolls-Royce Solutions products automatically capture and record data and transmit it to the manufacturer.
This does not apply to Rolls-Royce Solutions products in military applications.
The data transmitted includes operating data, GPS data, log files of malfunctions and fault messages. No per-
sonal data is collected and transmitted.
The data is used by the manufacturer for the purposes of product development and product improvement as
well as for service optimization.
TIM-ID: 0000106274 - 001

MS150094/07E 2022-05 | General Information | 37

 5 Technical Data
5.1 Product data 12/16V2000C66
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

Reference conditions
Engine model 12V2000 16V2000
C66 C66
Application group 5B 5B
Intake air temperature °C 25 25
Charge-air coolant temperature °C 45 45
Barometric pressure mbar 1000 1000
Site altitude above sea level m 100 100

Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 12 16
Rated engine speed A rpm 2100 2100
Effective power (w/o fan) (Fuel stop power ISO 3046) A kW 783 970

Boundary conditions (for max. power)

Number of cylinders 12 16
Intake depression (new filter) A mbar 15 15
Intake depression, max. L mbar 50 35
Exhaust overpressure A mbar 30 30
Exhaust gas overpressure, max. L mbar 100 75
Fuel temperature at engine inlet connection R °C 37 37
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Fuel temperature at engine inlet connection, max (w/o power re- L °C 65 65

duction)

Consumption
Number of cylinders 12 16
Lube oil consumption after 100 h runtime (B = hourly fuel con- R % of B 0.35 0.35
sumption)

38 | Technical Data | MS150094/07E 2022-05

 Model-related data (basic design)
Number of cylinders 12 16
Number of cylinders 12 16
Cylinder configuration: V angle Degrees 90 90
(°)
Bore mm 135 135
Stroke mm 156 156
Cylinder displacement Liters 2.233 2.233
Total displacement Liters 26.80 35.73
Number of inlet valves per cylinder 2 2
Exhaust valves per cylinder 2 2

Air / exhaust gas

Number of cylinders 12 16
Charge-air pressure before cylinder R bar abs 3.80 3.80
Exhaust temperature after exhaust turbocharger R °C 375 390

Coolant system (HT circuit)

Number of cylinders 12 16
Coolant temperature (at engine connection: outlet to cooling A °C 100 100
equipment)
Coolant temperature after engine, warning R °C 106 105
Coolant temperature after engine, shutdown L °C 108 107
Coolant antifreeze content, max. L % 50 50
Coolant pump: inlet pressure, max. L bar 1.3 1.3
Thermostat: Starts to open R °C 79 79
Thermostat: Fully open R °C 92 92

Coolant system (LT circuit)

Number of cylinders 12 16
Coolant antifreeze content, max. L % 50 50
Charge-air temperature after intercooler, max. L °C 95 95
Thermostat: Starts to open R °C 38 38
Thermostat: Fully open R °C 51 51
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Lube oil system

Number of cylinders 12 16
Lube-oil operating temperature before engine, from R °C 80 80
Lube oil operating temperature before engine, to R °C 103 104
Lube oil temperature before engine, alarm R °C 103 105
Lube oil temperature before engine, shutdown L °C 105 107
Lube oil operating pressure before engine, warning R bar 6.4 7.0
Lube oil operating pressure before engine, shutdown L bar 5.9 6.5

MS150094/07E 2022-05 | Technical Data | 39

 Fuel system
Number of cylinders 12 16
Fuel pressure at engine inlet connection, min. (when engine is L bar abs 0.5 0.5
starting)
Fuel pressure at engine inlet connection, min. (when engine is run- L bar abs 0.5 0.5
ning),
Fuel pressure at engine inlet connection, max. (when engine is L bar abs 1.5 1.5
starting)

General operating data

Number of cylinders 12 16
Coolant preheating: preheating temperature (min.) L °C 32 32

Inclinations, standard oil system (reference: waterline)

Number of cylinders 12 16
Longitudinal inclination, continuous max. driving end down (Op- L Degrees 15 10
tion: max. operating inclinations) (°)
Longitudinal inclination, continuous max. driving end up (Option: L Degrees 15 10
max. operating inclinations) (°)
Transverse inclination, continuous max. (option: max. operating in- L Degrees 15 10
clinations) (°)

Capacities
Number of cylinders 12 16
Engine coolant capacity, engine side (without cooling equipment) R Liters 63 83
Charge-air coolant, engine side R Liters 25 37
Total engine oil capacity at initial filling (standard oil system) (Op- R Liters 99 154
tion: max. operating inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Op- L Liters 73 107
tion: max. operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Op- L Liters 81 120
tion: max. operating inclinations)

Acoustics
Number of cylinders 12 16
Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, R dB(A) 103 109
1 m distance, ISO 6798, +3 dB(A) tolerance)
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Exhaust noise, unsilenced - BL (sound power level LW, ISO R dB(A) 116 122
6798+3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL R dB(A) 103 104
(free-field sound pressure level Lp, 1 m distance, ISO 6798,
+2 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL R dB(A) 121 122
(sound power level LW, ISO 6798+2 dB(A) tolerance)

40 | Technical Data | MS150094/07E 2022-05

 5.2 Product data 12V2000C66R
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

Reference conditions
Engine model 12V2000C
66R
Application group 5B
Intake air temperature °C 25
Charge-air coolant temperature °C 45
Barometric pressure mbar 1000
Site altitude above sea level m 100

Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 12
Rated engine speed A rpm 1800
Fuel stop power ISO 3046 A kW 783

Boundary conditions (for max. power)

Number of cylinders 12
Intake depression (new filter) A mbar 15
Intake depression, max. L mbar 39
Exhaust overpressure A mbar 30
Exhaust gas overpressure, max. L mbar 80

Model-related data (basic design)

Number of cylinders 12
Engine with exhaust turbocharging (ETC) and charge-air cooling (intercool- X
er)
TIM-ID: 0000063641 - 002

Uncooled exhaust lines X

Cylinder configuration: V angle Degrees (°) 90
Bore mm 135
Stroke mm 156
Cylinder displacement Liters 2.233
Total displacement Liters 26.80
Compression ratio 16.5

MS150094/07E 2022-05 | Technical Data | 41

 Number of cylinders 12
Number of inlet valves per cylinder 2
Exhaust valves per cylinder 2
Standard housing connecting flange (engine main PTO) SAE 0

Coolant system (HT circuit)

Number of cylinders 12
Coolant temperature (at engine connection: outlet to cooling equipment) A °C 100
Coolant temperature after engine, warning L °C 106
Coolant temperature after engine, shutdown L °C 108
Coolant antifreeze content, max. L % 50
Pressure loss in off-engine cooling system, max. L bar 0.8

Coolant system (LT circuit)

Number of cylinders 12
Coolant temperature before intercooler (at engine connection: inlet from A °C 45
cooling equipment)
Coolant antifreeze content, max. L % 50
Pressure loss in off-engine cooling system, max. L bar 0.8

Lube oil system

Number of cylinders 12
Lube-oil operating temperature before engine, from R °C 80
Lube oil operating temperature before engine, to R °C 103
Lube oil temperature before engine, alarm L °C 103
Lube oil temperature before engine, shutdown L °C 105
Lube-oil operating pressure before engine, from R bar 7.6
Lube oil operating pressure before engine, to R bar 8.5

Fuel system
Number of cylinders 12
Fuel pressure at engine inlet connection, min. (when engine is starting) L bar abs 0.5
Fuel pressure at engine inlet connection, max. (when engine is starting) L bar abs 1.5

General operating data

TIM-ID: 0000063641 - 002

Number of cylinders 12
Cold start capability: air temperature (w/o start aid, w/o preheating) - R °C 0
(case A)
Firing speed, from R rpm 100
Firing speed, to R rpm 120

42 | Technical Data | MS150094/07E 2022-05

 Inclinations, standard oil system (reference: waterline)
Number of cylinders 12
Longitudinal inclination, continuous max. driving end down (Option: max. L Degrees (°) 15
operating inclinations)
Longitudinal inclination, continuous max. driving end up (Option: max. op- L Degrees (°) 15
erating inclinations)
Transverse inclination, continuous max. (option: max. operating inclina- L Degrees (°) 15
tions)

Capacities
Number of cylinders 12
Engine coolant capacity, engine side (without cooling equipment) R Liters 63
Charge-air coolant, engine side R Liters 25
Total engine oil capacity at initial filling (standard oil system) (Option: max. R Liters 99
operating inclinations)
Oil change quantity max. (standard oil system) (option: max. operating in- R Liters 87
clinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: L Liters 73
max. operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: L Liters 81
max. operating inclinations)

Mass / main dimensions

Number of cylinders 12
Engine weight, dry (basic engine configuration acc. to scope of supply R kg 2950
specification)

Acoustics
Number of cylinders 12
Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1 m dis- R dB(A) 103
tance, ISO 6798, +3 dB(A) tolerance)
Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798+3 dB(A) R dB(A) 116
tolerance)
Engine surface noise with attenuated intake noise (filter) - BL (free-field R dB(A) 103
sound pressure level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL (sound power R dB(A) 121
level LW, ISO 6798+2 dB(A) tolerance)
TIM-ID: 0000063641 - 002

MS150094/07E 2022-05 | Technical Data | 43

 5.3 Product data 12/16V2000S56
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

Reference conditions
Engine model 12V2000 16V2000
S56 S56
Application group 4B 4B
Intake air temperature °C 25 25
Charge-air coolant temperature °C 45 45
Barometric pressure mbar 1000 1000
Site altitude above sea level m 100 100

Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 12 16
Rated engine speed A rpm 2100 2100
Fuel stop power ISO 3046 A kW 783 970

Boundary conditions (for max. power)

Number of cylinders 12 16
Intake depression (new filter) A mbar 15 15
Intake depression, max. L mbar 50 35
Exhaust overpressure A mbar 30 30
Exhaust gas overpressure, max. L mbar 100 75

Model-related data (basic design)

Number of cylinders 12 16
Engine with exhaust turbocharging (ETC) and charge-air cooling X X
(intercooler)
TIM-ID: 0000063640 - 002

Uncooled exhaust lines X X

Cylinder configuration: V angle Degrees 90 90
(°)
Bore mm 135 135
Stroke mm 156 156
Cylinder displacement Liters 2.233 2.233
Total displacement Liters 26.80 35.73
Compression ratio 16.5 16.5

44 | Technical Data | MS150094/07E 2022-05

 Number of cylinders 12 16
Number of inlet valves per cylinder 2 2
Exhaust valves per cylinder 2 2
Standard housing connecting flange (engine main PTO) SAE 0 0

Coolant system (HT circuit)

Number of cylinders 12 16
Coolant temperature (at engine connection: outlet to cooling A °C 100 100
equipment)
Coolant temperature after engine, warning L °C 106 105
Coolant temperature after engine, shutdown L °C 108 107
Coolant antifreeze content, max. L % 50 50
Pressure loss in off-engine cooling system, max. L bar 1.0 1.0

Coolant system (LT circuit)

Number of cylinders 12 16
Coolant temperature before intercooler (at engine connection: in- A °C 45 45
let from cooling equipment)
Coolant antifreeze content, max. L % 50 50
Pressure loss in off-engine cooling system, max. L bar 1.0 1.0

Lube oil system

Number of cylinders 12 16
Lube-oil operating temperature before engine, from R °C 80 80
Lube oil operating temperature before engine, to R °C 103 104
Lube oil temperature before engine, alarm L °C 103 105
Lube oil temperature before engine, shutdown L °C 105 107
Lube-oil operating pressure before engine, from R bar 7.6 7.8
Lube oil operating pressure before engine, to R bar 9.0 9.6

Fuel system
Number of cylinders 12 16
Fuel pressure at engine inlet connection, min. (when engine is L bar abs 0.5 0.5
starting)
Fuel pressure at engine inlet connection, max. (when engine is L bar abs 1.5 1.5
starting)
TIM-ID: 0000063640 - 002

General operating data

Number of cylinders 12 16
Cold start capability: air temperature (w/o start aid, w/o preheat- R °C 0 0
ing) - (case A)
Firing speed, from R rpm 100 100
Firing speed, to R rpm 120 120

MS150094/07E 2022-05 | Technical Data | 45

 Inclinations, standard oil system (reference: waterline)
Number of cylinders 12 16
Longitudinal inclination, continuous max. driving end down (Op- L Degrees 15 10
tion: max. operating inclinations) (°)
Longitudinal inclination, continuous max. driving end up (Option: L Degrees 15 10
max. operating inclinations) (°)
Transverse inclination, continuous max. (option: max. operating in- L Degrees 15 10
clinations) (°)

Capacities
Number of cylinders 12 16
Engine coolant capacity, engine side (without cooling equipment) R Liters 63 83
Charge-air coolant, engine side R Liters 25 37
Total engine oil capacity at initial filling (standard oil system) (Op- R Liters 99 154
tion: max. operating inclinations)
Oil change quantity max. (standard oil system) (option: max. oper- R Liters 87 130
ating inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Op- L Liters 73 109
tion: max. operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Op- L Liters 81 120
tion: max. operating inclinations)

Mass / main dimensions

Number of cylinders 12 16
Engine weight, dry (basic engine configuration acc. to scope of R kg 2950 3350
supply specification)

Acoustics
Number of cylinders 12 16
Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, R dB(A) 103 109
1 m distance, ISO 6798, +3 dB(A) tolerance)
Exhaust noise, unsilenced - BL (sound power level LW, ISO R dB(A) 116 122
6798+3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL R dB(A) 103 104
(free-field sound pressure level Lp, 1 m distance, ISO 6798,
+2 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL R dB(A) 121 122
(sound power level LW, ISO 6798+2 dB(A) tolerance)
TIM-ID: 0000063640 - 002

46 | Technical Data | MS150094/07E 2022-05

 5.4 Product data 12/16V2000S96
Explanation:
DL Reference value: Continuous power
BL Reference value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable

Reference conditions
Engine model 12V2000 16V2000
S96 S96
Application group 4D 4D
Intake air temperature °C 25 25
Charge-air coolant temperature °C 45 45
Barometric pressure mbar 1000 1000
Site altitude above sea level m 100 100

Power-related data (power ratings are net brake power as per ISO 3046)
Number of cylinders 12 16
Rated engine speed A rpm 2100 2100
Fuel stop power ISO 3046 A kW 858 1163

Boundary conditions (for max. power)

Number of cylinders 12 16
Intake depression (new filter) A mbar 15 15
Intake depression, max. L mbar 50 50
Exhaust overpressure A mbar 30 30
Exhaust gas overpressure, max. L mbar 100 75

Model-related data (basic design)

Number of cylinders 12 16
Engine with exhaust turbocharging (ETC) and charge-air cooling X X
(intercooler)
TIM-ID: 0000025538 - 003

Uncooled exhaust lines X X

Number of cylinders 12 16
Cylinder configuration: V angle Degrees 90 90
(°)
Bore mm 135 135
Stroke mm 156 156
Cylinder displacement Liters 2.233 2.233
Total displacement Liters 26.80 35.73

MS150094/07E 2022-05 | Technical Data | 47

 Number of cylinders 12 16
Compression ratio 16.5 16.5
Number of inlet valves per cylinder 2 2
Exhaust valves per cylinder 2 2
Standard housing connecting flange (engine main PTO) SAE 0 0

Coolant system (HT circuit)

Number of cylinders 12 16
Coolant temperature (at engine connection: outlet to cooling A °C 100 100
equipment)
Coolant temperature after engine, warning L °C 106 105
Coolant temperature after engine, shutdown L °C 108 107
Coolant antifreeze content, max. L % 50 50
Pressure loss in off-engine cooling system, max. L bar 1.0 1.0

Coolant system (LT circuit)

Number of cylinders 12 16
Coolant temperature before intercooler (at engine connection: in- A °C 45 45
let from cooling equipment)
Coolant antifreeze content, max. L % 50 50
Pressure loss in off-engine cooling system, max. L bar 1.0 1.0

Lube oil system

Number of cylinders 12 16
Lube-oil operating temperature before engine, from R °C 80 80
Lube oil operating temperature before engine, to R °C 103 104
Lube oil temperature before engine, alarm L °C 103 105
Lube oil temperature before engine, shutdown L °C 105 107
Lube-oil operating pressure before engine, from R bar 7.6 7.8
Lube oil operating pressure before engine, to R bar 9.0 9.6

Fuel system
Number of cylinders 12 16
Fuel pressure at engine inlet connection, min. (when engine is L bar abs 0.5 0.5
starting)
TIM-ID: 0000025538 - 003

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

General operating data

Number of cylinders 12 16
Cold start capability: air temperature (w/o start aid, w/o preheat- R °C 0 0
ing) - (case A)
Firing speed, from R rpm 100 100
Firing speed, to R rpm 120 120

48 | Technical Data | MS150094/07E 2022-05

 Inclinations, standard oil system (reference: waterline)
Number of cylinders 12 16
Longitudinal inclination, continuous max. driving end down (Op- L Degrees 15 10
tion: max. operating inclinations) (°)
Longitudinal inclination, continuous max. driving end up (Option: L Degrees 15 10
max. operating inclinations) (°)
Transverse inclination, continuous max. (option: max. operating in- L Degrees 15 10
clinations) (°)

Capacities
Number of cylinders 12 16
Engine coolant capacity, engine side (without cooling equipment) R Liters 63 83
Charge-air coolant, engine side R Liters 25 37
Total engine oil capacity at initial filling (standard oil system) (Op- R Liters 99 154
tion: max. operating inclinations)
Oil change quantity max. (standard oil system) (option: max. oper- R Liters 87 130
ating inclinations)
Oil pan capacity at dipstick mark “min.” (standard oil system) (Op- L Liters 73 109
tion: max. operating inclinations)
Oil pan capacity at dipstick mark “max.” (standard oil system) (Op- L Liters 81 120
tion: max. operating inclinations)

Mass / main dimensions

Number of cylinders 12 16
Engine weight, dry (basic engine configuration acc. to scope of R kg 2950 3350
supply specification)

Acoustics
Number of cylinders 12 16
Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, R dB(A) 103 110
1 m distance, ISO 6798, +3 dB(A) tolerance)
Exhaust noise, unsilenced - BL (sound power level LW, ISO R dB(A) 116 123
6798+3 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL R dB(A) 103 107
(free-field sound pressure level Lp, 1 m distance, ISO 6798,
+2 dB(A) tolerance)
Engine surface noise with attenuated intake noise (filter) - BL R dB(A) 121 125
(sound power level LW, ISO 6798+2 dB(A) tolerance)
TIM-ID: 0000025538 - 003

MS150094/07E 2022-05 | Technical Data | 49

 5.5 Firing order
Firing order
12V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7

TIM-ID: 0000038135 - 002

50 | Technical Data | MS150094/07E 2022-05

 5.6 Engine, main dimensions

Item Engine model/dimensions Engine model/dimensions

12V2000C66/C66R/S56/S96 16V2000C66/S56/S96
Length (A) Approx. 2028 mm Approx. 2378 mm
Width (B) Approx. 1279 mm Approx. 1289.5 mm
Height (C) Approx. 1452.6 mm Approx. 1479.6 mm
TIM-ID: 0000023835 - 002

MS150094/07E 2022-05 | Technical Data | 51

 6 Operation
6.1 Preparations for putting into operation after extended out-of-
service periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ Fluids and Lubricants Specifications (A001061/..) are available.

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

Item Action
Engine Depreserve (→ Preservation and Represervation Specifications (A001070/
…)).
Lube oil system Check engine oil level (→ Page 131).
Fuel system Use appropriate equipment to fill system via fuel supply line.
Fuel system Vent (→ Page 115).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 144). Change charge-air coolant (→ Page 153).
Coolant circuit Check engine coolant level (→ Page 143); Check charge-air coolant level
(→ Page 151).
Coolant circuit Preheat engine coolant with coolant preheating unit (if fitted).
Engine governor Check plug connections (→ Page 170).
Engine Control System Switch on.

TIM-ID: 0000010073 - 005

52 | Operation | MS150094/07E 2022-05

 6.2 Preparations for putting into operation after scheduled out-of-
service-period
Preconditions
☑ Engine is stopped and starting disabled.

Putting into operation

Item Action
Lube oil system Check engine oil level (→ Page 131).
Coolant circuit Check engine coolant level (→ Page 143).
Check charge-air coolant level (→ Page 151).
Coolant circuit Preheat engine coolant with coolant preheating unit, if fitted.
Fuel prefilter (if fitted) Drain water and contaminants, see manufacturer's documentation.
Engine Control System Switch on.
TIM-ID: 0000010642 - 004

MS150094/07E 2022-05 | Operation | 53

 6.3 Engine – Starting
Preconditions
☑ Engine is not under load.

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.

WARNING
Starter heats up during the starting procedure.
Risk of burning, in particular to the hands!
• Avoid skin contact with the starter.
• Wear suitable protective equipment, e.g industrial gloves.

WARNING
A high level of noise is produced when the system is running.
Risk of hearing loss!
• Wear suitable hearing protection.

WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.

Engine – Starting
Item Measure
Engine Start the engine (→ documentation of the vehicle manufacturer/plant manu-
facturer).

TIM-ID: 0000010107 - 010

54 | Operation | MS150094/07E 2022-05

 6.4 Re-starting the engine following an automatic safety
shutdown
NOTICE
Re-starting the engine following an automatic safety shutdown.
Risk of severe engine damage!
• Before starting the engine, make sure the root cause of the safety shutdown was eliminated.
• If the root cause cannot be identified or eliminated, contact Service.

Note: • If an engine has been shutdown by a fault (red alarm), the engine may only be re-started when the fault
has been identified and eliminated.

Procedure following an automatic safety shutdown

1. Eliminate fault.
2. If the root cause cannot be identified or eliminated, contact Service.
Important
The function "Overdrive safety system" (if fitted), which is only used in emergency situations, is not affect-
ed.
TIM-ID: 0000081383 - 001

MS150094/07E 2022-05 | Operation | 55

 6.5 Operational monitoring
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
A high level of noise is produced when the system is running.
Risk of hearing loss!
• Wear suitable hearing protection.

Operational monitoring
Item Measure
Control and display panels Check readings of operating data (speed, temperature, pressures).
Engine oil Check engine oil level (→ Page 131).
Engine operation Visually inspect engine for leaks and general condition;
Check engine for abnormal running noises, exhaust gas color and vibra-
tions.
Air filter Check maintenance indicator of air filter (if fitted), see manufacturer's
documentation.
Exhaust system Check exhaust gas color (→ Page 65).
Fuel prefilter (if fitted) Check reading at differential pressure gauge of fuel prefilter, see manufac-
turer's documentation.
Intercooler Check condensate drain for coolant discharge and obstruction
(→ Page 126).
Engine coolant pump Check relief bore (→ Page 148).
Charge-air coolant pump Check relief bore (→ Page 157).

TIM-ID: 0000025277 - 006

56 | Operation | MS150094/07E 2022-05

 6.6 Emission label – Check

Emission label – Check

Note: If there are any irregularities, notify your Rolls-Royce Solutions contact person/service partner without delay.
1. Check that emissions labels are present (there can be more than one).
2. Check emission labels for intactness.
3. Check emission labels for complete readability.
4. Check emission labels for content:
• Does the label on the engine match the label document in the Business Portal/Equipment?
• Does the engine number on the emission label match the engine nameplate?
• Does the Manufacturing Date match the year of manufacture on the nameplate?
TIM-ID: 0000063752 - 006

MS150094/07E 2022-05 | Operation | 57

 6.7 Engine shutdown
Preconditions
☑ Engine is not connected to load.

CAUTION
Shutting down from full-load operation may cause hot water to escape from the expansion tank.
Risk of scalding!
• Allow engine to cool down.
• Wear protective clothing, protective gloves, and safety goggles / safety mask.

NOTICE
Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress-
es.
Overheating of and, therefore, damage to components is possible!
• Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant
levels are indicated.

Preparation
Item Action
Engine Allow the engine to cool down by running it at idle speed for approx. 5 mi-
nutes.

Stopping the engine

Item Action
Engine Stopping (→ Documentation of the vehicle/plant manufacturer).

TIM-ID: 0000010138 - 007

58 | Operation | MS150094/07E 2022-05

 6.8 Emergency engine stop
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
A high level of noise is produced when the system is running.
Risk of hearing loss!
• Wear suitable hearing protection.

WARNING
Exhaust gases are harmful to health and may cause cancer.
Risk of poisoning and suffocation!
• Keep the engine room well-ventilated at all times.
• Repair leaking exhaust pipework immediately.

NOTICE
An emergency stop subjects the engine system to an extremely high load.
Risk of overheating, damage to components!
• Trigger an emergency stop only in emergency situations.

Emergency engine stop

Item Action
Emergency stop pushbutton Press EMERGENCY STOP pushbutton.
• Engine is stopped by disconnecting the power supply to the ECU;
• Emergency-air shutoff flaps close (if applicable);
• Signaling (e.g. by horn, flashing lamp) is activated.

After emergency engine stop

Item Action
Control cabinet, operator Press pushbutton for alarm acknowledgment.
station etc. (depending on • Audible and visual alarm signaling stops
manufacturer)
Engine Manually open emergency-air shutoff flaps (if applicable).
• Switch on ECU power supply
• Engine is ready for starting.
TIM-ID: 0000002307 - 009

MS150094/07E 2022-05 | Operation | 59

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

NOTICE
Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at
temperatures below 0 °C.
Risk of sensor damage!
• Remove pressure sensors and shake off residual water.

After stopping the engine

Item Action
Coolant circuit Drain engine coolant (→ Page 145) and
Drain charge-air coolant (→ Page 156) if
• freezing temperatures are expected, the engine is to remain out of service
for an extended period, but engine coolant has no antifreeze additive.
• 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.
• the antifreeze concentration is 50% and the engine room temperature is
below -40 °C.
Engine Control System Switch off (see manufacturer's documentation).
Air intake and exhaust sys- If the engine is to be taken out of service for longer than one week, seal the
tem engine on the air and exhaust side. Otherwise, components carrying air or
exhaust gas are at risk of corrosion.
If the engine is to be taken out of service for longer than one month, it has to
be preserved (→ Preservation and Represervation Specifications
A001070/..).

TIM-ID: 0000002709 - 011

60 | Operation | MS150094/07E 2022-05

 6.10 Plant – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.
☑ No operating voltage is applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Concentrated cleaning agent (Hakupur 449) X00071179 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and hearing protection.

WARNING
Water jet from high-pressure cleaning unit.
Risk of eye injury, risk of scalding!
• Do not direct water jet at persons.
• Wear protective clothing, protective gloves, and goggles/safety mask.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
• Do not aim compressed air gun directly at seals or electronic components such as connectors or
ECUs.

NOTICE
Incorrect disposal/handling of contaminated water after plant cleaning.
Environmental contamination possible!
• Dispose of contaminated water according to national requirements.

Plant – Cleaning
Important
Observe the valid version of the Fluids and Lubricants Specifications. Further approved cleaning agents
TIM-ID: 0000010171 - 038

may be used.

MS150094/07E 2022-05 | Operation | 61

 1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protec-
tion).
2. Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning
units carefully and observe the safety precautions.
3. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit:
• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
• A minimum distance between spray nozzle and plant of 1 m must be observed.
• The temperature of the cleaning medium must not exceed 80 °C.
4. For external cleaning with high-pressure jet, use a fan jet nozzle only.
Note: Never direct compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
Note: Observe the instructions from the manufacturer of the cleaner!
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use high-pressure jet to remove loosened dirt.
e) Dry engine with compressed air.

TIM-ID: 0000010171 - 038

62 | Operation | MS150094/07E 2022-05

 7 Maintenance
7.1 Maintenance task reference table [QL1] for Non-EPA regions
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a separate publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Option

Task Maintenance tasks

W0500 Check engine oil level. (→ Page 131)

W0501 Visually inspect engine for leaks and general condition. (→ Page 56)
W0502 X Check intercooler drain(s). (→ Page 56)
W0503 Check maintenance indicator of air filter. (→ Page 56)
W0505 Check relief bores of coolant pump(s). (→ Page 56)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 56)
and vibrations.
W0507 X Drain water and contaminants from fuel prefilter. (→ Page 56)
W0508 X Check reading on differential pressure gauge of fuel prefil- (→ Page 56)
ter.
W1001 Replace fuel filter or fuel filter element. (→ Page 117)
W1003 Check belt condition and tension, replace as necessary. (→ Page 158)
W1005 Replace air filter. (→ Page 127)
W1006 Replace fuel injectors. (→ Page 107)
W1008 Replace engine oil filter when changing engine oil, or when (→ Page 134)
the interval (years) is reached, at the latest.
W1009 X Check layer thickness of the oil residue, clean out and re- (→ Page 135)
place filter sleeve, at each oil change, at the latest.
W1178 Replace pressure pipe neck in cylinder head. (→ Page 113)
W1207 Check valve clearance, adjust as necessary. IMPORTANT! (→ Page 103)
First adjustment after 1,000 operating hours on a new en-
gine and after 1,000 operating hours following each over-
haul of the cylinder heads.
W1244 X Check function of rod electrode. -
W1245 X Check alarm function of differential pressure gauge. -
W1246 X Check pump capacity. -
W1523 Check operation of flaps and actuators. (→ Page 130)
TIM-ID: 0000022887 - 005

W1525 Replace sensor. (→ Page 175)

W1526 Replace sensor. (→ Page 173)
W1547 Replace oil mist separator. (→ Page 102)
W1636 Reset drift compensation (CDC) parameters and enter injec- (→ Page 179)
tor codes (IIG).

Table 2: Maintenance task reference table [QL1]

MS150094/07E 2022-05 | Maintenance | 63

 7.2 Maintenance task reference table [QL1] for EPA regions
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Maintenance tasks
W1002 Check valve clearance, adjust as necessary. (→ Page 103)
W1005 Replace air filter. (→ Page 127)
W1006 Replace fuel injectors. (→ Page 107)
W1011 Perform endoscopic examination. (→ Page 100)
W1523 Check operation of flaps and actuators. (→ Page 130)
W1525 Replace sensor. (→ Page 175)
W1526 Replace sensor. (→ Page 173)
W1547 Replace oil mist separator. (→ Page 102)
W1611 Replace sensor. (→ Page 177)
W1636 Reset drift compensation (CDC) parameters and enter injector (→ Page 179)
codes (IIG).
W2059 Clean fuel cooler. (→ Instructions for Overhaul of
Sub-assemblies)

Table 3: Maintenance task reference table [QL1]

TIM-ID: 0000079902 - 001

64 | Maintenance | MS150094/07E 2022-05

 8 Troubleshooting
8.1 Troubleshooting

Engine does not turn when starter is actuated

Component Cause Measure
Battery Discharged or faulty Charge or replace (see manufacturer's
documentation).
Cable connections faulty Check cable connections for secure
seating (see manufacturer's documenta-
tion).
Starter Engine cabling or starter faulty Check cable connections for secure
seating ; Contact Service.
Engine cabling Faulty Check (→ Page 171).
Engine governor Plug connections possibly loose Check plug connections (→ Page 170).
Engine Blocked (engine can not be cranked Contact Service.
manually)

Engine turns but does not fire

Component Cause Measure
Starter Poor rotation: Battery low or faulty Charge or replace battery (see manufac-
turer's documentation).
Engine cabling Faulty Check (→ Page 170).
Fuel system Air in fuel system, if fault occurs after Vent fuel system (→ Page 115).
filling the system
Engine governor Faulty Contact Service.

Engine fires unevenly

Component Cause Measure
Fuel injection equip- Injector faulty Replace (→ Page 107).
ment
Engine cabling Faulty Check (→ Page 171).
Fuel system Air in fuel system, if fault occurs after Vent fuel system (→ Page 115).
filling the system
Engine governor Faulty Contact Service.
TIM-ID: 0000025278 - 003

Engine does not reach rated speed

Component Cause Measure
Fuel supply Fuel prefilter (if fitted) clogged Clean or replace filter element (see man-
ufacturer's documentation).
Fuel filter contaminated Replace (→ Page 117).
Air supply Air filter contaminated Replace air filter (→ Page 127).
Fuel injection equip- Injector faulty Replace (→ Page 107).
ment

MS150094/07E 2022-05 | Troubleshooting | 65

 Component Cause Measure
Engine cabling Faulty Check (→ Page 171).
Engine Overloaded Contact Service.

Engine speed not steady

Component Cause Measure
Fuel injection equip- Injector faulty Replace (→ Page 107).
ment
Speed sensor Faulty Contact Service.
Fuel system Air in fuel system, if fault occurs after Vent fuel system (→ Page 115).
filling the system
Engine governor Faulty Contact Service.

Charge-air temperature too high

Component Cause Measure
Engine coolant Engine coolant concentration incorrect Check (mtu test kit).
Intercooler Contaminated Contact Service.
Engine room Air-intake temperature too high Check fan;
Check air supply / exhaust ducts.

Charge-air pressure too low

Component Cause Measure
Air supply Air filter contaminated Replace air filter (see manufacturer's
documentation).
Intercooler Contaminated Contact Service.
Exhaust turbocharger Faulty Contact Service.

Coolant leak at intercooler

Component Cause Measure
Intercooler Leaking, significant engine coolant dis- Contact Service.
charge

Black exhaust gas

Component Cause Measure
Air supply Air filter contaminated Replace air filter (see manufacturer's
documentation).
Fuel injection equip- Injector faulty Replace (→ Page 107).
TIM-ID: 0000025278 - 003

ment
Engine Overloaded Contact Service.

66 | Troubleshooting | MS150094/07E 2022-05

 Blue exhaust gas
Component Cause Measure
Engine oil Too much engine oil in the engine Drain engine oil (→ Page 132).
Crankcase ventilation, oil mist separator Replace (→ Page 102).
contaminated
Exhaust turbocharger Faulty Contact Service.
Cylinder head
Piston rings
Cylinder liner

White exhaust gas

Component Cause Measure
Engine Not at operating temperature Run engine to reach operating tempera-
ture.
Fuel system Water in fuel Check fuel system at fuel prefilter.
Drain fuel prefilter (→ Page 119).
Intercooler Leaking Contact Service.
TIM-ID: 0000025278 - 003

MS150094/07E 2022-05 | Troubleshooting | 67

 8.2 Engine Control Unit ECU9 – Fault messages
Possible engine reactions to yellow alarm:
Warning, power limitation / reduction, speed limitation, engine stop

Possible engine reactions to red alarm:

Engine stop, power limitation / reduction, speed limitation, warning

Procedure following an automatic safety shutdown (→ Page 55)

5 – HI T-Charge Air
Yellow alarm; warning
Cause Corrective action
Charge-air temperature too high 1. Check coolant cooler and intercooler.
(Level 1). 2. Contact Service if no malfunction can be detected.

6 – SS T-Charge Air
Red alarm; emergency stop
Cause Corrective action
Charge-air temperature too high 1. Check coolant cooler and intercooler.
(Level 2). 2. Contact Service if no malfunction can be detected.

9 – HI T-Coolant Intercooler
Yellow alarm; warning
Cause Corrective action
Coolant temperature in 1. Check coolant cooler for leaks, contamination and operation.
intercooler too high (Level 1). 2. Contact Service if no malfunction can be detected.

10 – SS T-Coolant Intercooler
Red alarm; emergency stop
Cause Corrective action
Coolant temperature in 1. Check coolant cooler for leaks, contamination and operation.
intercooler too high (Level 2). 2. Contact Service if no malfunction can be detected.

15 – LO P-Lube Oil
Yellow alarm; warning
TIM-ID: 0000079920 - 002

Cause Corrective action

Lube oil pressure too low (Level 1. Check oil level, top up as necessary (→ Page 131).
1). 2. Contact Service if no malfunction can be detected.

68 | Troubleshooting | MS150094/07E 2022-05

 16 – SS P-Lube Oil
Red alarm; emergency stop
Cause Corrective action
Lube oil pressure too low (Level 1. Check oil level, top up as necessary (→ Page 131).
2). 2. Contact Service if no malfunction can be detected.

23 – LO Coolant Level
Red alarm; emergency stop
Cause Corrective action
Coolant level too low. 1. Check coolant circuit for leaks. Check coolant level in expansion
tank, top up as necessary.
2. Contact Service if no malfunction can be detected.

25 – HI P-Diff. Lube Oil

Yellow alarm; warning
Cause Corrective action
Differential oil pressure at oil filter u Check oil filter, replace as necessary.
too high (Level 1).

26 – SS P-Diff. Lube Oil

Yellow alarm; warning
Cause Corrective action
Differential oil pressure at oil filter u Check oil filter, replace as necessary.
too high (Level 2).

27 – HI Level Leakage Fuel

Yellow alarm; warning
Cause Corrective action
Leak-off fuel level too high. u Contact Service.

30 – SS Engine Overspeed
Red alarm; emergency stop
Cause Corrective action
Engine speed too high. u Restart engine.
TIM-ID: 0000079920 - 002

33 – HI P-Diff-Fuel
Yellow alarm; warning
Cause Corrective action
Differential pressure at fuel filter u Check fuel filter, replace as necessary.
too high (Level 1).

MS150094/07E 2022-05 | Troubleshooting | 69

 34 – SS P-Diff-Fuel
Yellow alarm; warning
Cause Corrective action
Differential pressure at fuel filter u Check fuel filter, replace as necessary.
too high (Level 2).

44 – LO Coolant Level Intercooler

Red alarm; emergency stop
Cause Corrective action
Intercooler coolant level too low. 1. Check coolant circuit for leaks.
2. Check coolant level in expansion tank, top up as necessary.
3. Contact Service if no malfunction can be detected.

51 – HI T-Lube Oil
Yellow alarm; warning
Cause Corrective action
Lube oil temperature too high 1. Check cooling system.
(Level 1). 2. Contact Service if no malfunction can be detected.

52 – SS T-Lube Oil
Red alarm; emergency stop
Cause Corrective action
Lube oil temperature too high 1. Check cooling system.
(Level 2). 2. Contact Service if no malfunction can be detected.

53 – HI T-Intake Air
Yellow alarm; warning
Cause Corrective action
Intake air temperature too high 1. Check cooling system.
(Level 1). 2. Contact Service if no malfunction can be detected.

54 – HIHI T-Intake Air

Yellow alarm; warning
Cause Corrective action
Intake air temperature too high 1. Check cooling system.
TIM-ID: 0000079920 - 002

(Level 2). 2. Contact Service if no malfunction can be detected.

59 – SS T-Coolant L3
Red alarm; emergency stop
Cause Corrective action
Coolant temperature too high 1. Check cooling system.
(Level 3). 2. Contact Service.

70 | Troubleshooting | MS150094/07E 2022-05

 65 – LO P-Fuel
Yellow alarm; warning
Cause Corrective action
Fuel supply pressure too low 1. Check fuel lines for leakage.
(Level 1). 2. Drain fuel prefilter (→ Page 119).
3. Replace filter element of fuel prefilter (→ Page 124).
4. Replace main fuel filter and, if required, intermediate fuel filter
(→ Page 117).

66 – SS P-Fuel
Red alarm; emergency stop
Cause Corrective action
Fuel supply pressure too low 1. Check fuel lines for leakage.
(Level 2). 2. Drain fuel prefilter (→ Page 119).
3. Replace filter element of fuel prefilter (→ Page 124).
4. Replace main fuel filter and, if required, intermediate fuel filter
(→ Page 117).

67 – HI T-Coolant
Yellow alarm; warning
Cause Corrective action
Coolant temperature too high 1. Check cooling system.
(Level 1). 2. Contact Service if no malfunction can be detected.

68 – SS T-Coolant
Red alarm; emergency stop (3 min. delay)
Cause Corrective action
Coolant temperature too high 1. Check cooling system.
(Level 2). 2. Contact Service if no malfunction can be detected.

81 – AL Rail Leakage
Yellow alarm; warning
Cause Corrective action
Rail pressure gradient too low for 1. On engine stopping: Seal off system, contact Service
start or too high for stop => HP 2. On engine starting: Check engine for leakage, if none found,
fuel system leaky, air in system. attempt restarting as per operating instructions (air in system).
TIM-ID: 0000079920 - 002

82 – HI P-Fuel (Common Rail)

Yellow alarm; warning
Cause Corrective action
Rail pressure > Set value => HP 1. Check wiring of HP fuel control block.
fuel control block jamming or 2. Contact Service if no fault can be detected.
wiring faulty.

MS150094/07E 2022-05 | Troubleshooting | 71

 83 – LO P-Fuel (Common Rail)
Yellow alarm; warning
Cause Corrective action
Rail pressure < set value; Suction 1. Check wiring of HP fuel control block.
restrictor of HP fuel control block 2. Check high-pressure system for leaks.
faulty or leakage in HP fuel 3. Contact Service if no fault can be detected.
system.

89 – SS Engine Speed too Low

Yellow alarm; warning
Cause Corrective action
Engine speed too low. 1. Restart engine (→ Page 54).
2. Observe any other messages.

90 – SS Idle Speed Not Reached

Yellow alarm; warning
Cause Corrective action
Idling speed not reached, start 1. Restart engine (→ Page 54).
aborted. 2. Observe any other messages.

91 – SS Release Speed Not Reached

Yellow alarm; warning
Cause Corrective action
Run-up speed not reached, start 1. Restart engine (→ Page 54).
aborted. 2. Observe any other messages.

92 – SS Starter Speed Mot Reached

Yellow alarm; warning
Cause Corrective action
Starter speed not reached; 1. Check battery.
termination of starting sequence; 2. Check wiring and voltage supply.
starter does not turn or turns 3. Check fuel supply.
slowly. 4. Restart engine (→ Page 54).
5. Observe any other messages.

93 – SS T-Preheat
TIM-ID: 0000079920 - 002

Red alarm; engine start interlock

Cause Corrective action
Preheating temperature too low 1. Extend preheating period.
(Level 2); coolant temperature too 2. Check preheater.
low for engine start.

72 | Troubleshooting | MS150094/07E 2022-05

 94 – LO T-Preheat
Yellow alarm; warning
Cause Corrective action
Preheating temperature too low 1. Extend preheating period.
(Level 1); coolant temperature too 2. Check preheater.
low for engine start.

95 – AL Prelubrication Fault
Yellow alarm; warning
Cause Corrective action
Oil priming fault. u Contact Service.

102 – AL Fuel Cons. Meter Defect

Yellow alarm; warning
Cause Corrective action
Consumption meter faulty. u Replace Engine Control Unit at next opportunity.

104 – AL Eng Hours Counter Defect

Yellow alarm; warning
Cause Corrective action
Hour meter faulty. u Replace Engine Control Unit at next opportunity.

118 – LO ECU Power Supply Voltage

Yellow alarm; warning
Cause Corrective action
Supply voltage too low (Level 1). u Check batteries, charge as necessary; check alternator.

119 – LOLO ECU Power Supply Voltage

Yellow alarm; warning
Cause Corrective action
Supply voltage too low (Level 2). u Check batteries, charge as necessary; check alternator.

120 – HI ECU Power Supply Voltage

Yellow alarm; warning
TIM-ID: 0000079920 - 002

Cause Corrective action

Supply voltage too high (Level 1). u Check batteries, charge as necessary; check alternator.

121 – HIHI ECU Power Supply Voltage

Yellow alarm; warning
Cause Corrective action
Supply voltage too high (Level 2). u Check batteries, charge as necessary; check alternator.

MS150094/07E 2022-05 | Troubleshooting | 73

 122 – HI T-ECU
Yellow alarm; warning
Cause Corrective action
Temperature in ECS too high. u Check engine room ventilation.

141 – AL Power too high

Yellow alarm; warning
Cause Corrective action
The average power rate over the u Reduce power.
last 24 hours of engine operation
has exceeded the set maximum
value.

180 – AL CAN1 Node Lost

Yellow alarm; warning
Cause Corrective action
Connection to a node on CAN bus 1. Check devices connected to CAN.
1 failed. 2. Check wiring (termination resistor installed?).

181 – AL CAN2 Node Lost

Yellow alarm; warning
Cause Corrective action
Connection to a node on CAN bus 1. Check devices connected to CAN.
2 failed. 2. Check wiring (termination resistor installed?).

182 – AL CAN Wrong Parameters

Yellow alarm; warning
Cause Corrective action
Incorrect parameter values u Contact Service.
entered in data record.

183 – AL CAN No PU-Data

Yellow alarm; warning
Cause Corrective action
The selected CAN mode initializes 1. Check devices connected to CAN.
TIM-ID: 0000079920 - 002

communication by means of the 2. Contact Service.

PU data module. However, the
required PU data module is not
available or not valid.

74 | Troubleshooting | MS150094/07E 2022-05

 184 – AL CAN PU-Data Flash Error
Yellow alarm; warning
Cause Corrective action
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

Yellow alarm; warning
Cause Corrective action
CAN controller 1 is in "Bus-Off" 1. Check CAN bus for short circuit, rectify short circuit as necessary.
status. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

187 – AL CAN1 Error Passive

Yellow alarm; warning
Cause Corrective action
CAN controller 1 has signaled a 1. Check CAN bus for short circuit, rectify short circuit as necessary.
warning. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

188 – AL CAN2 Bus Off

Yellow alarm; warning
Cause Corrective action
CAN controller 2 is in "Bus-Off" 1. Check CAN bus for short circuit, rectify short circuit as necessary.
status. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

189 – AL CAN2 Error Passive

Yellow alarm; warning
Cause Corrective action
CAN controller 2 has signaled a 1. Check CAN bus for short circuit, rectify short circuit as necessary.
warning. 2. Check shielding, improve shielding as necessary.
3. Contact Service.

201 – SD T-Coolant
TIM-ID: 0000079920 - 002

Yellow alarm; warning

Cause Corrective action
Coolant temperature sensor u Check sensor B6 and wiring, replace as necessary (→ Page 171).
faulty.

MS150094/07E 2022-05 | Troubleshooting | 75

 203 – SD T-Charge Air
Yellow alarm; warning
Cause Corrective action
Charge-air temperature sensor u Check sensor B9 and wiring, replace as necessary (→ Page 171).
faulty.

205 – SD T-Coolant Intercooler

Yellow alarm; warning
Cause Corrective action
Intercooler coolant temperature u Check sensor B26 and wiring, replace as necessary (→ Page 171).
sensor faulty.

208 – SD P-Charge Air

Yellow alarm; warning
Cause Corrective action
Charge-air pressure sensor faulty. u Check sensor B10 and wiring, replace as necessary (→ Page 171).

211 – SD P-Lube Oil

Yellow alarm; warning
Cause Corrective action
Lube-oil pressure sensor faulty. u Check sensor B5.1 and wiring, replace as necessary (→ Page 171).

215 – SD P-HD
Yellow alarm; warning
Cause Corrective action
Rail pressure sensor faulty; High- u Check sensor B48.1 and wiring, replace as necessary
pressure governor emergency (→ Page 171).
operation.

216 – SD T-Lube Oil

Yellow alarm; warning
Cause Corrective action
Lube oil temperature sensor u Check sensor B7 and wiring, replace as necessary (→ Page 171).
faulty.
TIM-ID: 0000079920 - 002

219 – SD T-Intake Air

Yellow alarm; warning
Cause Corrective action
Intake air temperature sensor u Check sensor B3 and wiring, replace as necessary (→ Page 171).
faulty.

76 | Troubleshooting | MS150094/07E 2022-05

 220 – SD Level Coolant Water
Yellow alarm; warning
Cause Corrective action
Coolant level sensor faulty. 1. Check sensor F33 and wiring, replace as necessary (→ Page 171).
2. Fault is rectified when electronics are switched back on.

221 – SD P-Diff Lube Oil

Yellow alarm; warning
Cause Corrective action
Lube oil differential pressure u Check sensor B5.1 and B5.3 and wiring, replace as necessary
sensor faulty. (→ Page 171).

222 – SD Leak Fuel Level

Yellow alarm; warning
Cause Corrective action
Leak-off fuel level sensor faulty. u Check sensor F46 and wiring, replace as necessary (→ Page 171).

223 – SD Level Coolant Intercooler

Yellow alarm; warning
Cause Corrective action
Coolant level sensor for 1. Check sensor F57 and wiring, replace as necessary (→ Page 171).
intercooler faulty. 2. Fault is rectified when electronics are switched back on.

227 – SD P-Oil before Filter

Yellow alarm; warning
Cause Corrective action
Sensor for lube oil pressure u Check sensor B5.3 and wiring, replace as necessary (→ Page 171).
before filter faulty.

228 – SD P-Fuel before Filter

Yellow alarm; warning
Cause Corrective action
Fuel pressure sensor (before main u Check sensor B34.2 and wiring, replace as necessary
filter) faulty. (→ Page 171).
TIM-ID: 0000079920 - 002

229 – AL Stop Camshaft Sensor Defect

Red alarm; emergency stop
Cause Corrective action
Engine stop due to camshaft 1. Check sensor and wiring to connectors B1 and B13, replace as
sensor fault and a previous necessary (→ Page 171).
crankshaft sensor fault in the 2. Acknowledge alarm.
same operating cycle. 3. Restart engine (→ Page 54).

MS150094/07E 2022-05 | Troubleshooting | 77

 230 – SD Crankshaft Speed
Yellow alarm; warning
Cause Corrective action
Crankshaft sensor faulty. 1. Check sensor B13 and wiring, replace as necessary (→ Page 171).
2. Fault is rectified when engine is restarted, contact Service if this is
not the case.

231 – SD Camshaft Speed

Yellow alarm; warning
Cause Corrective action
Camshaft sensor faulty. 1. Check sensor B1 and wiring, replace as necessary (→ Page 171).
2. Fault is rectified when engine is restarted, contact Service if this is
not the case.

239 – SD P-Diff Fuel

Yellow alarm; warning
Cause Corrective action
Fuel pressure sensors faulty. u Check sensor B34.2, sensor 34.3 and wiring, replace as necessary
(→ Page 171).

240 – SD P-Fuel
Yellow alarm; warning
Cause Corrective action
Fuel pressure sensor before u Check sensor B34.3 and wiring, replace as necessary
intermediate filter faulty. (→ Page 171).

245 – SD ECU Power Supply Voltage

Yellow alarm; warning
Cause Corrective action
Internal ECU fault. u Replace Engine Control Unit.

266 – SD Speed Demand

Yellow alarm; warning
Cause Corrective action
Analog speed setting faulty. 1. Check speed setting transmitter and wiring, replace as necessary
TIM-ID: 0000079920 - 002

(→ Page 171).
2. Fault is rectified when engine is restarted.

269 – SD Loadp. Analog Filt.

Yellow alarm; warning
Cause Corrective action
Filtered analog signal of load 1. Check wiring, replace as necessary.
pulse missing. 2. Fault is rectified when engine is restarted.

78 | Troubleshooting | MS150094/07E 2022-05

 270 – SD Frequency Input
Yellow alarm; warning
Cause Corrective action
Frequency input faulty. 1. Check speed setting transmitter and wiring, replace as necessary
(→ Page 171).
2. Fault is rectified when engine is restarted.

321 – AL Wiring Cylinder A1

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder A1 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

322 – AL Wiring Cylinder A2

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder A2 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

323 – AL Wiring Cylinder A3

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder A3 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

324 – AL Wiring Cylinder A4

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder A4 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
TIM-ID: 0000079920 - 002

3. Fault is rectified when engine is restarted.

MS150094/07E 2022-05 | Troubleshooting | 79

 325 – AL Wiring Cylinder A5
Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder A5 1. Check injector wiring.
injector wiring. Result: Misfiring. 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

326 – AL Wiring Cylinder A6

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder A6 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

327 – AL Wiring Cylinder A7

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder A7 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

328 – AL Wiring Cylinder A8

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder A8 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

329 – AL Wiring Cylinder A9

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder A9 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
TIM-ID: 0000079920 - 002

(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

80 | Troubleshooting | MS150094/07E 2022-05

 331 – AL Wiring Cylinder B1
Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder B1 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

332 – AL Wiring Cylinder B2

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder B2 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

333 – AL Wiring Cylinder B3

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder B3 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

334 – AL Wiring Cylinder B4

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder B4 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

335 – AL Wiring Cylinder B5

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder B5 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
TIM-ID: 0000079920 - 002

(e.g. by exchanging injectors).

3. Fault is rectified when engine is restarted.

MS150094/07E 2022-05 | Troubleshooting | 81

 336 – AL Wiring Cylinder B6
Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder B6 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

337 – AL Wiring Cylinder B7

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder B7 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

338 – AL Wiring Cylinder B8

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder B8 1. Check injector wiring.
injector wiring. Result: Misfire 2. Rectify injector solenoid valve short circuit (positive to negative)
(e.g. by exchanging injectors).
3. Fault is rectified when engine is restarted.

339 – AL Wiring Cylinder B9

Yellow alarm; warning
Cause Corrective action
Short circuit in cylinder B9 1. Check injector wiring.
injector wiring. Result: Misfire 2. Short circuit of injector solenoid valve (positive to negative) (e.g. by
installing a new injector).
3. Fault is rectified when engine is restarted.

341 – AL Open Load Cylinder A1

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder A1 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
TIM-ID: 0000079920 - 002

2. Fault is rectified after each working cycle.

342 – AL Open Load Cylinder A2

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder A2 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

82 | Troubleshooting | MS150094/07E 2022-05

 343 – AL Open Load Cylinder A3
Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder A3 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

344 – AL Open Load Cylinder A4

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder A4 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

345 – AL Open Load Cylinder A5

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder A5 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

346 – AL Open Load Cylinder A6

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder A6 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

347 – AL Open Load Cylinder A7

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder A7 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfiring. injector replacement).
2. Fault is rectified after each working cycle.

348 – AL Open Load Cylinder A8

TIM-ID: 0000079920 - 002

Yellow alarm; warning

Cause Corrective action
Open circuit in cylinder A8 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

MS150094/07E 2022-05 | Troubleshooting | 83

 349 – AL Open Load Cylinder A9
Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder A9 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

351 – AL Open Load Cylinder B1

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder B1 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfiring. injector replacement).
2. Fault is rectified after each working cycle.

352 – AL Open Load Cylinder B2

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder B2 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

353 – AL Open Load Cylinder B3

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder B3 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

354 – AL Open Load Cylinder B4

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder B4 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

355 – AL Open Load Cylinder B5

TIM-ID: 0000079920 - 002

Yellow alarm; warning

Cause Corrective action
Open circuit in cylinder B5 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

84 | Troubleshooting | MS150094/07E 2022-05

 356 – AL Open Load Cylinder B6
Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder B6 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

357 – AL Open Load Cylinder B7

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder B7 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

358 – AL Open Load Cylinder B8

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder B8 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

359 – AL Open Load Cylinder B9

Yellow alarm; warning
Cause Corrective action
Open circuit in cylinder B9 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by
injector wiring. Result: Misfire injector replacement).
2. Fault is rectified after each working cycle.

361 – AL Power Stage Low

Yellow alarm; warning
Cause Corrective action
Internal electronic fault, 1. Start engine governor self-test.
electronics possibly faulty. 2. Replace ECU in case of fault; if self-test diagnoses “Electronics OK”
check for additional fault messages (e.g. wiring fault).

362 – AL Power Stage High

TIM-ID: 0000079920 - 002

Yellow alarm; warning

Cause Corrective action
Internal electronic fault, 1. Start engine governor self-test.
electronics possibly faulty. 2. Replace ECU in case of fault; if self-test diagnoses “Electronics OK”
check for additional fault messages (e.g. wiring fault).

MS150094/07E 2022-05 | Troubleshooting | 85

 363 – AL Stop Power Stage
Red alarm; self-restoring
Cause Corrective action
Internal electronic fault, 1. Start engine governor self-test.
electronics possibly faulty. 2. Replace ECU in case of fault; if self-test diagnoses “Electronics OK”
check for additional fault messages (e.g. wiring fault).

365 – AL Stop MV-Wiring Ground

Red alarm; self-restoring
Cause Corrective action
Injector wiring fault. u Check wiring, replace wiring harness as necessary.

381 – AL Wiring TOP 1

Yellow alarm; warning
Cause Corrective action
Short circuit or wire break on u Check wiring (→ Page 171).
transistor output 1 plant-side
(TOP 1).

382 – AL Wiring TOP 2

Yellow alarm; warning
Cause Corrective action
Short circuit or wire break on u Check wiring (→ Page 171).
transistor output 2 plant-side
(TOP 2).

383 – AL Wiring TOP 3

Yellow alarm; warning
Cause Corrective action
Short circuit or wire break on u Check wiring (→ Page 171).
transistor output 3 plant-side
(TOP 3).

384 – AL Wiring TOP 4

Yellow alarm; warning
TIM-ID: 0000079920 - 002

Cause Corrective action

Short circuit or wire break on u Check wiring (→ Page 171).
transistor output 4 plant-side
(TOP 4).

86 | Troubleshooting | MS150094/07E 2022-05

 390 – AL MCR exceeded
Yellow alarm; warning
Cause Corrective action
DBR/MCR function: MCR 1. No action required if alarm only applied temporarily.
(continuous maximum rate) was 2. Contact Service if alarm applied constantly.
exceeded.

400 – AL Open Load Digital Input 1

Yellow alarm; warning
Cause Corrective action
Line disruption at digital input 1. u Check wiring (→ Page 171).

401 – AL Open Load Digital Input 2

Yellow alarm; warning
Cause Corrective action
Line disruption at digital input 2. u Check wiring (→ Page 171).

402 – AL Open Load Digital Input 3

Yellow alarm; warning
Cause Corrective action
Line disruption at digital input 3. u Check wiring (→ Page 171).

403 – AL Open Load Digital Input 4

Yellow alarm; warning
Cause Corrective action
Line disruption at digital input 4. u Check wiring (→ Page 171).

404 – AL Open Load Digital Input 5

Yellow alarm; warning
Cause Corrective action
Line disruption at digital input 5. u Check wiring (→ Page 171).

405 – AL Open Load Digital Input 6

Yellow alarm; warning
TIM-ID: 0000079920 - 002

Cause Corrective action

Line disruption at digital input 6. u Check wiring (→ Page 171).

406 – AL Open Load Digital Input 7

Yellow alarm; warning
Cause Corrective action
Line disruption at digital input 7. u Check wiring (→ Page 171).

MS150094/07E 2022-05 | Troubleshooting | 87

 407 – AL Open Load Digital Input 8
Yellow alarm; warning
Cause Corrective action
Line disruption at digital input 8. u Check wiring (→ Page 171).

408 – AL Open Load Emerg. Stop Input ESI

Yellow alarm; warning
Cause Corrective action
Open circuit at input for u Check wiring (→ Page 171).
emergency stop.

410 – LO U-PDU
Yellow alarm; warning
Cause Corrective action
Injector voltage too low (Level 1). u Perform Engine Control Unit self-test, replace as necessary.

411 – LOLO U-PDU

Yellow alarm; warning
Cause Corrective action
Injector voltage too low (Level 2). u Perform Engine Control Unit self-test, replace as necessary.

412 – HI U-PDU
Yellow alarm; warning
Cause Corrective action
Injector voltage too high (Level 1). u Perform Engine Control Unit self-test, replace as necessary.

413 – HIHI U-PDU

Yellow alarm; warning
Cause Corrective action
Injector voltage too high (Level 2). u Perform Engine Control Unit self-test, replace as necessary.

414 – HI Level Water Fuel Prefilter

Yellow alarm; warning
TIM-ID: 0000079920 - 002

Cause Corrective action

Water level in fuel prefilter too u Empty fuel prefilter.
high.

88 | Troubleshooting | MS150094/07E 2022-05

 415 – LO P-Coolant Intercooler
Yellow alarm; warning
Cause Corrective action
Coolant pressure in intercooler 1. Check coolant level in expansion tank, top up as necessary.
too low (Level 1). 2. Check coolant circuit for leaks.
3. Check coolant pump.

416 – SS P-Coolant Intercooler

Yellow alarm; warning
Cause Corrective action
Coolant pressure in intercooler 1. Check coolant level in expansion tank, top up as necessary.
too low (Level 2). 2. Check coolant circuit for leaks.
3. Check coolant pump.

417 – SD Level Water Fuel Prefilter

Yellow alarm; warning
Cause Corrective action
Water level sensor of fuel prefilter u Check sensor F70 and wiring, replace as necessary .
faulty, short circuit or wire break.

438 – LO P-Fuel 2 (Common Rail)

Yellow alarm; warning
Cause Corrective action
Rail pressure below specified u Contact Service.
value.
Suction restrictor of HP fuel
control block faulty or leakage in
HP fuel system.

439 – HI P-Fuel 2 (Common Rail)

Yellow alarm; warning
Cause Corrective action
Rail pressure above specified 1. Check wiring of HP fuel control block.
value. 2. Contact Service if no fault can be detected.
Suction restrictor of HP fuel block
jamming or HP fuel control block
wiring faulty.
TIM-ID: 0000079920 - 002

441 – AL Rail 2 Leakage

Yellow alarm; warning
Cause Corrective action
Pressure gradient in rail is too low 1. On engine stopping: Seal off system, contact Service.
during starting or too high during 2. On engine starting: Check engine for leakage, if none found,
stopping. attempt restarting as per operating instructions (air in system).

MS150094/07E 2022-05 | Troubleshooting | 89

 444 – SD U-PDU
Yellow alarm; warning
Cause Corrective action
Sensor defect of injector power u Replace Engine Control Unit.
stage.

445 – SD P-Ambient Air

Yellow alarm; warning
Cause Corrective action
Ambient air pressure sensor u Replace Engine Control Unit (sensor is in the ECU).
faulty.

446 – SD P-HD2
Yellow alarm; warning
Cause Corrective action
Rail pressure sensor faulty, high- u Check sensor B48.2 and wiring, replace as necessary
pressure regulator emergency (→ Page 171).
mode.

450 – SD Idle/End-Torque Input [%]

Yellow alarm; warning
Cause Corrective action
Input signal for initial/final torque 1. Check signal transmitter and wiring, replace as necessary.
faulty. 2. Restart engine (→ Page 54).

454 – SS Power Reduction Active

Yellow alarm; warning
Cause Corrective action
Power reduction activated. u Observe any other messages.

470 – SD T-ECU
Yellow alarm; warning
Cause Corrective action
Temperature sensor for engine u Replace Engine Control Unit at next opportunity.
governor faulty.
TIM-ID: 0000079920 - 002

471 – SD Coil Current

Yellow alarm; warning
Cause Corrective action
Control of HP fuel control block 1. Check HP fuel control block and wiring, replace as necessary
faulty. (→ Page 171).
2. Fault is rectified when engine is restarted.

90 | Troubleshooting | MS150094/07E 2022-05

 472 – AL Stop SD
Red alarm; emergency stop
Cause Corrective action
Sensor fault of shutdown u Contact Service.
channels.

474 – AL Wiring FO
Yellow alarm; warning
Cause Corrective action
Wire break or short circuit at FO u Contact Service.
channel.

476 – AL Crash Rec. Init. Error

Yellow alarm; warning
Cause Corrective action
Initialization error of crash u Contact Service.
recorder.

478 – AL Comb. Alarm Yel (Plant)

Yellow alarm; warning
Cause Corrective action
Combined alarm initiated by plant u Observe any other fault messages.
(yellow).

479 – AL Comb. Alarm Red (Plant)

Yellow alarm; warning
Cause Corrective action
Combined alarm initiated by plant u Observe any other fault messages.
(red).

480 – AL Ext. Engine Protection

Yellow alarm; warning
Cause Corrective action
External engine protection u Contact Service.
function active.
TIM-ID: 0000079920 - 002

514 – AL Write Error Flash

Yellow alarm; warning
Cause Corrective action
Value was not accepted into flash. u Contact Service.

MS150094/07E 2022-05 | Troubleshooting | 91

 536 – AL Wiring PWM_CM1
Yellow alarm; warning
Cause Corrective action
Wire break or short circuit on u Check wiring to connected device or check connected device
channel PWM_CM1. (actuator/sensor), replace as necessary.

549 – AL Power Cut-Off detected

Entered in fault memory only
Cause Corrective action
The operating voltage of the u Instruct the operator only to disconnect the power supply when the
Engine Control Unit was switched engine has stopped.
of with the engine running. This
may lead to overpressure in the
HP fuel system, which might
cause damage to the engine.

551 – SS Engine Overspeed Camshaft

Red alarm, emergency stop
Cause Corrective action
Engine overspeed, camshaft. u Restart engine (→ Page 54).

558 – AL Wiring PWM_CM2

Yellow alarm; warning
Cause Corrective action
Wire break or short circuit on u Check wiring to connected device or check connected device
channel PWM_CM2. (actuator/sensor), replace as necessary.

582 – AL Emergency Stop Failed

Entered in fault memory only
Cause Corrective action
Emergency stop command was u Contact Service.
not executed.

596 – AL Cons. Parameter Record

Yellow alarm; warning
TIM-ID: 0000079920 - 002

Cause Corrective action

Standard production data record u Contact Service.
available. The data record stored
is for testing.

92 | Troubleshooting | MS150094/07E 2022-05

 602 – AL CAN Engine Start Lock
Yellow alarm; warning
Cause Corrective action
Start interlock initiated by plant. 1. Check plant configuration.
2. Restart engine (→ Page 54).

610 – AL Wiring Suction Restrictor 1

Yellow alarm; warning
Cause Corrective action
Wire break or short circuit at PWM u Check wiring or HP fuel control block, replace as necessary.
channel HP fuel control block.

611 – AL Wiring Suction Restrictor 2

Yellow alarm; warning
Cause Corrective action
Fuel prefilter differential pressure u Check wiring or HP fuel control block, replace as necessary.
too high.

615 – AL EIL Protection

Yellow alarm; emergency stop (15 min. delay)
Cause Corrective action
Alarm for Protection module as u Replace EIL.
reaction to faulty or manipulated
EIL.

616 – AL EIL Error

Yellow alarm; warning
Cause Corrective action
Alarm with faulty or manipulated u Replace EIL.
EIL.

762 – AL Smart Connect Lost

Yellow alarm; warning
Cause Corrective action
Smart Connect device has failed u Check wiring or Smart Connect, replace as necessary.
TIM-ID: 0000079920 - 002

on CAN bus.

832 – AL EIL Different Engine Number

Yellow alarm; warning
Cause Corrective action
Alarm when fault numbers differ u Contact Service.
between ECU and EIL.

MS150094/07E 2022-05 | Troubleshooting | 93

 836 – AL Speed Demand Failure
Yellow alarm; warning
Cause Corrective action
Active analog speed setting faulty. u Check wiring (CAN MD).

851 – AL External Start and HD too high

Entered in fault memory only
Cause Corrective action
An external start is pending and u Contact Service.
high pressure is too high.

852 – AL Max. Blank Shot time expired

Yellow alarm; warning
Cause Corrective action
High pressure could not be u Contact Service.
released in the max. blankshot
time.

947 – AL Wrong LSI Channel Config

Yellow alarm; warning
Cause Corrective action
Data fault on allocating LSI u Contact Service.
channels.

973 – AL Check Sum IIG

Yellow alarm; warning
Cause Corrective action
Checksum calculation or word u Contact Service.
limit check for one of the injectors
is not correct.

1130 – AL Short Circuit Analog Out 1

Yellow alarm; warning
Cause Corrective action
The value output at analog output u Check cabling.
TIM-ID: 0000079920 - 002

1 deviates excessively from the

value read back.

94 | Troubleshooting | MS150094/07E 2022-05

 1131 – AL Short Circuit Analog Out 2
Yellow alarm; warning
Cause Corrective action
The value output at analog output u Check cabling.
2 deviates excessively from the
value read back.
TIM-ID: 0000079920 - 002

MS150094/07E 2022-05 | Troubleshooting | 95

 9 Task Description
9.1 Engine
9.1.1 Engine – Barring manually
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine barring device F6783914 1
Ratchet bit with extension F30006212 1

DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Barring engine manually

1. Fit ratchet with barring device on barring device connection at the vibration damper on engine free end.
2. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there
should be no resistance.
Result: If the resistance exceeds the normal compression resistance, contact Service.

TIM-ID: 0000002527 - 006

96 | Task Description | MS150094/07E 2022-05

 9.1.2 Engine – Turning on starting system
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Engine, turning on starting system

1. Turn engine, preventing it from firing, see documentation of vehicle/plant manufacturer.
2. Do not actuate starter for more than 10 seconds.
3. Repeat procedure after about 20 seconds as necessary.
TIM-ID: 0000010695 - 003

MS150094/07E 2022-05 | Engine | 97

 9.2 Cylinder Liner
9.2.1 Cylinder liner – Instructions and comments on endoscopic and visual
examination
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina-
tion report.
Finding Explanations/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 honing pattern in the direction of stroke.
Findings not critical
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Findings not critical
Polished area Polished areas are on the running surface but almost the whole honing pattern is
still visible. Polished areas appear brighter and more shiny than the surrounding
running surface.
Findings not critical
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from the 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.
Findings not critical
Corrosion fields / Corrosion fields / spots result from moisture (condensate) 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 preliminary stage of burn marks. 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 These are caused by a disturbance in the liner / ring tribo system. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
TIM-ID: 0000000014 - 018

coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks starting in TDC ring 1 have to be replaced.

98 | Cylinder Liner | MS150094/07E 2022-05

 Finding Explanations/Action
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 (smears), heavy discolora-
tion. Severe, visible scoring.
Replace liner.
Cylinder liner wear in Cylinder liner wear in the TDC area occurs when hydrodynamic friction between
TDC area piston rings and cylinder changes to mixed friction under maximum firing pres-
sures.

Table 4: Endoscopic examination – Terms used

Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and burn marks 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.
TIM-ID: 0000000014 - 018

MS150094/07E 2022-05 | Cylinder Liner | 99

 9.2.2 Cylinder liner – Endoscopic examination
Preconditions
☑ Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Endoscope Y20097353 1

Preparatory steps
1. Remove cylinder head cover (→ Page 106).
2. Remove injector (→ Page 108).

Moving piston into BDC position

1. Crank engine manually until piston of cylinder to be checked is in BDC position.(→ Page 96)
2. Insert endoscope into cylinder liner / combustion chamber through injector seat.

Examining cylinder liners / combustion chamber with endoscope

Findings Action
• Thin carbon coating around carbon scraper ring No actions 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
• Discoloration in the upper section of the cooling bore, remaining cir-
cumference can not be faultless
• Piston ring set faultless
• 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 contact Service.
ring
• Heat discoloration in the direction of stroke and honing pattern dam-
age
• Heat discoloration of piston ring set
TIM-ID: 0000067215 - 007

1. Compile endoscopic report using the table.

2. Use technical terms to describe the liner surface (→ Page 98).
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.

100 | Cylinder Liner | MS150094/07E 2022-05

 Final steps
1. Install injector (→ Page 108).
2. Install cylinder head cover (→ Page 106).
3. Start engine.
4. Perform a leak test.
TIM-ID: 0000067215 - 007

MS150094/07E 2022-05 | Cylinder Liner | 101

 9.3 Crankcase Breather
9.3.1 Crankcase breather – Oil mist separator replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil
Oil mist separator (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Replacing oil mist separator

1. Unscrew screws (1) and remove together
with washers (2) and retainer (3).
2. Replace oil mist separator (4).
3. Replace O-ring (5).
4. Screw in screws (1) with washers (2) and re-
tainer (3).
5. Replace other oil mist separators in the same
way.

TIM-ID: 0000053449 - 005

102 | Crankcase Breather | MS150094/07E 2022-05

 9.4 Valve Drive
9.4.1 Valve clearance – Check and adjustment
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine coolant temperature is max. 40 °C.
☑ Valves are closed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Feeler gauge Y4345893 1
Barring device F6783914 1
Ratchet with extension F30006212 1
Double-head box wrench F30002800 1
Ring socket, 19 mm F30038493 1
Torque wrench, 20–100 Nm F30026582 1
Ratchet F30027340 1

WARNING
Valve gear is moving.
Risk of crushing!
• Keep hands clear of the danger zone when barring the engine.

Preparatory steps
u Remove cylinder head cover (→ Page 106).

Positioning A1 piston at TDC

1. Install barring device.
2. Losen plug screw (1) and remove.
3. Using ratchet and barring device, rotate
crankshaft in engine direction of rotation un-
til the bore (2) on the flywheel is visible in the
center of the exposed opening.
TIM-ID: 0000023895 - 004

MS150094/07E 2022-05 | Valve Drive | 103

 Checking valve clearance at two crankshaft positions
1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet (E) = 0.3 mm;
• Exhaust (A) = 0.4 mm.
3. Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC) according to the table
below.
12 V 2000
Position Cylinder 1 2 3 4 5 6 7 8
Firing TDC in cylinder A1 Bank A EA E- -A E- -A --
Bank B E- -- -A E- EA -A
Overlap TDC in cylinder A1 Bank A -- -A E- -A E- EA
Bank B -A EA E- -A -- E-
“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

16 V 2000
Position Cylinder 1 2 3 4 5 6 7 8
Firing TDC in cylinder A1 Bank A E A - A E A E - -A E - - - - -
Bank B E - - A - - - - E A E - EA - A
Overlap TDC in cylinder A1 Bank A - - E - - - - A E - -A EA EA
Bank B -A E - E A E A - - -A -- E-
“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted

4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

Valve clearance adjustment

1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.
2. Insert feeler gauge between valve bridge and
rocker arm.
3. Readjust adjusting screw (2) so that the feel-
er gauge just passes through the gap.
TIM-ID: 0000023895 - 004

4. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2)
with Allen key to prevent it from turning.
Name Size Type Lubricant Value/Standard
Locknut Tightening torque 50 Nm +5 Nm

104 | Valve Drive | MS150094/07E 2022-05

 5. Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the
gap.
Result: If not, adjust valve clearance again.

Final steps
1. Install plug screw and tighten.
2. Remove barring device.
3. Install cylinder head cover (→ Page 106).
TIM-ID: 0000023895 - 004

MS150094/07E 2022-05 | Valve Drive | 105

 9.4.2 Cylinder head cover – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 8–40 Nm F30043446 1
Ratchet bit F30027340 1
Gasket (→ Spare Parts Catalog)

Preparatory steps
1. On cylinder head covers with crankcase breather: Loosen clamps.
2. Slide rubber sleeves onto the pipe.

Cylinder head cover – Removal

and installation
1. Remove cylinder head cover (2) with gas-
ket (1) from cylinder head.
2. Clean installation surface.
3. Check condition of gasket (1) in cylinder
head cover (1).
4. Replace damaged gasket(s) (1).
5. Install cylinder head cover (2) with screws (4)
and washers (3).

Final steps
1. Slide rubber sleeves onto the relevant fitting.
2. Tighten all clamps.
TIM-ID: 0000000019 - 006

106 | Valve Drive | MS150094/07E 2022-05

 9.5 Injector
9.5.1 Injector – Replacement
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Injector (→ Spare Parts Catalog)

Injector – Replacement
u Remove injector and install new one (→ Page 108).
TIM-ID: 0000042329 - 002

MS150094/07E 2022-05 | Injector | 107

 9.5.2 Injector – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Installation device F6790085 1
Puller F6790636 1
Fuel suction device F30378207 1
Torque wrench, 1–5 Nm F30452774 1
Torque wrench, 20–100 Nm F30026582 1
Ratchet F30027340 1
Adapter F30006234 1
Adapter F30452771 1
Socket wrench, 19 mm F30453236 1
Crowfoot wrench, 19 mm F30027424 1
Crowfoot wrench, 22 mm F30027425 1
Double-head box wrench F30011450 1
Socket wrench, 24 mm F30453238 1
Assembly compound (Hakuform 30–15) X00067260 1
Engine oil
Sealing ring (→ Spare Parts Catalog)

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and hearing protection.

Preparatory steps
1. Shut off fuel supply line.
TIM-ID: 0000023980 - 005

2. Drain fuel (→ Page 116).

3. Remove cylinder head cover (→ Page 106).

108 | Injector | MS150094/07E 2022-05

 Removing injector
1. Remove fuel line (1).
2. Unscrew union nut (2).
3. Pull off pressure pipe neck (3).
4. Extract fuel from the exposed bores using the
suction device.

5. Loosen terminals (arrow) on injector and pull

off terminal lugs.
6. Remove gasket.

7. Remove screw (3).

Note: Screw (3) must be used only once.
8. Take off hold-down clamp (2).
9. Carefully remove injector (1) with puller.
10. After removal, seal all openings with suitable
covers.
TIM-ID: 0000023980 - 005

MS150094/07E 2022-05 | Injector | 109

 Installing injector
1. Remove all covers before installation.
2. Clean sealing surface on cylinder head and
protective sleeve.
3. Apply grease to sealing ring on injector (1).
Note: Always use the installation device or the hold-
down clamp to press injector (1) into cylinder
head.
4. Align square on injector (1) with seat in hold-
down clamp (2) and insert injector manually
into cylinder head.
5. Place hold-down clamp (2) in position by
hand, ensuring the position is correct

Assembly without installation device

1. Install new screw (3) and tighten screw (3) to carefully press injector (1) into cylinder head.
Name Size Type Lubricant Value/Standard
Screw M8 Preload torque 2 Nm +2 Nm

2. Loosen screw (3) again and relieve hold-down clamp.

Assembly with installation device

1. Place installation device onto hold-down clamp and carefully press injector (1) into cylinder head.
2. Fit clamp (2) in correct position, install screw (3) and tighten hand-tight.

Installing pressure pipe neck

1. Blow out fuel line (1) and pressure pipe
neck (3) with compressed air.
2. Coat sealing ring with grease.
3. Coat sealing cone of pressure pipe neck (3)
with engine oil.
4. Slide pressure pipe neck (3) into cylinder
head until it rests against the sealing ring.
5. Press in pressure pipe neck (3) completely by
hand.
6. Align HP connection of injector to pressure
pipe neck (3).
TIM-ID: 0000023980 - 005

7. Apply engine oil to thread and mating face of union nut (2) and use torque wrench to tighten it to the speci-
fied tightening torque.
Name Size Type Lubricant Value/Standard
Union nut Preload torque (Engine oil) 15 Nm +5 Nm

110 | Injector | MS150094/07E 2022-05

 8. Use torque wrench to tighten screw (3) for hold-down clamp (2) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M8 Tightening torque (Engine oil) 40 Nm +4 Nm

9. Using a torque wrench, tighten union nut (2) on pressure pipe neck (3) to specified torque.
Name Size Type Lubricant Value/Standard
Union nut Tightening torque 45 Nm +5 Nm
TIM-ID: 0000023980 - 005

Installing fuel line

1. Apply engine oil to thread and mating face of union nut of fuel line (1).
Note: Position fuel line, ensuring that it is free of tension.
2. Position fuel line (1) so that the end with the marked union faces the rail and the end with the unmarked
union nut faces the pressure pipe neck (2) and tighten it hand-tight.
3. Tighten union nut of fuel line (1) on rail to specified tightening torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Union nut Tightening torque (Engine oil) 45 Nm +5 Nm

MS150094/07E 2022-05 | Injector | 111

 4. Tighten union nut of fuel line (1) on pressure pipe neck (2) to specified tightening torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Union nut Tightening torque (Engine oil) 37 Nm +3 Nm

Fitting gasket and connecting

injector
1. Place gasket in correct position onto cylinder
head.

2. Slide terminal lugs under terminals (arrow) on injector and use torque wrench to tighten to the specified
tightening torque.
Name Size Type Lubricant Value/Standard
Nut M4 Tightening torque (Engine oil) 1.5 Nm ±0.25 Nm

Final steps
1. Install cylinder head cover (→ Page 106).
2. Open fuel supply line.
3. Vent fuel system (→ Page 115).

TIM-ID: 0000023980 - 005

112 | Injector | MS150094/07E 2022-05

 9.6 Fuel System
9.6.1 HP fuel line and pressure pipe neck – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 20–100 Nm F30026582 1
Ratchet bit F30027340 1
Adapter F30006234 1
Socket wrench, 19 mm F30025897 1
Crowfoot wrench, 19 mm F30027424 1
Crowfoot wrench, 22 mm F30027425 1
Double-end box wrench F30011450 1
Assembly compound (Hakuform 30–15) X00067260 1
Pressure pipe neck (→ Spare Parts Catalog)
HP fuel line (→ Spare Parts Catalog)

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Preparatory steps
1. Close fuel supply line.
2. Drain fuel (→ Page 116).

HP fuel line and pressure pipe

neck – Replacement
1. Remove leak-off fuel line from cylinder head.
2. Remove HP fuel line (2).
3. Remove thrust screw (4).
4. Withdraw pressure pipe neck (5).
5. Coat sealing ring of new pressure pipe neck
with grease.
TIM-ID: 0000012538 - 005

6. Coat sealing cone of pressure pipe neck with

engine oil.
7. Insert pressure pipe neck into cylinder head
until it is in contact with the sealing ring.
8. Fully press in pressure pipe neck by hand.

MS150094/07E 2022-05 | Fuel System | 113

 9. Use torque wrench to tighten thrust screw (4) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque 40 Nm

10. Coat mating face between union nut and HP fuel line, ball seal, and thread on both ends of the new HP fuel
line (2) with engine oil.
11. Install new HP fuel line (2).
12. Observe marking on union nut (1).
13. Use torque wrench to tighten union nut (1) with marking (see arrow) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Nut with marking Tightening torque 35 Nm

14. Use torque wrench to tighten union nut (1) without marking to specified tightening torque.
Name Size Type Lubricant Value/Standard
Nut without mark- Tightening torque 30 Nm
ing

15. Observe marking on union nut (3).

16. Use torque wrench to tighten union nut (3) with marking (see arrow) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Nut with marking Tightening torque 35 Nm

17. Use torque wrench to tighten union nut (3) without marking to specified tightening torque.
Name Size Type Lubricant Value/Standard
Nut without mark- Tightening torque 25 Nm
ing

18. Install leak-off fuel line on cylinder head.

Final steps
1. Open fuel supply line.
2. Vent fuel system (→ Page 115).
TIM-ID: 0000012538 - 005

114 | Fuel System | MS150094/07E 2022-05

 9.6.2 Fuel system – Venting
Preconditions
☑ Engine is not connected to load.

Fuel system – Venting

Note: The fuel system can only be vented with the engine running.
1. Start engine (→ Page 54).
2. Operate the engine until it runs smoothly.
TIM-ID: 0000012554 - 002

MS150094/07E 2022-05 | Fuel System | 115

 9.6.3 Fuel – Draining
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or smoke.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
• Keep the engine room well ventilated at all times.

Draining fuel
1. Provide a suitable container to collect escaping fuel.
2. Remove fuel filter (→ Page 117).
3. Catch fuel as it runs out.
4. Install fuel filter (→ Page 117).

TIM-ID: 0000004702 - 006

116 | Fuel System | MS150094/07E 2022-05

 9.7 Fuel Filter
9.7.1 Fuel filter – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104 1
Diesel fuel
Easy-change filter (→ Spare Parts Catalog)

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

Replacing fuel filter

1. Use filter wrench to remove easy-change fil-
ter.
2. Clean sealing surface on filter head.
3. Check sealing ring on new easy-change filter
and moisten with fuel.
4. Fill the new easy-change filter with clean fuel.
5. Screw on easy-change filter and tighten
hand-tight.
6. Replace other fuel filters in the same way.
7. Vent fuel system (→ Page 115).
TIM-ID: 0000012700 - 003

MS150094/07E 2022-05 | Fuel Filter | 117

 9.7.2 Fuel prefilter – Differential pressure check and adjustment of gauge
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
A high level of noise is produced when the system is running.
Risk of hearing loss!
• Wear suitable hearing protection.

Differential pressure gauge ad-

justment
1. After installation of a new filter element: Align
adjustable pointer (2) with pressure indica-
tor (3) on pressure gauge (1).
2. Check differential pressure.

Checking fuel prefilter differential pressure

1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure between timing pointer (2) and pressure gauge (3) ≥ 0.3 bar, flush filter element of the
cut-in filter (→ Page 121).
TIM-ID: 0000004926 - 007

118 | Fuel Filter | MS150094/07E 2022-05

 9.7.3 Fuel prefilter – Draining
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 4–20 Nm F30044239 1
Ratchet bit F30027340 1

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
A high level of noise is produced when the system is running.
Risk of hearing loss!
• Wear suitable hearing protection.

Note: Only with duplex fuel prefilter:

Cutting out the filter to be

drained
1 Left filter cut in
2 Right filter cut in
TIM-ID: 0000004933 - 009

MS150094/07E 2022-05 | Fuel Filter | 119

 Draining fuel prefilter
1. Open threaded vent plug (5) of filter to be
drained.
Note: Catch water and contaminants into a suitable
container and dispose of in an appropriate
manner.
2. Press on drain valve (6) to unlock it and turn
it anticlockwise by 90° into the vertical posi-
tion.
Result: Water and contaminants drain off the filter.
3. As soon as clean fuel emerges: Turn drain
valve (6) by 90° clockwise. Make sure that it
is engaged in the correct position "closed"
(horizontal position) and fuel no longer
emerges.

Final steps
1. Cut in the cut-out filter again.
2. Vent fuel system.
• When fuel emerges from system, close threaded vent plug (5).
Name Size Type Lubricant Value/Standard
Threaded vent plug M6 Tightening torque 4 Nm

TIM-ID: 0000004933 - 009

120 | Fuel Filter | MS150094/07E 2022-05

 9.7.4 Fuel prefilter – Flushing
Preconditions
☑ Engine is stopped and starting disabled (only in the case of single fuel prefilter).

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Diesel fuel

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or smoke.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
• Keep the engine room well ventilated at all times.

WARNING
A high level of noise is produced when the system is running.
Risk of hearing loss!
• Wear suitable hearing protection.
TIM-ID: 0000004937 - 029

MS150094/07E 2022-05 | Fuel Filter | 121

 Note: Only with duplex fuel prefilter:

Cutting out the contaminated

fuel prefilter
1 Left filter cut in
2 Right filter cut in

Flushing the fuel prefilter

1. Open threaded vent plug (5) of filter to be
flushed.
Note: Catch fuel and contaminants in a suitable
container and dispose of properly.
2. Drain fuel by actuating drain valve (6):
a) Press toggle of drain valve (6) to unlock it
and turn it anticlockwise by 90° into the
vertical position.
Result: Fuel flows from filtered side back to unfil-
tered side, flushing contaminants down-
wards out of the filter.
b) Drain fuel until all contaminants have
been flushed out of the bowl.
c) Turn toggle on valve by 90° clockwise
and ensure that it is engaged in the cor-
rect position "closed" (horizontal posi-
tion) and that fuel no longer emerges.
d) If the valve toggle does not close proper-
ly: Open and close briefly several times
until contaminants have been flushed off
completely.
Result: • Toggle of valve closes properly and
engages in horizontal position when
the valve is closed.
TIM-ID: 0000004937 - 029

• Drain valve (6) is leak-tight.

Final steps
1. Cut in the cut-out filter again.
2. Vent fuel system.
• When fuel emerges from system, close vent plug (5).
Name Size Type Lubricant Value/Standard
Threaded vent plug M6 Tightening torque 4 Nm

122 | Fuel Filter | MS150094/07E 2022-05

 3. Check differential pressure (→ Page 118).
4. If flushing did not lead to an improvement of the differential pressure, replace filter element (→ Page 124).
TIM-ID: 0000004937 - 029

MS150094/07E 2022-05 | Fuel Filter | 123

 9.7.5 Fuel prefilter – Filter element replacement
Preconditions
☑ Engine is stopped and starting disabled (only in the case of single fuel prefilter).

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Fuel
Filter element (→ Spare Parts Catalog)
Seal (→ Spare Parts Catalog)

DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or smoke.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
• Keep the engine room well ventilated at all times.

WARNING
A high level of noise is produced when the system is running.
Risk of hearing loss!
• Wear suitable hearing protection.

NOTICE
Damage to component!
Severe material damage!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be replaced must be cut out for a brief period only.
TIM-ID: 0000004946 - 014

124 | Fuel Filter | MS150094/07E 2022-05

 Note: Only with duplex fuel prefilter:

Cutting out the contaminated

fuel prefilter
1 Left filter cut in
2 Right filter cut in

Replacing filter element

1. Drain water and contaminants from fuel pre-
filter (→ Page 119). Carry out the final steps
as well.
2. Remove screws securing cover and take off
cover (2). Loosen the screws in several cy-
cles crosswise to avoid damage.
3. Remove spring cartridge (4) and filter ele-
ment (3) and dispose of filter element proper-
ly.
4. Place new filter element (3) in spring hous-
ing (4). Please note the alignment:
• The sealing surface is the lower side.
• The "Separ" lettering is the front side.
5. Insert air filter cartridge (4) in filter housing.
6. Fill filter housing with clean fuel.
7. Place new seal (clean and with grease ap-
plied to it) in cover (2) if required.
8. Fit cover with gasket and secure it with screws. Tighten the screws in several cycles crosswise to avoid dam-
age.
Name Size Type Lubricant Value/Standard
Cover screw M6 x 30 Tightening torque 8 Nm

Final work
TIM-ID: 0000004946 - 014

Note: Only with duplex fuel prefilter

1. Cut in the cut-out filter again.
2. Vent fuel system.
• When fuel emerges from system, close vent plug (5).
Name Size Type Lubricant Value/Standard
Threaded vent plug M6 Tightening torque 4 Nm

3. Set differential pressure gauge (→ Page 118).

MS150094/07E 2022-05 | Fuel Filter | 125

 9.8 Charge-Air Cooling
9.8.1 Intercooler – Checking condensate drain for coolant leakage and obstruction
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
A high level of noise is produced when the system is running.
Risk of hearing loss!
• Wear suitable hearing protection.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and hearing protection.

Intercooler – Checking conden-

sate drain for coolant leakage
and obstruction
1. With the engine running, check the drains or
condensate drain lines (if applicable) on en-
gine driving end for air discharge.
2. When air stops escaping, shut the engine
down and lockout/tagout to prevent starting,
remove drains or drain lines and blow out
with compressed air.
3. Replace obstructed drain lines with new
ones.
4. Install drains or drain lines.
5. If a large amount of coolant is discharged,
the intercooler is leaking. Contact Service.

Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 108).
2. Crank engine manually (→ Page 96).
3. Crank engine on starting system to blow out combustion chambers (→ Page 97).
4. Install injectors (→ Page 108).
TIM-ID: 0000013211 - 004

126 | Charge-Air Cooling | MS150094/07E 2022-05

 9.9 Air Filter
9.9.1 Air filter – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Note: Component is genset manufacturer's or vehicle manufacturer's scope of supply.

Air filter – Replacement

u Perform tasks according to manufacturer's specifications.
TIM-ID: 0000013387 - 004

MS150094/07E 2022-05 | Air Filter | 127

 9.10 Air Intake
9.10.1 Service indicator – Check
See manufacturer's documentation.

TIM-ID: 0000005482 - 004

128 | Air Intake | MS150094/07E 2022-05

 9.11 Exhaust Gas Recirculation
9.11.1 Exhaust gas recirculation flaps – Overview
TIM-ID: 0000024288 - 002

MS150094/07E 2022-05 | Exhaust Gas Recirculation | 129

 9.11.2 Exhaust gas recirculation – Flap function check
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Hot components/surfaces.
Risk of burns!
• Allow the system to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.

Checking exhaust flap operation

1. For installation locations of exhaust flaps, refer to overview drawing (→ Page 129).
2. Check exhaust flap and control linkage func-
tionality and ease of movement by moving
them at the marked points (arrowed).
Result: Exhaust flap is stuck or stiff: Contact Service.

TIM-ID: 0000024000 - 004

130 | Exhaust Gas Recirculation | MS150094/07E 2022-05

 9.12 Lube Oil System, Lube Oil Circuit
9.12.1 Engine oil level – Check
Preconditions
☑ Engine is stopped and starting disabled

Checking oil level prior to en-

gine start
1. Pull out dipstick from guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the
stop, pull it out after approx. 10 seconds and
check oil level.
Note: The oil level may be up to 2 cm above the
mark (1) after extended out-of-service peri-
ods. The reason for this may be oil returning
to the oil pan e.g. from oil filters and heat ex-
changers.
3. The oil level must reach the mark (2) or ex-
ceed the mark (1) by up to 2 cm.
Note: Topping up oil manually is not required on en-
gines featuring automatic oil replenishment.
On all other engines, oil must be topped up
manually. The oil level check is only intended
to confirm that the automatic oil replenish-
ment feature works properly.
4. Insert oil dipstick into guide tube up to the
stop.

Checking engine oil level after engine has stopped

1. 5 minutes after stopping the engine, pull out oil dipstick from guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, pull it out after approx. 10 seconds and check oil level.
Note: Topping up oil manually is not required on engines featuring automatic oil replenishment. On all other en-
gines, oil must be topped up manually. The oil level check is only intended to confirm that the automatic oil
replenishment feature works properly.
3. Oil level must be between marks (1) and (2).
4. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000000032 - 007

MS150094/07E 2022-05 | Lube Oil System, Lube Oil Circuit | 131

 9.12.2 Engine oil – Change
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine is at operating temperature.
☑ Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Engine oil
Sealing ring (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

WARNING
Oils/oil vapors are combustible/explosive.
Risk of fire and explosion!
• Avoid open flames, electric sparks and ignition sources.
• Do not smoke.

Oil change without semirotary hand pump: Draining oil at drain plug on oil
pan
1. Provide a suitable container to collect the oil.
2. Remove drain plug and drain oil.
3. Screw in drain plug with new sealing ring.
4. Replace engine oil filter (→ Page 134).

Version with semirotary hand pump: Extracting oil

1. Provide a suitable container to collect the oil.
2. Extract all oil from oil pan using the semirotary hand pump.
3. Replace engine oil filter (→ Page 134).
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132 | Lube Oil System, Lube Oil Circuit | MS150094/07E 2022-05

 Filling with new oil
1. Open cover on filler neck.
2. Fill oil in at filler neck up to “max.” mark at oil
dipstick.
3. Close cap on filler neck.
4. Check engine oil level (→ Page 131).
Note: Note max. starter actuation times (see data
in technical sales documentation (TVU)).
5. Crank engine on starter (→ Page 97) until ap-
propriate oil pressure is indicated after oil
change and filter replacement.
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MS150094/07E 2022-05 | Lube Oil System, Lube Oil Circuit | 133

 9.13 Oil Filtration / Cooling
9.13.1 Engine oil filter – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Filter wrench F30379104 1
Engine oil
Oil filter (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Replacing engine oil filter

1. Unscrew oil filter with filter wrench.
2. Clean the sealing surface on the oil filter
housing.
3. Check condition of new oil filter sealing ring
and coat it with oil.
4. Screw on oil filter and tighten hand-tight.
5. Replace other oil filters in the same way.
6. After each oil change and filter replacement,
bar engine with starting system (→ Page 97).
7. Check oil level (→ Page 131).
TIM-ID: 0000014212 - 003

134 | Oil Filtration / Cooling | MS150094/07E 2022-05

 9.13.2 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 8–40 Nm F30043446 1
Ratchet bit F30027340 1
Oil filter wrench F30379104 1
Cold cleaner (Hakutex 60) X00070585/GET 1
Cold cleaner (Hakutex 50) X00056751/GET 1
Filter sleeve (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

WARNING
Oil is hot.
Oil can contain residue/substances which are harmful to health.
Risk of injury and poisoning!
• Allow the product to cool to below 50 °C before beginning work.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and hearing protection.
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MS150094/07E 2022-05 | Oil Filtration / Cooling | 135

 Centrifugal oil filter – Cleaning
and filter sleeve replacement
1. Loosen nuts (1) diagonally.
2. Remove housing cover (20) and O-ring (19).
3. Carefully remove rotor cap (17) from lower
part of housing (4).
4. Remove knurled nut (18).
5. Disassemble rotor cap (17), standpipe (15)
and rotor body (13).
6. Remove filter sleeve (16) from rotor cap (17).
7. Measure thickness of oil residues on filter
sleeve (16).
Result: If the oil residues exceed the maximum layer
thickness of 25 mm, shorten the mainte-
nance interval.
8. Wash out rotor cover, rotor cap, standpipe
and rotor body with cold cleaner.
9. Blow out with compressed air.
10. Check O-ring (14), replace if necessary.
11. Insert new filter sleeve (16) into rotor cap
(17) with the smooth paper surface facing the
outer wall.
12. Assemble rotor cap (17), standpipe (15) and
rotor body (13) with O-ring (14).
13. If the rotor features a knurled nut, turn it up-
side down and clamp it in a vise.

14. Place two washers and one hex nut (DIN, size
30) into the bottom side of the rotor.
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136 | Oil Filtration / Cooling | MS150094/07E 2022-05

 15. Use torque wrench to tighten knurled nut (18) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Knurled nut Tightening torque 8 Nm ± 1 Nm

16. If the rotor features a hex nut, hold it with strap wrench to tighten hex nut (18) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Hex nut Tightening torque 17 Nm ± 2.5 Nm

17. Carefully insert rotor in lower part of housing (4).

18. Install housing cover (20) and O-ring (19).
19. Screw on nuts (1).
20. Use torque wrench to tighten nuts (1) diagonally to specified tightening torque.
Name Size Type Lubricant Value/Standard
Hex nut Tightening torque 12 Nm ± 2 Nm
TIM-ID: 0000051622 - 012

MS150094/07E 2022-05 | Oil Filtration / Cooling | 137

 9.14 Coolant Circuit, General, High-Temperature Circuit
9.14.1 Drain and vent points
12 V, 16 V

1 Engine coolant vent

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138 | Coolant Circuit, General, High-Temperature Circuit | MS150094/07E 2022-05

 Left side

1 Engine coolant drain plug 2 Oil drain plug 3 Engine coolant drain plug
TIM-ID: 0000025286 - 001

MS150094/07E 2022-05 | Coolant Circuit, General, High-Temperature Circuit | 139

 Right side

1 Engine coolant drain plug 3 Oil drain plug

2 Engine coolant drain plug 4 Engine coolant drain plug

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140 | Coolant Circuit, General, High-Temperature Circuit | MS150094/07E 2022-05

 Driving end (KS)

1 Oil drain plug

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MS150094/07E 2022-05 | Coolant Circuit, General, High-Temperature Circuit | 141

 Free end (KGS)

1 Oil drain plug 3 Oil drain plug

2 Engine coolant filling plug 4 Engine coolant drain plug

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142 | Coolant Circuit, General, High-Temperature Circuit | MS150094/07E 2022-05

 9.14.2 Engine coolant – Level check
Preconditions
☑ Engine is stopped and starting disabled.
☑ Fluids and Lubricants Specifications (A001061/..) are available.

DANGER
Falling from great heights.
Risk of serious injury – danger to life!
• When working high on the equipment, always use suitable ladders or work platforms.
• Use personal protective equipment.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Coolant contains antifreeze and is toxic.
Risk of poisoning and slipping!
• Avoid contact with eyes and skin.
• Do not inhale vapors or mist, wear breathing protection.
• Do not eat, drink, smoke when working with antifreeze.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Wipe up escaped/spilled coolant immediately.

NOTICE
Closing the cover on the coolant expansion tank when the engine is warm. After starting the engine, the
necessary coolant pressure cannot be built up.
Risk of severe engine damage due to cavitation, especially with extended periods of operation!
• Before closing the coolant expansion tank, make sure that the coolant has cooled down to below
40°C.

Checking coolant level at filler

neck
1. Turn valve cover of coolant expansion tank
counterclockwise until the first stop and al-
low pressure to escape.
2. Continue to turn valve cover counterclock-
wise and remove.
3. Check coolant level (coolant must be visible
at the lower edge of the cast-in eye or at the
marking plate).
4. Top up with treated coolant as necessary
TIM-ID: 0000000037 - 005

(→ Page 146).
5. Check and clean valve cover.
6. Place valve cover on filler neck and close.

Checking coolant level by means of level sensor

1. Switch on engine control system and check readings on the display.
2. Top up with treated coolant as necessary (→ Page 146).

MS150094/07E 2022-05 | Coolant Circuit, General, High-Temperature Circuit | 143

 9.14.3 Engine coolant – Change
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Coolant

Engine coolant change

1. Drain engine coolant (→ Page 145).
2. Fill with engine coolant (→ Page 146).

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144 | Coolant Circuit, General, High-Temperature Circuit | MS150094/07E 2022-05

 9.14.4 Engine coolant – Draining
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Sealing rings (→ Spare Parts Catalog)

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Engine coolant – Draining

1. Provide a suitable receptacle to catch the
coolant.
2. Switch off preheating unit, if fitted.
3. Turn breather valve of coolant expansion tank
counterclockwise until the first stop and al-
low pressure to escape.
4. Continue to turn breather valve counterclock-
wise and remove.
5. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
6. Open drain plug at drain point in coolant line
to engine coolant cooler and drain coolant.
7. Draining of residual coolant:
• At the preheating unit, if fitted.

8. Drain engine coolant:

• At the elbow of the engine coolant pump
• At the crankcase, left and right side
• At the thermostat housing.
9. Close all drain valves and screw in drain
plugs with new sealing rings.
10. Place breather valve on filler neck and close.
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MS150094/07E 2022-05 | Coolant Circuit, General, High-Temperature Circuit | 145

 9.14.5 Engine coolant – Filling
Preconditions
☑ Engine is stopped and starting disabled.
☑ Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Coolant

DANGER
Falling from great heights.
Risk of serious injury – danger to life!
• When working high on the equipment, always use suitable ladders or work platforms.
• Use personal protective equipment.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Coolant contains antifreeze and is toxic.
Risk of poisoning and slipping!
• Avoid contact with eyes and skin.
• Do not inhale vapors or mist, wear breathing protection.
• Do not eat, drink, smoke when working with antifreeze.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Wipe up escaped/spilled coolant immediately.

NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.

NOTICE
Closing the cover on the coolant expansion tank when the engine is warm. After starting the engine, the
necessary coolant pressure cannot be built up.
Risk of severe engine damage due to cavitation, especially with extended periods of operation!
• Before closing the coolant expansion tank, make sure that the coolant has cooled down to below
40°C.
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146 | Coolant Circuit, General, High-Temperature Circuit | MS150094/07E 2022-05

 Preparatory steps
1. Turn valve cover (1) on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn valve cover (1) counter-
clockwise and remove.

Engine coolant – Filling

1. Fill coolant through filler neck on expansion tank or through filling line until coolant level reaches lower edge
of cast-in eye or marking plate.
2. Check proper condition of valve cover (1), clean sealing faces if required.
3. Fit valve cover (1) and close it.

Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 143), top up with coolant if required.
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MS150094/07E 2022-05 | Coolant Circuit, General, High-Temperature Circuit | 147

 9.14.6 Engine coolant pump – Relief bore check
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
A high level of noise is produced when the system is running.
Risk of hearing loss!
• Wear suitable hearing protection.

Engine coolant pump – Relief

bore check
u Check relief bore for oil and coolant dis-
charge.
• Permissible coolant discharge: Up to
2.5 ml/10 hours
Result: Contact Service if discharge exceeds the
specified limits.

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148 | Coolant Circuit, General, High-Temperature Circuit | MS150094/07E 2022-05

 9.14.7 Engine coolant – Sample extraction and analysis
Preconditions
☑ Engine is stopped and starting disabled.
☑ Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
mtu test kit 5605892099/00 1

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Engine coolant – Sample extraction and analysis

1. Turn valve cover of coolant expansion tank counterclockwise until the first stop and allow pressure to es-
cape.
2. Continue to turn valve cover counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil.
4. Draw off approx. 1 liter coolant and drain into a clean container.
5. Use equipment and chemicals from the mtu test kit to examine coolant for:
• antifreeze concentration;
• corrosion inhibitor concentration;
• pH value.
6. Fit valve cover and close it.
7. Engine coolant change intervals (→ Fluids and Lubricants Specifications A001061/..).
TIM-ID: 0000014607 - 004

MS150094/07E 2022-05 | Coolant Circuit, General, High-Temperature Circuit | 149

 9.15 Low-Temperature Circuit
9.15.1 Intercooler – Vent and drain points
12 V, 16 V

1 Intercooler vent plugs

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150 | Low-Temperature Circuit | MS150094/07E 2022-05

 9.15.2 Charge-air coolant level – Check
Preconditions
☑ Engine is stopped and starting disabled.
☑ Fluids and Lubricants Specifications (A001061/..) are available.

DANGER
Falling from great heights.
Risk of serious injury – danger to life!
• When working high on the equipment, always use suitable ladders or work platforms.
• Use personal protective equipment.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Coolant contains antifreeze and is toxic.
Risk of poisoning and slipping!
• Avoid contact with eyes and skin.
• Do not inhale vapors or mist, wear breathing protection.
• Do not eat, drink, smoke when working with antifreeze.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Wipe up escaped/spilled coolant immediately.

NOTICE
Closing the cover on the coolant expansion tank when the engine is warm. After starting the engine, the
necessary coolant pressure cannot be built up.
Risk of severe engine damage due to cavitation, especially with extended periods of operation!
• Before closing the coolant expansion tank, make sure that the coolant has cooled down to below
40°C.

Checking charge-air coolant level at filler neck

1. Turn cover on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.
2. Continue to turn cover counterclockwise and remove.
Note: Charge-air coolant must be visible at marker
plate.
3. Check charge-air coolant level.
4. Top up charge-air coolant as necessary
(→ Page 154).
5. Check that cover is in serviceable condition.
6. Clean sealing surfaces as necessary.
7. Fit cover and close it.
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MS150094/07E 2022-05 | Low-Temperature Circuit | 151

 Checking charge-air coolant level by means of level sensor
Note: The charge-air coolant level is monitored automatically by the engine control system.
1. Switch on engine control system and check readings on the display.
2. Top up with charge-air coolant as necessary (→ Page 154).

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152 | Low-Temperature Circuit | MS150094/07E 2022-05

 9.15.3 Charge-air coolant – Change
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Coolant

Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 156).
2. Fill with charge-air coolant (→ Page 154).
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MS150094/07E 2022-05 | Low-Temperature Circuit | 153

 9.15.4 Charge-air coolant – Filling
Preconditions
☑ Engine is stopped and starting disabled.
☑ Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Coolant
Sealing ring (→ Spare Parts Catalog)

DANGER
Falling from great heights.
Risk of serious injury – danger to life!
• When working high on the equipment, always use suitable ladders or work platforms.
• Use personal protective equipment.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Coolant contains antifreeze and is toxic.
Risk of poisoning and slipping!
• Avoid contact with eyes and skin.
• Do not inhale vapors or mist, wear breathing protection.
• Do not eat, drink, smoke when working with antifreeze.
• Wear protective clothing, protective gloves and goggles/safety mask.
• Wipe up escaped/spilled coolant immediately.

NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.

NOTICE
Closing the cover on the coolant expansion tank when the engine is warm. After starting the engine, the
necessary coolant pressure cannot be built up.
Risk of severe engine damage due to cavitation, especially with extended periods of operation!
• Before closing the coolant expansion tank, make sure that the coolant has cooled down to below
40°C.
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154 | Low-Temperature Circuit | MS150094/07E 2022-05

 Preparatory steps
1. Turn valve cover (1) on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn valve cover (1) counter-
clockwise and remove.
3. Remove plug screw from filling point on cool-
ant line to intercooler.

Charge-air coolant – Filling

1. Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level
reaches marking plate.
2. Install plug screws of filling points with new sealing rings.
3. Check proper condition of valve cover (1), clean sealing faces if required.
4. Fit valve cover (1) and close it.

Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 151).
TIM-ID: 0000000039 - 008

MS150094/07E 2022-05 | Low-Temperature Circuit | 155

 9.15.5 Charge-air coolant – Draining
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Sealing ring (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Draining charge-air coolant

TIM-ID: 0000051488 - 003

1. Provide a suitable container to catch the coolant.

2. Turn valve cover on coolant expansion tank counterclockwise to first stop and release pressure.
3. Continue to turn valve cover counterclockwise and take off.
4. Draw off precipitated corrosion inhibitor oil from the coolant expansion tank through filler neck.
5. Open drain plugs and drain engine coolant at the following drain points:
• At the charge-air coolant pump (1),
6. Screw in all drain plugs with new sealing rings.
7. Place valve cover on filler neck and close.

156 | Low-Temperature Circuit | MS150094/07E 2022-05

 9.15.6 Charge-air coolant pump – Relief bore check
DANGER
Components are moving or rotating.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Operate the engine at low load only. Keep clear of the danger zone of the engine.

WARNING
A high level of noise is produced when the system is running.
Risk of hearing loss!
• Wear suitable hearing protection.

Charge-air coolant pump – Re-

lief bore check
1. Check relief bore for oil and coolant dis-
charge.
• Permissible coolant discharge: up to 10
drops per hour
• Permissible oil discharge: up to 5 drops
per hour
Result: Contact Service if discharge exceeds the
specified limits.
2. If relief bore is contaminated
• Stop engine (→ Page 58) and disable en-
gine start.
• Clean relief bore with a wire.
TIM-ID: 0000025276 - 004

MS150094/07E 2022-05 | Low-Temperature Circuit | 157

 9.16 Belt Drive
9.16.1 Drive belt – Condition check
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Exposed rotating parts can eject drawn-in components or draw in body parts.
Risk of crushing, limbs or extremities may be pinched, trapped or entangled!
Risk of injury due to flying parts!
• Install rotating components at a suitable distance from other components.
• Never operate the engine without protective covers or safety guards which meet applicable accident
prevention regulations.
• Ensure that the safety guards can prevent body parts from being drawn in by rotating components.

Drive belt – Condition check

1. Remove cover.

2. Checking drive belt condition:

Item Findings Action
Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Replace (→ Page 166)
Drive belt C Chunking
Drive belt Belt is oily, shows signs of over-
heating

3. Install cover.
TIM-ID: 0000000920 - 014

158 | Belt Drive | MS150094/07E 2022-05

 9.16.2 Drive belt – Tension check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Tester Y4345711 1

Fan drive – Checking belt ten-

sion
1. Remove protective cover.
Note: Frequency measurement method is preferred
over depression depth measurement method.
2. Conduct measurement with tester.
3. Read off measured value at the intersection
of display arm and "KG" scale. For specifica-
tions, refer to table below.

Application Spec. value Spec. value

Initial installation (new belt) Operating tension (used belt)
Drive belt 1558 mm – fan Frequency: 113 ±1 Hz Frequency: 103 ±1 Hz
Drive belt 1558 mm – fan (with Frequency: 113 ±1 Hz Frequency: 103 ±1 Hz
supplementary mass)
Drive belt 1522 mm – fan Frequency: 113 ±1 Hz Frequency: 103 ±1 Hz
Drive belt 1707 mm – fan Frequency: 113 ±1 Hz Frequency: 103 ±1 Hz
Drive belt 1665 mm – fan Frequency: 113 ±1 Hz Frequency: 103 ±1 Hz
Drive belt 1623 mm – fan Frequency: 113 ±1 Hz Frequency: 103 ±1 Hz
Drive belt 1854 mm – fan Frequency: 114 ±1 Hz Frequency: 104 ±1 Hz
Drive belt 1800 mm – fan Frequency: 118 ±1 Hz Frequency: 104 ±1 Hz
Drive belt 2008 mm – fan Frequency: 115 ±1 Hz Frequency: 105 ±1 Hz
Drive belt 1971 mm – fan Frequency: 116 ±1 Hz Frequency: 106 ±1 Hz
TIM-ID: 0000025518 - 003

Drive belt 1936 mm – fan Frequency: 117 ±1 Hz Frequency: 110 ±1 Hz

Table 5: Measuring belt tension with frequency meter

MS150094/07E 2022-05 | Belt Drive | 159

 Application Spec. value Spec. value
Initial installation (new belt, (used belt, runtime 500 h)
runtime 0.5-4 h)
Drive belt 1558 mm – fan Depression depth: 6 mm Depression depth: 5 mm
Test force: 188 N Test force: 188 N
Drive belt 1558 mm – fan (with Depression depth: 6 mm Depression depth: 5 mm
supplementary mass) Test force: 188 N Test force: 188 N
Drive belt 1522 mm – fan Depression depth: 6 mm Depression depth: 5 mm
Test force: 188 N Test force: 188 N
Drive belt 1707 mm – fan Depression depth: 6 mm Depression depth: 5 mm
Test force: 188 N Test force: 188 N
Drive belt 1665 mm – fan Depression depth: 6 mm Depression depth: 5 mm
Test force: 188 N Test force: 188 N
Drive belt 1623 mm – fan Depression depth: 6 mm Depression depth: 5 mm
Test force: 188 N Test force: 188 N
Drive belt 1854 mm – fan Depression depth: 6 mm Depression depth: 5 mm
Test force: 188 N Test force: 188 N
Drive belt 1800 mm – fan Depression depth: 6 mm Depression depth: 5 mm
Test force: 188 N Test force: 188 N
Drive belt 2008 mm – fan Depression depth: 6 mm Depression depth: 5 mm
Test force: 188 N Test force: 188 N
Drive belt 1971 mm – fan Depression depth: 6 mm Depression depth: 5 mm
Test force: 188 N Test force: 188 N
Drive belt 1936 mm – fan Depression depth: 6 mm Depression depth: 6 mm
Test force: 188 N Test force: 188 N

Table 6: Measuring depression depth with tension tester

Application Spec. value Spec. value
Initial installation (new belt, (used belt, runtime 500 h)
runtime 0.5-4 h)
Drive belt 1558 mm – fan Strand pull: 4500 N Strand pull: 3750 N
Drive belt 1558 mm – fan (with Strand pull: 4500 N Strand pull: 3750 N
supplementary mass)
Drive belt 1522 mm – fan Strand pull: 4500 N Strand pull: 3750 N
Drive belt 1707 mm – fan Strand pull: 4500 N Strand pull: 3750 N
Drive belt 1665 mm – fan Strand pull: 4500 N Strand pull: 3750 N
Drive belt 1623 mm – fan Strand pull: 4500 N Strand pull: 3750 N
Drive belt 1854 mm – fan Strand pull: 4500 N Strand pull: 3750 N
Drive belt 1800 mm – fan Strand pull: 4500 N Strand pull: 3750 N
TIM-ID: 0000025518 - 003

Drive belt 2008 mm – fan Strand pull: 4500 N Strand pull: 3750 N
Drive belt 1971 mm – fan Strand pull: 4500 N Strand pull: 3750 N
Drive belt 1936 mm – fan Strand pull: 4500 N Strand pull: 4000 N

Table 7: Measuring static belt tension

4. If the measured values deviate from the specifications above, adjust drive belt tension (→ Page 161).
5. Install protective cover.

160 | Belt Drive | MS150094/07E 2022-05

 9.16.3 Drive belt – Tension adjustment
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 20–100 Nm F30026582 1
Ratchet adapter F30027340 1
Torque wrench, 60–320 Nm F30047446 1
Ratchet adapter F30450902 1
Engine oil

WARNING
Belt tensioner spring is pretensioned.
Risk of hands being crushed!
• Lock belt tensioner in position.
• Only use specified tools and devices.

Drive belt – Tension adjustment

1. Loosen screws (1).
2. Set distance (A) to 100 mm with screw (2).

3. Use torque wrench to tighten screws (1) to specified tightening torque.

Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 180 Nm +18 Nm

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

TIM-ID: 0000025520 - 003

Name Size Type Lubricant Value/Standard

Screw M16 Tightening torque (Engine oil) 50 Nm +5 Nm

5. Loosen screws (3).

6. Adjust belt tension with screw (4) (→ Page 159).
7. Use torque wrench to tighten screws (3) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M18 Tightening torque (Engine oil) 74 Nm +7 Nm

MS150094/07E 2022-05 | Belt Drive | 161

 8. Use torque wrench to tighten screw (4) to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M18 Tightening torque (Engine oil) 30 Nm +3 Nm

TIM-ID: 0000025520 - 003

162 | Belt Drive | MS150094/07E 2022-05

 9.16.4 Drive belt – Replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Drive belt (→ Spare Parts Catalog)

Fan drive – Drive belt replace-

ment
1. Remove protective cover from radiator.
2. Remove fan.
3. Slacken off securing screws (1).
4. Screw out screw (2) as far as necessary to al-
low drive belt removal.
5. Check belt pulley on radiator bearing mount
and crankshaft for contamination and clean if
necessary.
Note: When placing the drive belt in the grooves, no
force must be applied.
6. Fit new drive belt.
7. Screw in screw (2) until distance (A) is 100
mm.
8. Adjust and check drive belt tension
(→ Page 161).
9. Install fan.
10. Install protective cover.
TIM-ID: 0000025462 - 002

MS150094/07E 2022-05 | Belt Drive | 163

 9.17 Battery-Charging Generator
9.17.1 Battery-charging generator drive – Drive-belt check and adjustment
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Belt tension tester, 150–600 N Y20097429 1
Torque wrench, 20–100 Nm F30026582 1
Ratchet adapter F30027340 1
Engine oil

Preparatory steps
u Remove protective cover.

Drive belt – Condition check

u Visually inspect condition of drive belt.

Item Findings Action
Drive belt A Singular cracks None
Drive belt B Cracks on entire circumference Replace (→ Page 166)
Drive belt C Chunking
TIM-ID: 0000000043 - 007

Drive belt Belt is oily, shows signs of over-

heating

164 | Battery-Charging Generator | MS150094/07E 2022-05

 Checking drive belt tension
1. Position pretension gage on drive belt mid-
way between belt pulleys.
2. Actuate pushbutton to press the tester uni-
formly on the drive belt surface until the
spring disengages.
3. Do not press any further, otherwise the dis-
play value will be falsified.
4. Take off tension tester without changing the
position of the display arm.
5. Read off measured value at the intersection
of display arm and "KG" scale. The specified
values are listed in the table below.

Application Specified value (new drive belt) Specified value (used drive belt)
Battery-charging generator drive 450 N -50 N 350 N -50 N
belt

6. If the measured value does not correspond to the specified measured value, adjust the drive belt tension.

Adjusting drive belt tension

1. Release screws (2, 3).
2. Tension drive belt with tensioning nut (1) and
check belt tension.

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

Name Size Type Lubricant Value/Standard
Screw M18 Tightening torque (Engine oil) 40 Nm +4 Nm
TIM-ID: 0000000043 - 007

4. Tighten screw (3).

5. Check drive belt tension.

Final steps
u Install protective cover.

MS150094/07E 2022-05 | Battery-Charging Generator | 165

 9.17.2 Battery-charging generator drive – Drive belt replacement
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Drive belt (→ Spare Parts Catalog)

Preparatory steps
1. Remove safety equipment (if fitted).
2. Remove screws of protective cover (engine free end).
3. Remove protective cover.

Drive belt – Replacement

1. Hold adjusting lever firmly at square.
2. Rotate adjusting lever until drive belt is released.
3. Secure adjusting lever with screwdriver.
4. Remove drive belt.
5. Check cleanness of belt pulleys.
6. Fit new drive belt.
7. Release securing element at adjusting lever.
8. Place adjusting lever with square slowly on drive belt.

Final steps
1. Install protective cover.
2. Install screws of protective cover.
3. Install safety equipment (if fitted).
4. Check function of safety equipment (if fitted).

TIM-ID: 0000079168 - 001

166 | Battery-Charging Generator | MS150094/07E 2022-05

 9.18 Engine Governor
9.18.1 Engine governor – Overview

1 Screw 4 Engine governor 7 Connector X1

2 Washer 5 Connector X3 8 Screw for grounding strap
3 Damper 6 Screw
TIM-ID: 0000031588 - 002

MS150094/07E 2022-05 | Engine Governor | 167

 9.18.2 Engine governor – Removal
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
1. Observe safety instructions.
2. Switch off operating voltage.
3. Note or mark assignment of cables and plugs.

Engine governor – Removal

u Remove engine governor as per overview drawing (→ Page 167).

TIM-ID: 0000031586 - 001

168 | Engine Governor | MS150094/07E 2022-05

 9.18.3 Engine governor – Installation
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 8–40 Nm F30043446 1
Ratchet F30027340 1
Engine oil
Damping element (→ Spare Parts Catalog) 8

Engine governor – Installation

1. Install engine governor as per overview drawing (→ Page 167).
Name Size Type Lubricant Value/Standard
Screw for grounding M6 Tightening torque (Engine oil) max. 8 Nm
strap

2. Fit connector X1 and X3 on engine governor and engage locks.

3. Install retainer for engine cabling.

Final step
u Enable engine start.
TIM-ID: 0000031642 - 002

MS150094/07E 2022-05 | Engine Governor | 169

 9.18.4 Engine governor plug connections – Check
Preconditions
☑ Engine stopped and starting disabled.
☑ Electronic engine management system is de-energized.

NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.

Checking plug connections at engine governor

1. Check all plug connections for secure seating.
2. Lock loose connectors.
3. Check dust cap on ECU and EXU connectors for damage and correct seating.

TIM-ID: 0000000048 - 009

170 | Engine Governor | MS150094/07E 2022-05

 9.19 Wiring (General) for Engine/Gearbox/Unit
9.19.1 Engine cabling – Check
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Solvent (isopropyl alcohol) X00058037/GET 1

Engine cabling – Check

1. Check securing screws of cable clamps on engine and tighten loose screw connections.
2. Ensure that cables are securely seated in clamps and cannot move freely.
3. Check if all cable clips are closed and intact.
4. Replace faulty cable clips.
5. Check that cable ties are firmly seated, tighten loose cable ties.
6. Replace faulty cable ties.
7. Visually inspect the following electrical components for damage:
• Connector housings
• Contacts
• Sockets
• Cables and terminals
• Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close off disconnected connectors with protective caps provided.
8. Use isopropyl alcohol to clean dirty connector housings, sockets and contacts.
9. Ensure that all connecting plugs of the sensors are correctly engaged.
Important
Connecting connectors to sensors is only permitted when the engine is stopped.
TIM-ID: 0000000029 - 029

MS150094/07E 2022-05 | Wiring (General) for Engine/Gearbox/Unit | 171

 9.19.2 Lambda, NOx and humidity sensors – Overview

1 Humidity sensor 2 NOx sensor 3 Lambda sensor

TIM-ID: 0000025179 - 001

172 | Wiring (General) for Engine/Gearbox/Unit | MS150094/07E 2022-05

 9.19.3 Lambda sensor – Replacement
Preconditions
☑ Engine is stopped and starting disabled.
☑ Power supply to electronic engine management system is switched off

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 20–100 Nm F30026582 1
Ratchet bit F30027340 1
Assembly compound (Molykote P 37) 50564 1
Lambda sensor (→ Spare Parts Catalog) 1

WARNING
Hot components/surfaces.
Risk of burns!
• Allow the system to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.

NOTICE
Incorrect measurement of the sensors are possible even with small amounts of contamination during
assembly and due to contaminated process materials.
Sensor damage resultant damage to components is possible!
• Prior to assembly, check sensors for particular cleanness and install with clean hands.
• Protect sensor against contamination with certain materials (e.g. thread grease, engine oil, silicone,
reducing agent and others).
• The process materials must meet the requirements of the Fluids and Lubricants Specifications.

NOTICE
High voltage.
Risk of damage to components!
• Switch off ignition before replacing components.

NOTICE
Ceramic cell breakage due to shock or impact.
Risk of damage to components!
• Avoid shocks and impacts.
• Exercise extreme care when handling sensors.
TIM-ID: 0000079921 - 002

MS150094/07E 2022-05 | Wiring (General) for Engine/Gearbox/Unit | 173

 Removing lambda sensor
1. Observe the following general information:
• Layout and position of sensor
(→ Page 172).
2. Loosen and remove connector (1).
3. Remove sensor (2).

Installing lambda sensor

Note: When the sensor was subjected to shock or
impact load, it is deemed to be defective and
may not be used.
1. Remove protective cap on thread only just
before installation.
Note: Do not wipe off the thread lubricant applied
by the manufacturer.
2. Coat sensor thread thinly with specified as-
sembly compound as necessary.
3. Screw in sensor by hand.

4. Use a torque wrench to tighten nut (2) to specified tightening torque.

Name Size Type Lubricant Value/Standard
Nut M18 x 1.5 Tightening torque (Assembly compound 40 Nm +4 Nm
(Molykote P 37))

5. Fit connector (1) and latch it.

6. Reset lambda sensor calibration with DiaSys® (→ Dialog system DiaSys® E531920/..). If no DiaSys® is
available, contact Service.
TIM-ID: 0000079921 - 002

174 | Wiring (General) for Engine/Gearbox/Unit | MS150094/07E 2022-05

 9.19.4 NOx sensor – Replacement
Preconditions
☑ Engine is stopped and starting disabled.
☑ Power supply to electronic engine management system is switched off.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 20–100 Nm F30026582 1
Ratchet bit F30027340 1
Assembly compound (Molykote P 37) 50564 1
NOx sensor (→ Spare Parts Catalog) 1

WARNING
Hot components/surfaces.
Risk of burns!
• Allow the system to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.

NOTICE
Incorrect measurement of the sensors are possible even with small amounts of contamination during
assembly and due to contaminated process materials.
Sensor damage resultant damage to components is possible!
• Prior to assembly, check sensors for particular cleanness and install with clean hands.
• Protect sensor against contamination with certain materials (e.g. thread grease, engine oil, silicone,
reducing agent and others).
• The process materials must meet the requirements of the Fluids and Lubricants Specifications.

NOTICE
High voltage.
Risk of damage to components!
• Switch off ignition before replacing components.

NOTICE
Ceramic cell breakage due to shock or impact.
Risk of damage to components!
• Avoid shocks and impacts.
• Exercise extreme care when handling sensors.
TIM-ID: 0000079922 - 002

MS150094/07E 2022-05 | Wiring (General) for Engine/Gearbox/Unit | 175

 Removing NOx sensor
Note: Observe arrangement and position of sensor
(→ Page 172).
1. Disconnect and remove connector (2) from
control unit (1).
2. Unscrew control unit (1) at the eyelets.
3. Remove sensor (3).

Installing NOx sensor

Note: Note the following:
• If sensor (3) has suffered shock or impact
it is deemed as being defective and shall
not be used.
• Always replace NOx sensor (3) together
with control unit (1).
1. Screw on control unit (1) at the eyelets and
tighten screws.
2. Remove protective cap on thread of sen-
sor (3) only just before installation.
Note: Do not wipe off the thread lubricant applied
by the manufacturer.
3. Coat sensor thread (3) thinly with specified
assembly compound as necessary.
4. Screw in sensor (3) by hand.

5. Tighten nut (3) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Nut M20 Tightening torque (Assembly compound 40 Nm
(Molykote P 37))

6. Fit connector (2) and latch it.

TIM-ID: 0000079922 - 002

176 | Wiring (General) for Engine/Gearbox/Unit | MS150094/07E 2022-05

 9.19.5 Humidity sensor – Replacement
Preconditions
☑ Engine is stopped and starting disabled.
☑ Preparatory steps are completed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Torque wrench, 8–40 Nm F30043446 1
Ratchet adapter F30027340 1
Assembly compound (Kluthe Hakuform 30–15) X00067260
Humidity sensor (→ Spare Parts Catalog) 1

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Removing humidity sensor

1. Observe the following general information:
• Layout and position of sensor
(→ Page 172).
2. Unplug and remove male connector.
3. Remove screws (1).
4. Remove sensor (2).
TIM-ID: 0000025206 - 006

MS150094/07E 2022-05 | Wiring (General) for Engine/Gearbox/Unit | 177

 Installing humidity sensor
Note: Apply assembly compound for O-ring sparing-
ly.
1. Insert sensor (2) in bore, ensuring correct in-
stallation position.
Note: Observe air flow direction.
2. Screw in screws (1).

3. Use torque wrench (1) to tighten screws to specified tightening torque.

Name Size Type Lubricant Value/Standard
Sensor M6 Tightening torque 12 Nm +5 Nm

4. Fit male connector and latch.

TIM-ID: 0000025206 - 006

178 | Wiring (General) for Engine/Gearbox/Unit | MS150094/07E 2022-05

 9.20 Accessories for (Electronic) Engine Governor / Control System
9.20.1 Resetting CDC parameter and entering IIG with DiaSys®
Preconditions
☑ Engine is stopped and starting disabled.

Note: The engine will lose its emissions certification of the drift correction parameters (CDC) if not reset.

Parameters for drift correction (CDC) – Resetting with DiaSys®

1. Use DiaSys® to reset the CDC parameters (→ Dialog system DiaSys® E531920/..).
2. If no DiaSys® is available, contact Service.

Entering the codes for the injectors (IIG) with DiaSys®

1. Use DiaSys® to enter the IIG (→ Dialog system DiaSys® E531920/..).
2. If no DiaSys® is available, contact Service.
TIM-ID: 0000045613 - 002

MS150094/07E 2022-05 | Accessories for (Electronic) Engine Governor / Control System | 179
 9.20.2 Еngine governor and connectors – Cleaning
Preconditions
☑ Engine is stopped and starting disabled.
☑ Power supply to electronic engine management system is switched off.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Solvent (isopropyl alcohol) X00058037/GET 1

NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.

Еngine governor and connectors – Cleaning

1. Use isopropyl alcohol to remove coarse dirt from housing surface.
2. Use isopropyl alcohol to remove dirt from the connector and cable surfaces.
3. Check legibility of cable markers. Clean or replace illegible markers.

Heavily contaminated connectors on engine governor – Cleaning

Note: Close off disconnected connectors with protective caps provided.
1. Release the latch and pull off connector.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit and latch connectors.

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180 | Accessories for (Electronic) Engine Governor / Control System | MS150094/07E 2022-05
 9.20.3 Engine governor plug connections – Check
Preconditions
☑ Engine stopped and starting disabled.
☑ Electronic engine management system is de-energized.

NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.

Checking plug connections at engine governor

1. Check all plug connections for secure seating.
2. Lock loose connectors.
3. Check dust cap on ECU and EXU connectors for damage and correct seating.
TIM-ID: 0000000048 - 009

MS150094/07E 2022-05 | Accessories for (Electronic) Engine Governor / Control System | 181
 10 Appendix A
10.1 List of abbreviations
Abbre- Meaning Explanation
viation
ADEC Advanced Diesel Engine Controller Engine management system
AET Außenerprobungsträger Field Test Engine (FTE)
AL Alarm General Alarm
ANSI American National Standards Institute Association of American standardization organiza-
tions
BDM Backup Data Module -
BR Baureihe Series
BSP British Standard Pipe British Whitworth pipe threads
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications (Publication No.
A001061/..)
CAD Computer-Aided Design -
CAN Controller Area Network Data bus system, bus standard
CCS Compatibility Check System -
CPP Controllable Pitch Propeller -
cpsi cells per square inch -
CR Common Rail –
CSMF Coated Sintered Metal Filter –
DAS Duty Alarm System –
DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards (“Deutsche In-
dustrie-Norm”)
DIS Display Unit -
DL Default Lost Alarm: Default CAN bus failure
DOC Diesel Oxidation Catalyst -
DPF Diesel Particulate Filter –
ECS Engine Control System -
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EGAT Exhaust Gas Aftertreatment -
EGR Exhaust Gas Recirculation -
TIM-ID: 0000002045 - 029

EIL Engine Ident Label Electronic nameplate with specifications

EIM Engine Interface Module -
EMU Engine Monitoring Unit -
EPA Enviromental Protection Agency US Environmental Protection Agency
ETC Exhaust Turbocharger -
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
FPP Fixed Pitch Propeller -
GCU Gear Control Unit -

182 | Appendix A | MS150094/07E 2022-05

 Abbre- Meaning Explanation
viation
GMU Gear Monitoring Unit -
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
value
HT High Temperature High temperature (HT)
ICFN ISO - Continuous rating - Fuel stop power - Power specification in accordance with DIN-ISO
Net 3046-7
IDM Interface Data Module Memory module for interface data
IGI Ignition Input Binary input for ignition
IMO International Maritime Organisation -
ISO International Organization for Standardiza- International umbrella organization of all standardi-
tion zation institutes
KGS Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204
KS Kupplungsseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal Device -
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode -
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
value
LOLO Low Low Alarm: Measured value lower than 2nd minimum lim-
it value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station Local control unit
LPU Lubricating Oil Pump Control Unit -
MCS Monitoring and Control System -
MG Message -
MPU Microprocessor Unit, Microprocessing Unit Microprocessor unit
OPU Operator Panel Unit User interface panel
ORFS O-Ring face seal Flush seal design with O-ring fitted at the front face
OT Oberer Totpunkt Top Dead Center (TDC)
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PAU Power Automation Unit Module for monitoring, control and plant-related sys-
tem integration of peripheral components
TIM-ID: 0000002045 - 029

PCD Programmable Controller Device -

PCU Propeller Control Unit -
PIM Peripheral Interface Module -
PLD Pumpe Leitung Düse Unit pump injection system
POM Power Output Module Module to control starter and battery-charging gen-
erator
PPC Priming Pump Control Oil priming pump
PTO Power Take-Off Main and auxiliary PTOs
RCS Remote Control System -

MS150094/07E 2022-05 | Appendix A | 183

 Abbre- Meaning Explanation
viation
RL Redundancy Lost Alarm: Redundant CAN bus failure
rpm revolutions per minute -
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency air shut-off flap(s)
SFB Safety Function Box Control unit
SFS Safety Function System Control system
SMF Sintered Metal Filter –
SS Safety System Safety system alarm
SUE- Steuerungs- und Überwachungseinrichtung Control and Monitoring unit for oil priming pump
VSP Vorschmierpumpe
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Deviation in transmitter values
USV Unterbrechungsfreie Stromversorgung Uninterrupted Power Supply (UPS)
UT Unterer Totpunkt Bottom Dead Center (BDC)
UNF Unified Fine Thread -
VS Voith Schneider Voith-Schneider drive
VSP Vorschmierpumpe Oil priming pump
WJ Water Jet Waterjet drive
WZK Werkzeugkatalog Tool Catalog (TC)

TIM-ID: 0000002045 - 029

184 | Appendix A | MS150094/07E 2022-05

 10.2 Contact person/Service partner
Service
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-
er service centers ensure fast and direct support on site and ensure 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 Internet site: http://www.mtu-solutions.com

24-h Hotline
With our 24-h hotline and high flexibility, we are your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
Tel: +49 7541 9077777
Fax.: +49 7541 9077778
Asia/Pacific: +65 6860 9669
North and Latin America: +1 248 560 8888

Spare Parts Service

Quick, easy and correct identification of the spare part required for your product. The right spare part at the
right time at the right place.
With this aim in mind, we can call on a globally networked parts logistics system, a central warehouse at
headquarters and on-site stores at our subsidiary companies, representatives and contractual workshops.
Your contact person:
E-mail: Please contact your spare parts order manager
Tel: +49 7541 9077777
Fax: +49 7541 9077778
TIM-ID: 0000000873 - 020

MS150094/07E 2022-05 | Appendix A | 185

 11 Appendix B
11.1 Standard Tools and Special Tools
Adapter
Part No.: F30006234
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)
Qty.: 1
Used in: 9.6.1 HP fuel line and pressure pipe neck – Replacement
(→ Page 113)

Adapter
Part No.: F30452771
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)

Barring device
Part No.: F6783914
Qty.: 1
Used in: 9.4.1 Valve clearance – Check and adjustment
(→ Page 103)
DCL-ID: 0000007590 - 015

186 | Appendix B | MS150094/07E 2022-05

 Belt tension tester, 150–600 N
Part No.: Y20097429
Qty.: 1
Used in: 9.17.1 Battery-charging generator drive – Drive-belt check
and adjustment (→ Page 164)

Crossbeam
Part No.: T80091731
Qty.: 1
Used in: 3.1 Transport (→ Page 21)

Crowfoot wrench, 19 mm
Part No.: F30027424
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)
Qty.: 1
Used in: 9.6.1 HP fuel line and pressure pipe neck – Replacement
(→ Page 113)

Crowfoot wrench, 22 mm
Part No.: F30027425
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)
Qty.: 1
Used in: 9.6.1 HP fuel line and pressure pipe neck – Replacement
DCL-ID: 0000007590 - 015

(→ Page 113)

MS150094/07E 2022-05 | Standard Tools and Special Tools | 187

 Double-end box wrench
Part No.: F30011450
Qty.: 1
Used in: 9.6.1 HP fuel line and pressure pipe neck – Replacement
(→ Page 113)

Double-head box wrench

Part No.: F30002800
Qty.: 1
Used in: 9.4.1 Valve clearance – Check and adjustment
(→ Page 103)

Double-head box wrench

Part No.: F30011450
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)

Endoscope
Part No.: Y20097353
Qty.: 1
Used in: 9.2.2 Cylinder liner – Endoscopic examination
(→ Page 100)
DCL-ID: 0000007590 - 015

188 | Standard Tools and Special Tools | MS150094/07E 2022-05

 Engine barring device
Part No.: F6783914
Qty.: 1
Used in: 9.1.1 Engine – Barring manually (→ Page 96)

Feeler gauge
Part No.: Y4345893
Qty.: 1
Used in: 9.4.1 Valve clearance – Check and adjustment
(→ Page 103)

Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 9.7.1 Fuel filter – Replacement (→ Page 117)
Qty.: 1
Used in: 9.13.1 Engine oil filter – Replacement (→ Page 134)

Fuel suction device

Part No.: F30378207
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)
DCL-ID: 0000007590 - 015

MS150094/07E 2022-05 | Standard Tools and Special Tools | 189

 Installation device
Part No.: F6790085
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)

mtu test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 9.14.7 Engine coolant – Sample extraction and analysis
(→ Page 149)

Oil filter wrench

Part No.: F30379104
Qty.: 1
Used in: 9.13.2 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 135)

Puller
Part No.: F6790636
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)
DCL-ID: 0000007590 - 015

190 | Standard Tools and Special Tools | MS150094/07E 2022-05

 Ratchet
Part No.: F30027340
Qty.: 1
Used in: 9.4.1 Valve clearance – Check and adjustment
(→ Page 103)
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)
Qty.: 1
Used in: 9.18.3 Engine governor – Installation (→ Page 169)

Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 9.16.3 Drive belt – Tension adjustment (→ Page 161)
Qty.: 1
Used in: 9.17.1 Battery-charging generator drive – Drive-belt check
and adjustment (→ Page 164)
Qty.: 1
Used in: 9.19.5 Humidity sensor – Replacement (→ Page 177)

Ratchet adapter
Part No.: F30450902
Qty.: 1
Used in: 9.16.3 Drive belt – Tension adjustment (→ Page 161)
DCL-ID: 0000007590 - 015

MS150094/07E 2022-05 | Standard Tools and Special Tools | 191

 Ratchet bit
Part No.: F30027340
Qty.: 1
Used in: 9.4.2 Cylinder head cover – Removal and installation
(→ Page 106)
Qty.: 1
Used in: 9.6.1 HP fuel line and pressure pipe neck – Replacement
(→ Page 113)
Qty.: 1
Used in: 9.7.3 Fuel prefilter – Draining (→ Page 119)
Qty.: 1
Used in: 9.13.2 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 135)
Qty.: 1
Used in: 9.19.3 Lambda sensor – Replacement (→ Page 173)
Qty.: 1
Used in: 9.19.4 NOx sensor – Replacement (→ Page 175)

Ratchet bit with extension

Part No.: F30006212
Qty.: 1
Used in: 9.1.1 Engine – Barring manually (→ Page 96)

Ratchet with extension

Part No.: F30006212
Qty.: 1
Used in: 9.4.1 Valve clearance – Check and adjustment
(→ Page 103)
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192 | Standard Tools and Special Tools | MS150094/07E 2022-05

 Ring socket, 19 mm
Part No.: F30038493
Qty.: 1
Used in: 9.4.1 Valve clearance – Check and adjustment
(→ Page 103)

Socket wrench, 19 mm
Part No.: F30453236
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)

Socket wrench, 19 mm
Part No.: F30025897
Qty.: 1
Used in: 9.6.1 HP fuel line and pressure pipe neck – Replacement
(→ Page 113)

Socket wrench, 24 mm
Part No.: F30453238
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)
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MS150094/07E 2022-05 | Standard Tools and Special Tools | 193

 Tester
Part No.: Y4345711
Qty.: 1
Used in: 9.16.2 Drive belt – Tension check (→ Page 159)

Torque wrench, 1–5 Nm

Part No.: F30452774
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)

Torque wrench, 20–100 Nm

Part No.: F30026582
Qty.: 1
Used in: 9.4.1 Valve clearance – Check and adjustment
(→ Page 103)
Qty.: 1
Used in: 9.5.2 Injector – Removal and installation (→ Page 108)
Qty.: 1
Used in: 9.6.1 HP fuel line and pressure pipe neck – Replacement
(→ Page 113)
Qty.: 1
Used in: 9.16.3 Drive belt – Tension adjustment (→ Page 161)
Qty.: 1
Used in: 9.17.1 Battery-charging generator drive – Drive-belt check
and adjustment (→ Page 164)
Qty.: 1
Used in: 9.19.3 Lambda sensor – Replacement (→ Page 173)
DCL-ID: 0000007590 - 015

Qty.: 1
Used in: 9.19.4 NOx sensor – Replacement (→ Page 175)

194 | Standard Tools and Special Tools | MS150094/07E 2022-05

 Torque wrench, 4–20 Nm
Part No.: F30044239
Qty.: 1
Used in: 9.7.3 Fuel prefilter – Draining (→ Page 119)

Torque wrench, 60–320 Nm

Part No.: F30047446
Qty.: 1
Used in: 9.16.3 Drive belt – Tension adjustment (→ Page 161)

Torque wrench, 8–40 Nm

Part No.: F30043446
Qty.: 1
Used in: 9.4.2 Cylinder head cover – Removal and installation
(→ Page 106)
Qty.: 1
Used in: 9.13.2 Centrifugal oil filter – Cleaning and filter sleeve re-
placement (→ Page 135)
Qty.: 1
Used in: 9.18.3 Engine governor – Installation (→ Page 169)
Qty.: 1
Used in: 9.19.5 Humidity sensor – Replacement (→ Page 177)
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MS150094/07E 2022-05 | Standard Tools and Special Tools | 195

 11.2 Index
A Cylinder liner
After shuting down engine – Endoscopic examination 100
– Putting engine out of operation 60 – Endoscopic inspection
Air filter – Instructions and comments on endoscopic and visu-
– Replacement 127 al examination 98

B D
Battery-charging generator drive Data
– Drive belt – Product 38
– Replacement 166 Data acquisition
Belt – Data transmission 37
– Drive Differential pressure gauge
– Replacement 163 – Fuel prefilter
– Tension check 159 – Adjustment 118
– Check 118
C Dimensions
Cabling – Engine 51
– Check Drain and vent points 138
– On engine 171 Drive belt
CDC – Condition check 158, 164
– Reset 179 – Replacement 163
Centrifugal oil filter – Battery-charging generator drive 166
– Cleaning 135 – Tension adjustment 164
Charge-air coolant – Tension check 159, 164
– Change 153 Drive belt tension
– Check – Adjustment 161
– Level at filler neck 151
E
– Level via level sensor 151
– Draining 156 Emergency stop
– Filling 154 – Engine 59
Charge-air coolant pump – Relief bore check 157 Emission label
Connectors – Check 57
– Cleaning 180 Endoscopic inspection
Contact person 185 – Cylinder liner
Coolant – Instructions and comments 98
– Change 144, 153 Engine
– Charge air – Barring
– Filling 154 – Manually 96
– Draining 145 – Emergency stop 59
– Filling 146 – Main dimensions 51
– Intercooler – Overview 23
– Draining 156 – Shutdown 58
– Sample – Starting 54
– Starting system
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– Extraction and analysis 149

Coolant level – Turning 97
– Check 143 Engine cabling
Crankcase breather – Check 171
– Oil mist separator Engine Control Unit
– Replacement 102 – Fault messages 68
Cylinder Engine coolant
– Designation 22 – Change 144
Cylinder head cover – Draining 145
– Removal and installation 106 – Filling 146
– Sample
– Extraction and analysis 149

196 | Index | MS150094/07E 2022-05

 Engine coolant level Fuel prefilter
– Check 143 – Adjustment
Engine coolant pump – Relief bore check 148 – Differential pressure gauge 118
Engine driving end – Check
– Definition 22 – Differential pressure gauge 118
Engine free end – Draining 119
– Definition 22 – Flushing 121
Engine governor – Replacement
– Cleaning 180 – Filter element 124
– Installation 169 Fuel system
– Overview 167 – Venting 115
– Plug connections
– Check 170, 181 H
– Removal 168 Hotline 185
Engine oil Humidity sensor
– Centrifugal oil filter – Replacement 177
– Cleaning 135
– Change 132 I
– Filter IIG
– Replacement 134 – Input 179
– Filter sleeve Injector
– Replacement 135 – Installation 108
Engine oil filter – Removal 108
– Replacement 134 – Replacement 107
Engine oil level Injector coding (IIG)
– Check 131 – Input 179
Engine sides Intercooler
– Designation 22 – Checking condensate drain for coolant leakage and ob-
Exhaust gas recirculation struction 126
– Flaps Intercooler
– Function check 130 – Vent and drain points 150

F L
Fault messages Lambda sensor
– Engine Control Unit 68 – Replacement 173
Filter List of abbreviations 182
– Engine oil
M
– Replacement 134
– Fuel Maintenance schedule
– Replacement 117 – Maintenance task reference table [QL1] for EPA re-
Filter element gions 64
– Replacement – Maintenance task reference table [QL1] for Non-EPA
– Fuel prefilter 124 regions 63
Filter sleeve
N
– Replacement 135
Firing order 50 NOx sensor
Flaps – Replacement 175
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– Exhaust gas recirculation

O
– Function check 130
– Overview 129 Operational monitoring 56
Fuel Overview
– Draining 116 – Engine 23
– Filter – Exhaust gas recirculation
– Replacement 117 – Flaps 129
– Prefilter – Lambda, NOx and humidity sensor 172
– Draining 119
P
Fuel filter
– Replacement 117 Parameters for drift correction (CDC)
– Resetting 179

MS150094/07E 2022-05 | Index | 197

 Plant Transport
– Cleaning 61 – Description 21
Preparations for putting into operation after extended out- Troubleshooting 65
of-service-periods (>3 months) 52
Preparations for putting into operation after scheduled V
out-of-service-period 53 Valve clearance
Pressure pipe neck – Adjustment 103
– Replacement 113 – Check 103
Product Vent and drain points 138
– Data 38 – Intercooler 150
Product data 12/16V2000S56 44
Product data 12/16V2000S96 47 W
Product data 12V2000C66R 41 Warning messages, standards 20
Pump
– Charge-air coolant
– Relief bore check 157
– Engine coolant
– Relief bore check 148
Putting into operation
– After extended out-of-service periods
– Preparations 52
– After scheduled out-of-service-period
– Preparations 53

S
Safety regulations
– Assembly work 13
– Auxiliary materials 17
– Commissioning 11
– Environmental protection 17
– Fire protection 17
– Important provisions 8, 9
– Indirect materials 17
– Maintenance work 13
– Operation 11
– Organizational requirements 10
– Personnel requirements 10
– Repair work 13
– Warning messages, standards 20
Sensor
– Replacement
– Lambda 173
Sensors
– Replacement
– NOx 175
Service indicator
– Check 128
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Service partner 185

Spare parts service 185

T
Tension
– Adjustment
– Drive belt 161
Tightening specifications
– Nuts 24
– Screws 24
– Screws and nuts 24

198 | Index | MS150094/07E 2022-05